Separating A-pillar - AR63.20-P-1100-01P

Fig 1: Identifying Spot Weld Cutter (201 589 00 51 00)

Fig 2: Identifying Cutting Templates (203 589 06 23 00)

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1002-01A	Ball cutter, dia. 12 mm
WH58.30-Z-1006-01A	Vario Drill WS 91 spot weld removing tool
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-1004-20A	Hot-air gun

WORKSHOP EQUIPMENT

WE58.40-Z-1001-03A	Drill (electric/pneumatic)
WE58.40-Z-1002-03A	Straight grinder (electric/pneumatic)
WE58.40-Z-1004-03A	Body saw (electric/pneumatic)

Mark separation points on side longitudinal member and cut through completely with body saw (area A).
Do not damage main floor.

Fig 3: Identifying Separation Points On Side Longitudinal Member
Mark separation point on outer A-pillar with cutting templates and cut with body saw (area B).
Do not damage longitudinal member outer shell below.
Expose spot welds in between and cut out.
Remove section.

Fig 4: Identifying Separation Point On Outer A-Pillar
Mark separation point on longitudinal member outer shell with cutting template (area C).

Fig 5: Identifying Separation Point On Longitudinal Member Outer Shell (1 Of 2)
Cut separation point on longitudinal member outer shell with body saw (area C).
Do not damage main floor.
Expose spot welds between separation points A and C and cut out.
Remove section of outer longitudinal member.

Fig 6: Identifying Separation Point On Longitudinal Member Outer Shell (2 Of 2)

Fig 7: Identifying Separation Points On A-Pillar
Mark separation points on A-pillar and cut through completely with body saw (areas D and E).
Dimensions: a = approx. 150 mm b = approx. 50 mm

Do not damage roof frame on inside of vehicle.

Fig 8: Identifying Spot Welds Area - F And G
Expose spot welds and cut out with spot weld cutter (area G).
Spot weld (arrow) is not visible and must be felt from the inside of the spot welding flange.
Separate separation points with straight grinder (area F).
Remove section.

Fig 9: Identifying Spot Welds Area - H
Expose spot welds and cut out with spherical cutter (area H).

Fig 10: Identifying Spot Welds Area - I, J, K And L
Expose spot welds and cut out with spherical cutter (areas J, K and L).
Expose spot welds and cut out with spot weld cutter (area I).

Fig 11: Identifying Spot Welds Area - M
Expose spot welds and cut out with spot weld cutter (area M).
Spot welds (arrows) are not visible and must be felt from the inside of the spot welding flange.

Fig 12: Identifying Spot Welds Area - N
Expose spot welds and cut out with spot weld cutter and spherical cutter (area N).

Fig 13: Identifying Spot Welds Area - O
Expose spot welds and cut out with spherical cutter (area O).

Fig 14: Identifying A-Pillar Heated Area
Heat up A-pillar in shaded areas with hot air blower.
Remove A-pillar.

Fig 15: Identifying Separation Points On Outer A-Pillar Paneling And A-Pillar Reinforcement
Mark separation points on outer A-pillar paneling and cut with body saw (area P).
Dimension: c = approx. 100 mm
Expose spot welds and cut out with spot weld cutter (area Q), remove remaining part.
Expose spot welds and cut out with spot weld cutter (area R), remove remaining part.
Mark separation point on A-pillar reinforcement and cut with body saw (area S).
Dimension: d = approx. 30 mm
Expose spot welds and cut out with spot weld cutter (areas Y), remove remaining part.
Grind down weld (area V).
Expose spot welds and cut out with spot weld cutter (areas T), remove remaining part.
Expose spot welds and cut out with spot weld cutter (area W).
Heat inner longitudinal member with hot air blower in shaded area (foam filled area).
Remove remaining reinforcement (1).
Expose spot welds and cut out with spot weld cutter (area X), remove remaining part.

Fig 16: Identifying Spot Welds Area - W And X