AR63.20-S-1107-03P | Partially weld in A-pillar | ||
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. | |
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. | |
Topical note | Measures for preventing damage to components when performing electric welding and soldering work | ||
Topical note | Pretreatment of bonding surfaces | ||
| 000 588 01 84 00 Welder | ||
| 000 588 02 84 00 Welder |
210 589 17 23 00
Side portal frame
Repair materials |
Number | Designation | Order number |
BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
BR00.45-Z-1001-13A | Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN) | A 003 990 35 97 |
BR00.45-Z-1003-01A | White sealing compound, 310 ml, DBL 6069.20 | A 001 989 63 20 |
BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |
The following steps are shown on the left side of the vehicle and must be performed analogously on the right side in the event of damage.
S63.20-4927-09
1 | Install, fit A-pillar reinforcement (2) and fix in place with side portal frame, welding fixture and screws (3, 4). |
Commercially available devices/tools |
2 | Drill rivet holes in A-pillar reinforcement (2) with Ø 6.5 mm (area A). |
Commercially available devices/tools |
3 | Remove bolts (3, 4). |
4 | Remove A-pillar reinforcement (2) and welding fixture. |
5 | Deburr rivet holes (area A) on both sides. |
6 | Coat insides of the riveted joints and rivet holes with zinc dust paint. |
7 | Apply 2-component adhesive to the body (area B). |
Observe pretreatment of bonding surfaces (area B). Observe manufacturer's specifications for curing and processing times of 2-component adhesive. |
8 | Install and fit A-pillar reinforcement (2) and fix in place with welding fixture and screws (3, 4). |
Commercially available devices/tools |
S63.20-4928-09
9 | A-pillar reinforcement (2) (areas C, C1, D and E). |
10 | A-pillar reinforcement (2) (area F). |
11 | Rivet A-pillar reinforcement (2) with rivets with a diameter of 6.4 x 14 (area G). |
Commercially available devices/tools |
12 | Remove welding device. |
13 | Face-grind spot welds (areas C, C1, D and E). |
Commercially available devices/tools |
14 | Remove shavings. |
Commercially available devices/tools |
15 | Apply sealant (area H). |
S63.20-4929-06
S63.20-4930-09
16 | Clean areas that are no longer accessible after installing the A-pillar outer section (1) and coat with zinc dust paint. |
17 | Install, fit A-pillar outer section (1) and fix in place with side portal frame, welding fixture and screw (6). |
Commercially available devices/tools |
18 | A-pillar outer section (1) (areas I, J and K). |
19 | A-pillar outer section (1) (areas L, M and N). |
20 | Remove welding device. |
21 | Face-grind inert gas spot welds (areas L, M and N). |
Commercially available devices/tools |
22 | A-pillar outer section (1) (areas O and P). |
Inert gas weld in intervals and allow to cool down in between. Reduces heat distortion. |
23 | Grind inert gas welds down flat (areas O and P). |
Commercially available devices/tools |
24 | Clean weld joints. |
Commercially available devices/tools |
25 | Remove shavings. |
Commercially available devices/tools |
26 | Repair and smooth surfaces on A-pillar outer section (1) (areas O and P). |
Different methods can be used to restore the surfaces. |
S63.20-4931-06