Commercially available tools
Number | Designation | |
WH58.30-Z-1003-01A | Electrode miller | |
WH58.30-Z-1003-02A | Clamping pliers | |
WH58.30-Z-1001-03A | Round wire brush, braided, dia. 70 mm | |
WH58.30-Z-1021-04A | Cutting disk, dia. 65 mm, 80 m/s (max. 23,500 rpm) | |
WH58.30-Z-1024-04A | Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm) |
Workshop equipment
WE58.40-Z-1002-02A | Spot 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-1004-03A | Body saw (electric/pneumatic) |
Repair materials
Number | Designation | Order number |
BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
P63.20-5151-09
1 Mark separation line on inner longitudinal member (1) (area A).
Transfer dimension for separation point on inner longitudinal member (1) from vehicle
2 Cut separation point on inner longitudinal member (1) with body saw (area A).
3 Grind connection surfaces on inner longitudinal member (1) and rear reinforcement (2 in shaded areas down to bare metal with round wire brush.
Grind spot weld flanges down to bare metal on both sides.
4 Coat insides of spot weld flanges with zinc dust paint.
P63.20-5152-09
Dimensions:
a approx. 100 mm
5 Mark separation line on A-pillar with side longitudinal member (3) (area B).
Transfer dimension for separation point of A-pillar with side longitudinal member (3) from vehicle
6 Cut separation point on A-pillar with side longitudinal member (3) with body saw (area B).
7 Mark separation line on A-pillar with side longitudinal member (3) (area C).
8 Cut separation point on A-pillar with side longitudinal member (3) with body saw (area C).
Do not throw away remaining piece; required for reinstallation.
9 Grind connection surfaces on center reinforcement (4) in shaded areas down to bare metal with round wire brush.
Grind spot weld flanges down to bare metal on both sides.
10 Coat insides of spot weld flanges with zinc dust paint.
P63.20-5162-09
11 Mark separation lines on longitudinal member reinforcement (5) (areas D and E).
Transfer cut in area (D) from new part of A-pillar with side longitudinal member and transfer cut in area (E) from vehicle
12 Cut separation point on longitudinal member reinforcement (5) with body saw (areas D and E).
13 Grind connection surfaces on section of longitudinal member reinforcement (6) in shaded areas down to bare metal with round wire brush
P63.20-5163-09
14 Grind connection surfaces on A-pillar with side longitudinal member (3) in shaded areas down to bare metal with round wire brush.
Grind spot weld flanges down to bare metal on both sides.
15 Coat insides of spot weld flanges with zinc dust paint.
P63.20-5169-09
16 Grind connection surfaces on A-pillar with side longitudinal member (3) in shaded areas down to bare metal with round wire brush
Grind spot weld flanges down to bare metal on both sides.
17 Coat insides of spot weld flanges with zinc dust paint.
P63.20-5170-08
18 Grind connection surfaces on inner A-pillar (7) and front cover (8) in shaded areas down to bare metal with round wire brush.
Grind spot weld flanges down to bare metal on both sides.
19 Coat insides of spot weld flanges with zinc dust paint.
P63.20-5175-09
20 Install center reinforcement (4) in A-pillar with side longitudinal member (3), fit and fasten with clamping pliers.
21 Weld in center reinforcement (4) in A-pillar with side longitudinal member (3) with (area F).
22 Coat spot welding flanges with zinc dust paint.
P63.20-5176-06
23 Install rear reinforcement (2) in A-pillar with side longitudinal member (3), fit and fasten with clamping pliers.
24 Weld in rear reinforcement (2) in A-pillar with side longitudinal member (3) with
(areas G, H and I).
25 Coat spot welding flanges with zinc dust paint.