Remove/install side roof frame - AR65.20-P-1200MCO
MODEL 451.4
| Removing | |||
| Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding splatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. | Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. | AS00.00-Z-0007-01A | |
| Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. | AS00.00-Z-0017-01A | |
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-P-0005-01FF | ||
| Notes on performing repair, body work and welding on vehicles with airbags and ETR units | AH91.00-P-0002-01SM | ||
| Notes on replacing body parts | AH60.00-P-0027-01FF | ||
| General information on body repair | AH60.00-P-0001-01FF | ||
| The following workshop equipment and tools are required for repair: | Round wire brush Cartridge gun Drill Wet/dry vacuum cleaner Vise grip pliers MIG MAG gas welder (steel, brazing, aluminum) |
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| Tarp (fire-resistant) | Welding protective blanket |
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| 1 | Remove detachable parts in the repair area | ||
| 2 | Cover all detachable parts remaining in vehicle (area to be repaired) | ||
| 3 | Remove roof paneling | AR65.10-P-5702MCO | |
| 4 | Remove upper A-pillar outer paneling | AR63.20-P-1105MCO | |
| 5 | Partially remove side wall paneling | AR63.10-P-0115MCO | |
| 6 | Partially remove side wall reinforcement | AR63.20-P-0862MCC | |
| 7 | Remove lower A-pillar outer section | AR63.20-P-1102MCO | |
| 8 | Remove lower A-pillar reinforcement | AR63.20-P-1114MCO | |
| 9 | Partially remove upper A-pillar reinforcement | AR63.20-P-1116MCO | |
| 10 | Expose spot welds on side roof frame (1) and cut out (areas A and B). | ||
| 11 | Remove damaged side roof frame (1). | ||
| 12 | Grind connection surfaces down to bare metal in cross-hatched areas. | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 13 | Grind new side roof frame (1) down to bare metal in cross-hatched areas. | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 14 | Fit new side roof frame (1) and fasten with vise grip pliers. | ||
| 15 | New side roof frame (1) |
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| 16 | Level spot welds (areas C and D) | ||
| 17 | Partially install upper A-pillar reinforcement | AR63.20-P-1116MCO | |
| 18 | Install lower A-pillar reinforcement | AR63.20-P-1114MCO | |
| 19 | Install lower outer A-pillar | AR63.20-P-1102MCO | |
| 20 | Partially install side wall reinforcement | AR63.20-P-0862MCC | |
| 21 | Partially install side wall paneling | AR63.10-P-0115MCO | |
| 22 | Install upper A-pillar outer paneling | AR63.20-P-1105MCO | |
| 23 | Install roof paneling | AR65.10-P-5702MCO | |
| 24 | Clean sheet metal flange with wire brush and clean areas to repaired | ||
| 25 | Prime repair area using primer filler | ||
| 26 | Supply standard seam seals with body sealant | AR97.10-P-4000MCC | |
| Sealant | *BR00.45-Z-1003-01A | ||
| 27 | Paint repair area adjacent surfaces | ||
| Notes on paintwork repairs | AH98.00-P-9408-02MCC | ||
| 28 | Apply additional cavity preservation | AR97.20-P-1500FF | |
| Teroson protective wax | *BR00.45-Z-1008-05A | ||
| 29 | Reinstall all detachable parts removed |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | White sealing compound, 310 ml, DBL 6069.20 | A 001 989 63 20 |
| BR00.45-Z-1008-05A | Teroson protective wax | Henkel Loctite |
| Art. no.: 122.73Q | ||
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |