P63.20-7607-09
Dimensions:
a approx. 5 mm
In principle replacement parts required for this repair can be replaced completely. Ensure that the standard joining and bonding connections are observed or are coordinated with the responsible Daimler departments in individual cases. On cut panels also ensure that the joints to the present paneling are accessible for later cavity preservation and that the minimum distance between foam-protected areas and connection points is approx. 100 mm.
1 Scribe separation point on side roof paneling (1) (area A).
2 Cut side roof paneling (1) at separation point (area A).
Do not damage A-pillar outer section (2) laying below.
3 Expose spot welds on side roof paneling (1) (areas B, C and D).
4 Cut out spot welds on side roof paneling (1) (areas B, C and D).
P63.20-7612-06
5 Heat side roof paneling (1) in crosshatched areas.
Crosshatched areas are bonded.
6 Remove damaged side roof paneling (1).
7 Remove upper foam element between side roof paneling (1) and outer section of A pillar (2).
P63.20-7615-09
Dimensions:
b approx. 75 mm
8 Mark separation points on A-pillar outer section (2) (areas D and E).
Measure dimension a for separation point at Y-markings (arrows) (area F).
9 Cut A-pillar outer section (2) at separation points (areas D and E).
Do not damage components below.
10 Expose spot welds on A-pillar outer section (2) (areas G, H, I, J and K).
11 Cut out welds on A-pillar outer section (2) (areas G, H, I, J and K).
P63.20-7619-08
12 Heat outer A-pillar section (2) in crosshatched areas.
Crosshatched areas are bonded.
13 Remove damaged A-pillar outer section (2)
14 Sand down connection surfaces on body to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.
15 Remove drill shavings.
16 Coat insides of spot weld flanges with zinc dust paint.
To prevent adhesion problems, do not coat bonding surfaces with zinc dust paint (areas L, and M).
Observe pretreatment of bonding surfaces (areas L and M).