Install and weld in complete outer side longitudinal member

AR63.30-S-1000-03P

Install and weld in complete outer side longitudinal member

 Danger

The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases

Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system.

AS00.00-Z-0007-01A

 Caution

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

Topical note

Measures for preventing damage to components when performing electric welding and soldering work

AH60.00-P-0001-02A



000 588 01 84 00 Welder

WS60.00-P-0021K



000 588 02 84 00 Welder

WS60.00-P-0022K

Model

470, 471

Gap dimensions

Number

Designation

Model 470, 471

BE60.00-N-1005-01P

Gap dimensions

Front door to longitudinal member

Dimension "H"

mm

6 (1,5)

Front door to rear door

Dimension "I"

mm

4,4 (1)

Front door to A-pillar

Dimension "J"

mm

5,5 (1)

Fuel filler flap, all round

Dimension "K"

mm

3,5 (1)

NOx reducing agent tank filler flap, all round

Dimension "L"

mm

3,5 (1)

For picture, see

AR60.00-S-0700-01P

Gap dimensions

Number

Designation

Model 470, 471

BE60.00-N-1006-01P

Gap dimensions

Rear door to roof frame

Dimension "M"

mm

5,5 (1)

Rear door to C-pillar

Dimension "N"

mm

4,5 (1)

Rear door to longitudinal member

Dimension "O"

mm

6 (1,5)

For picture, see

AR60.00-S-0700-01P

Repair materials

Number

Designation

Order number

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

1

Apply sealant on body (areas A and B).

2

Install and fit outer side longitudinal member (1), lower hinges, doors and sealing frames.

 Commercially available devices/tools
Clamping pliers (Standard)

3

Check gaps using  feeler gauge and adjust.   

4

Fix in place outer side longitudinal member (1).

 Commercially available devices/tools
Clamping pliers (Standard)

5

Remove doors, lower hinges and sealing frames.

6

Outer side longitudinal member (1)   (areas C, D, E, F and G).

7

Outer side longitudinal member (1)   (areas K, L and M).

8

Outer side longitudinal member (1)   (areas H, I and J).

 Inert gas weld in intervals and allow to cool down in between. Reduces heat distortion.

9

Grind inert gas welds and inert gas spot welds down flat.

 Commercially available devices/tools
Angular grinder

10

Clean weld joints.

 Commercially available devices/tools
Rotary wire brush

11

Restore surfaces on outer side longitudinal member (1) and smoothen.

 Different methods can be used to restore the surfaces.

12

Remove shavings.

 Commercially available devices/tools
Wet and dry vacuum cleaner