AR63.10-L-0805-03VB | Installing outer side wall | ||
| Measures for preventing damage to vehicles or components when performing arc welding work | All models |
Test and adjusting values, gap sizes at hoods, doors and covers
Number | Designation | Models | |||
BE60.00-P-1002-01A | Gap size | Front door to A-pillar | Dimension" B" | mm | 5.0 (0.5) |
Front door and front fender | Dimension "H" | mm | 5.0 (0.5) | ||
Front door and rear door | Dimension" I" | mm | - | ||
Front door to roof | Dimension "C" | mm | - | ||
Rear door and upper side section | Dimension "D" | mm | - | ||
Rear door to lower side section | Dimension" J" | mm | - | ||
Fender to A-pillar | Dimension" Q" | mm | 2.0 (0.5) | ||
Front door to rear fender | Dimension "P" | mm | 5.0 (0.5) | ||
Fig. see | - | ||||
BE60.00-P-1011-01A | Gap size | Rear door to rear light unit | Dimension" G" | mm | 5.0 (0.5) |
Tailgate to bumper | Dimension "I" | mm | 7.0 (0.5) | ||
Tailgate to tailgate | Dimension" L" | mm | 7.0 (0.5) | ||
Tailgate to rear spoiler | Dimension" M" | mm | 5.0 (0.5) | ||
Rear spoiler to roof | Dimension "T" | mm | 7.0 (0.5) | ||
Fig. see | - | ||||
168 589 02 37 00
Flange crimping pliers
Feeler gage
129 589 03 21 00
Commercially available tools
Number | Designation | |
WH58.30-Z-1003-01A | Electrode miller | |
WH58.30-Z-1003-02A | Clamping pliers | |
WH58.30-Z-1031-02A | C-clamp | |
WH58.30-Z-1001-03A | Round wire brush, braided, dia. 70 mm | |
WH58.30-Z-1024-04A | Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm) | |
WH58.30-Z-1001-29A | Lever riveting device |
Workshop equipment
WE58.40-Z-1001-02A | Inert gas welder |
WE58.40-Z-1002-02A | Spot welder |
WE58.40-Z-1001-03A | Drill (electric/pneumatic) |
WE58.40-Z-1003-03A | Angle grinder (electric/pneumatic) |
WE58.40-Z-1005-03A | Wet/dry vacuum cleaner |
L63.10-0200-06
1 Install side wall, fit and fasten with clamping pliers and pop-up rivets with locking thread..
2 Insert tail lamp, install rubber seal and locking eye.
3 Check gaps between side wall, front door and tailgate, adjust.
Use feeler gauge.
L63.10-0207-09
4 Rivet side wall in area A (use 4.0 x 10 mm dia. Polygrip aluminum/steel countersunk rivets dia.).
5 Side wall in marked areas (spots) and in wheelhouse
.
6 Only tack weld side wall in area B.
7 Side wall in area C .
L63.10-0212-06
8 Side wall in areas D and E (weld areas E1 to E3 from inside of vehicle and outside of vehicle).
9 Side wall in areas F and G .
10 Side wall in area B .
Always weld from countersunk side.
11 Grind areas D to G down flat.
12 Fill area F with solder and smooth.
P63.50-2005-05
13 Crimp spot welding flange on rear wheelhouse (analog to undamaged side of vehicle).
L63.10-0080-01
14 Install outer reinforcement, fit and fasten with clamping pliers and pop-up rivets with locking thread.
15 Rivet outer reinforcement in area H (use 4.0 x 10 mm dia. Polygrip aluminum/steel countersunk rivets).
16 Outer reinforcement in area J .
Always weld from countersunk side.
17 Outer reinforcement in area K .
18 Weld down flat in area K.
For reasons of strength and cost, do not grind down all welds in the area which is not visible.
19 Clean all welds with wire brush.
20 Fill area K and above reinforcement with solder and grind down flat
Referenced documents
- ah0000n000501a Measures for preventing damage to vehicles or components when performing electric welding work