Prepare front entrance box for installation

AR61.10-D-0031-02TS	Prepare front entrance box for installation
 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

Model

907, 910

Repair materials

Number	Designation	Order number
BR00.45-Z-1056-07A	1K-zinc dust paint	A 000 986 28 00

 The next steps are shown on the left component parts and must be performed in a similar manner on vehicles with damage on the right side of the vehicle.

Prepare front entrance box for installation

D61.10-A006-07

1	Punch holes in strut (1) with a diameter of 6 mm (area A).

 Commercially available devices/tools
Hole punching pliers 6 mm

2	Grind mating surfaces down to bare metal in cross-hatched areas and around holes (area A).

 Sand down spot weld flanges to bare metal on both sides.

 Commercially available devices/tools
Rotary wire brush

3	Remove shavings.

 Commercially available devices/tools
Wet and dry vacuum cleaner

4	Zinc dust paint to insides of spot weld flanges.

5	Punch holes at front entrance (2) with a diameter of 6 mm (area B).

 Commercially available devices/tools
Hole punching pliers 6 mm

6	Grind mating surfaces down to bare metal in cross-hatched areas and around holes (area B).

 Sand down spot weld flanges to bare metal on both sides.

 Commercially available devices/tools
Rotary wire brush

D61.10-A007-05

7	Remove shavings.

 Commercially available devices/tools
Wet and dry vacuum cleaner

8	Zinc dust paint to insides of spot weld flanges.

9	Punch holes at rear entrance (3) with a diameter of 6 mm (areas C and D).

 Commercially available devices/tools
Hole punching pliers 6 mm

10	Grind mating surfaces in cross-hatched areas and around holes (areas C and D) down to bare metal.

 Sand down spot weld flanges to bare metal on both sides.

 Commercially available devices/tools
Rotary wire brush

11	Remove shavings.

 Commercially available devices/tools
Wet and dry vacuum cleaner

12	Zinc dust paint to insides of spot weld flanges.

D61.10-A008-12

13	Mark separating point on lower A-pillar inner section (4) (area E).

 Transfer separation point from vehicle.

14	Separate separating point on lower A-pillar inner section (4) (area E).

 Commercially available devices/tools
Body power jigsaw

15	Dispose of remaining piece.

16	Grind down mating surfaces to bare metal in cross-hatched areas.

 Sand down spot weld flanges to bare metal on both sides.

 Commercially available devices/tools
Rotary wire brush

D61.10-A009-05

17	Remove shavings.

 Commercially available devices/tools
Wet and dry vacuum cleaner

18	Zinc dust paint to insides of spot weld flanges.

19	Punch holes in crossmember (5) with a diameter of 6 mm (area F).

 Commercially available devices/tools
Hole punching pliers 6 mm

20	Grind mating surfaces down to bare metal in cross-hatched areas and around holes (area F).

 Sand down spot weld flanges to bare metal on both sides.

 Commercially available devices/tools
Rotary wire brush

D61.10-A010-05

21	Remove shavings.

 Commercially available devices/tools
Wet and dry vacuum cleaner

22	Zinc dust paint to insides of spot weld flanges.

23	Grind down mating surfaces to bare metal in cross-hatched areas.

 Sand down spot weld flanges to bare metal on both sides.

 Commercially available devices/tools
Rotary wire brush

24	Remove shavings.

 Commercially available devices/tools
Wet and dry vacuum cleaner

25	Zinc dust paint to insides of spot weld flanges.

D61.10-A011-12

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