Shown on model 452.4 |
1 | Outer roll bar |
P65.20-2144-02
Shown on model 452.4 |
2 | Welding flange |
3 | Welding points |
4 | Spot weld pitches |
Pfeil | Welding edges |
P65.20-2145-06
| 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. | |
Topical note | Measures for preventing damage to vehicles or components when performing electric welding work | ||
Topical note | General information on body repair | ||
Topical note | Notes on performing repair, body work and welding on vehicles with airbags and RTE units | ||
Notes on replacing body parts | |||
1 | Disconnect battery ground line | ||
2 | Drill out spot welds (3) at the weld flange (2) using a spot weld removing tool | In addition, the fold in the front area must be folded upward. | |
3 | Remove the outer roll bar (1) | ||
| Install | ||
4 | Smooth the welding edges (arrow) and remove the paint in the welding area of the separating point | ||
5 | Apply primer to bare weld points in repair area | Zinc dust paint suitable for spot welding | |
6 | Prepare the welding edges (arrow) | ||
7 | Remove the protective paint at the welding areas on the new outer roll bar (1) and apply primer to the bare welding areas | Zinc dust paint suitable for spot welding | |
8 | Punch welding flanges (2) with hole punching pliers at specified spot weld pitches (4) | Not in case of resistance spot welding. | |
9 | Fit the outer roll bar (1) | When fitting observe correct distances. Place body if necessary on straightening bench. The straightening bench and straightening set of the companies Celette, Car Bench, Car-O-Liner or Blackhawk can be optionally used. | |
10 | Weld the outer roll bar (1) by means of the inert gas / resistance spot welding method at the specified spot weld pitches (4) | ||
11 | Slightly smooth spot welds and unevennesses | ||
12 | Clean repair areas with wire brush and then apply primer | ||
13 | Supplement standard sealants with body sealant | White sealing compound, 310 ml, DBL 6069.20 | |
14 | Paint repair area adjacent surfaces | ||
Topical note | Notes on paintwork repairs | ||
15 | Add cavity preserving agent |
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