Prepare complete outer side longitudinal member

AR63.30-S-1000-02P	Prepare complete outer side longitudinal member
 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. Deburr repair panels.	AS00.00-Z-0017-01A
	000 588 00 84 00 Heat gun		WS54.00-P-0049B

Model

470, 471

Repair materials

Number	Designation	Order number
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42

 The following operation steps are shown as per the "entire longitudinal member variant" for the left side of the vehicle and must be similarly performed on the right side in the event of damage.

Prepare complete outer side longitudinal member

1	Mark separating points on new outer side longitudinal member part (2) and cut (areas A, B and C).

 Transfer separation lines from vehicle.

 Commercially available devices/tools
Body power jigsaw

a	Dimension approx. 140 mm
b	Dimension approx. 170 mm
c	Dimension approx. 175 mm

S63.30-4784-06

S63.30-4803-09

2	Mill off spot welds on new outer side longitudinal member part (2) (areas D, E, F and I).

 Cut off spot welds (arrows) through 2 panel thicknesses.

 Commercially available devices/tools
Spot weld milling machine

3	Heat new outer side longitudinal member part (2) in cross-hatched areas (areas G and H).

 Cross-hatched areas are bonded (areas G and H).

4	Remove longitudinal member inner shell (3) from new outer side longitudinal member part (2).

If longitudinal member inner shell (3) will be replaced.

 New outer side longitudinal member part (2) is assembled from multiple pieces.

5	Remove outer side longitudinal member (1) and longitudinal member inner shell (3) from new outer side longitudinal member part (2).

 New outer side longitudinal member part (2) is assembled from multiple pieces.

S63.30-4791-09

6	Drill holes for MAG welding in outer side longitudinal member (1) (areas J, K and L).

 Commercially available devices/tools
Hand drill

7	Grind mating surfaces on outer side longitudinal member (1) down to bare metal in cross-hatched areas and around the holes (areas J, K and L).

 Sand down spot weld flanges to bare metal on both sides.

 Commercially available devices/tools
Rotary wire brush

8	Remove shavings, millings and drilling chips.

 Commercially available devices/tools
Wet and dry vacuum cleaner

9	Apply zinc dust paint to insides of spot weld flanges. onto connecting flanges that are no longer accessible after installing side roof paneling .

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