Replace longitudinal member outer shell on entrance

AR63.30-P-1102FF

Replace longitudinal member outer shell on entrance

14.05.2019

Model

454.0

1

Longitudinal member outer shell



Remove

 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

General information on body repair

AH60.00-N-0001-01A

Topical note

Notes on performing repair, body work and welding on vehicles with airbags and RTE units

AH91.00-P-0002-01M

1

Remove detachable parts in the repair area

2

Cover all detachable parts remaining in vehicle (area to be repaired)


Use fire-resistant tarp
to prevent damage due to flying sparks.

3

Position body on the straightening bench, check, and straighten if necessary

CAR-BENCH straightening systems

AR60.10-P-0100FF

Celette straightening systems

AR60.10-P-0100FG

BLACKHAWK straightening systems

AR60.10-P-0100FH

CAR-O-Liner straightening systems

AR60.10-P-0100FJ

4

Remove side wall paneling

AR63.10-P-0110FF

5

Remove B-pillar reinforcement

AR63.20-P-1351FF

6

Completely remove A-pillar

AR63.20-P-1100FF

7

Remove longitudinal member outer shell (1) from the entrance

AR63.30-P-1102-01FF

8

Prepare longitudinal member outer shell (1) at the entrance and mating surfaces on the body for installation

AR63.30-P-1102-02FF

Notes on replacing body parts

AH60.00-P-0027-01FF

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

9

Set up Car-O-Flex holding system for installation of the longitudinal member outer shell (1)

Only for CAR-O-Liner straightening system.

 Determine positioning of the Car-O-Flex holding system with the Car-O-Tronic measuring system.



Install

 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

10

Install longitudinal member outer shell (1) at entrance

AR63.30-P-1102-03FF

Topical note

Measures for preventing damage to vehicles or components when performing electric welding work

AH00.00-N-0005-01A

11

Clean weld joints and sheet metal flanges with wire brush and clean repair areas

12

Prime repair area using primer filler

13

Supply standard seam seals with body sealant

AR97.10-P-4000FF

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

14

Supplement standard underbody protection with permanent underfloor protection

Underfloor protection 800 ml

*BR00.45-Z-1001-05A

15

Completely install A-pillar

AR63.20-P-1100FF

16

Install B-pillar reinforcement

AR63.20-P-1351FF

17

Install side wall paneling

AR63.10-P-0110FF

18

Remove Car-O-Flex holding system

Only for CAR-O-Liner straightening system.

19

Take body off the straightening bench and remove straightening bench

CAR-BENCH straightening systems

AR60.10-P-0100FF

Celette straightening systems

AR60.10-P-0100FG

BLACKHAWK straightening systems

AR60.10-P-0100FH

CAR-O-Liner straightening systems

AR60.10-P-0100FJ

20

Reinstall all removed assembly parts

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-05A

Underfloor protection 800 ml

A 001 986 46 10

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20