Replace side longitudinal member reinforcement

AR63.30-P-0816SO

Replace side longitudinal member reinforcement

05.03.2019

Model

450.4

Front side longitudinal member reinforcement

1

Front side longitudinal member reinforcement

X

110 mm

Y

220 mm

2

Spot weld removing tool

1

Front side longitudinal member reinforcement

X

110 mm

Y

220 mm



Remove

 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

Topical note

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

AH91.00-P-0002-01M

Topical note

General information on body repair

AH60.00-N-0001-01A

Topical note

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

AH00.00-N-0005-01A

Notes on replacing body parts

AH60.00-P-0027-01FF

1

Mark specified cutting interface on the side front longitudinal member (1)

 See Fig. A.

2

Open up cutting interface using a body saw

 When cutting, pay attention to the sheet metal panels underneath.

3

Drill out spot welds on the welding flanges of the side front longitudinal member reinforcement (1) with a spot weld removing tool (2)

 See Fig. B.

4

Remove side front longitudinal member reinforcement (1)



Install

5

Smooth welding edges and remove paint in the welding area of the separating point

6

Apply weldable priming to the blank welds in the repair area

Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint

*BR00.45-Z-1001-07A

7

Cut new part to the specified dimension

 See fig. C.
The cutting area for the butt welding must be made very precisely.

8

Remove protective paint on the welding areas of the new side front longitudinal member reinforcement (1) and apply weldable priming to the blank welding areas

Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint

*BR00.45-Z-1001-07A

9

Punch side front welding flanges of the new longitudinal member reinforcement (1) with hole punching pliers at the specified point distances

Not for resistance spot welding.

 See fig. D.

10

Fit side front longitudinal member reinforcement (1)

 When fitting observe correct distances.

11

Weld in side front longitudinal member reinforcement (1) during the inert gas or resistance spot welding process

 See fig. E.

12

Smooth spot welds and unevenness slightly

13

Tin bluntly welded points

14

Clean repair areas with a wire brush and then prime

15

Supplement standard sealants with body sealant

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

16

Paint repair area adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02SM

17

Add cavity preserving agent

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint

A 000 986 34 42

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20