S62.20-0026-06
| Removing | ||
Danger! | The high voltage used for arc welding presents a lethal hazard. Explosion hazard when welding in the area of highly combustible materials. Risk of injury from welding spatter and UV light while welding. Risk of poisoning if welding vapors are inhaled | Use insulating mats. Wear protective clothing, protective goggles and protective mask. Remove highly combustible materials from hazard area. Use evacuation system. | |
| Measures for preventing damage to vehicles or components when performing arc welding work | All models | |
| General notes on body repair | All models | |
| Gap dimensions on hoods, doors and covers | Model 638 | |
1 | Dismantle assembly parts in repair area | ||
2 | Cover all detachable body components remaining in area to be repaired | Tarpaulin (fireproof) | |
3 | Removing front end crossmember | ||
4 | Removing front fender | ||
5 | Removing cross member | ||
6 | Removing headlamp support | ||
| |||
| |||
Drill (electric/pneumatic) | |||
Angle grinder (electric/pneumatic) | |||
N | Vacuum hollow spaces | Wet/dry vacuum cleaner | |
| Installing | ||
8 | Prepare headlamp supports | ||
Drill (electric/pneumatic) | |||
Straight grinder (electric/pneumatic) | |||
Angle grinder (electric/pneumatic) | |||
Zinc dust paint which can be spot welded | |||
9 | Prepare headlamp support's connecting points. | ||
Drill (electric/pneumatic) | |||
Straight grinder (electric/pneumatic) | |||
Angle grinder (electric/pneumatic) | |||
Zinc dust paint which can be spot welded | |||
10 | Welding in headlamp support with assembly gage | ||
| |||
Inert gas welding equipment | |||
11 | Conduct corrosion prevention measure | Refer to Paintwork Manual | |
12 | Installing cross member | ||
13 | Installing front fenders | ||
14 | Installing front end crossmember | ||
15 | Mount assembly parts |
201 589 00 51 01
Test and welding gage for front end
Cutter head
Spot weld cutter
201 589 00 51 00
638 589 01 23 00
Commercially available tools
Workshop equipment
WE58.40-Z-1001-02A | Inert gas welder |
WE58.40-Z-1001-03A | Drill (electric/pneumatic) |
WE58.40-Z-1002-03A | Straight grinder (electric/pneumatic) |
WE58.40-Z-1003-03A | Angle grinder (electric/pneumatic) |
WE58.40-Z-1005-03A | Wet/dry vacuum cleaner |
Referenced documents
- ah0000n000501a Measures for preventing damage to vehicles or components when performing electric welding work
- ah6000n000101a General information on body repair
- ar6000s070001v Gap dimensions on hoods, doors and covers
- ar6220s130001a Removing headlamp mount
- ar6220s130002a Preparing headlamp holder
- ar6220s130003a Preparing connection points of headlamp holder
- ar6220s130004a Welding in headlamp mount with welding gauge
- ar6230s1360a Remove/install crossmember
- ar8800s2302a Removing and installing lock cross member
- ar8810s1000a Remove/install front fenders
- as0000z000701a 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