Replace complete A-pillar together with side longitudinal member - AR63.20-P-1150QA: Notes
| Removing | |||
|---|---|---|---|
| Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding spatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. | Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. | AS00.00-Z-0007-01A | |
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. | AS00.00-Z-0010-01A | |
| 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. | AS00.00-Z-0017-01A | |
| Deburr repair panels. | |||
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-N-0005-01A | ||
| General information on repairs to body | AH60.00-N-0001-01A | ||
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| 1 | Prepare required workshop equipment and commercially available tools for repair | ||
| 2 | Remove engine hood | AR88.40-P-3000Q | |
| 3 | Remove front fender | AR88.10-P-1000Q | |
| 4 | Remove front door | AR72.10-P-0500Q | |
| 5 | Remove front seat | AR91.10-P-1000Q | |
| 6 | Remove floor mats | ||
| 7 | Remove cross member under instrument panel | AR68.10-P-1120QA | |
| 8 | Remove pedal assembly for parking brake | AR42.20-P-0510P | |
| 9 | Remove or free up electrical lines and vacuum lines in area to be repaired. | ||
| 10 | Remove windshield | AR67.10-P-1000P | |
| 11 | Remove insulating material from inner firewall, floor and A-pillar. | ||
| 12 | Remove all detachable body components in area to be repaired | ||
| 13 | Cover all detachable parts remaining vehicle with fireproof tarpaulin | ||
| 14 | Equip straightening bench with module members, cross members and straightening bracket set. | Celette straightening bracket set 7203.300 (for model 203), Celette straightening bracket set 7203.309 (for model 209), as supplement to 7203.300, Celette straightening bracket set 7203.310 (for model 209), only for new orders includes supplement 7203.309, Celette straightening bracket set 7209.309 (for model A 209), as supplement to 7203.300, as well as 7203.310 see GOTIS http://gotis.aftersales.daimlerchrysler.com Car-bench straightening set 82434 (for model 203) see GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| 15 | Lift vehicle with two-column lifting platform | ||
| 16 | Set vehicle onto straightening bench | ||
| 17 | Fasten vehicle to straightening bench | ||
| 18 | Set up side portal frame with check and welding devices | ||
| Figure | |||
| Figure | |||
| Figure | |||
| 19 | Set up front portal frame with welding devices | Observe body plans provided. see GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Fig 6 | |||
| Fig 7 | |||
| Fig 8 | |||
| 20 | Check installation position of A-pillar, align | ||
| 21 | Remove portal frame with check and welding devices | ||
| 22 | Remove welding panel on side longitudinal member | Shown on model 209.3 | AR63.30-P-1500Q |
| 23 | Remove outer paneling from A-pillar (1). | AR63.20-P-1105QA | |
| 24 | Separate A-pillar with outer longitudinal member (2). | AR63.20-P-1150-01QA | |
| Figure | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 25 | Separate inner A-pillar (5) | AR63.20-P-1106-01QA | |
| Figure | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 26 | Prepare inner A-pillar (5) | AR63.20-P-1106-02QA | |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 27 | Prepare A-pillar with outer longitudinal member (2) for installation | AR63.20-P-1150-06QA | |
| Figure | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 28 | Set up side portal frame with check and welding devices | ||
| Figure | |||
| Figure | |||
| Figure | |||
| 29 | Set up front portal frame with welding devices | ||
| Fig 6 | |||
| Fig 7 | |||
| Fig 8 | |||
| 30 | Install and weld in inner A-pillar (5) | AR63.20-P-1106-03QA | |
| Figure | |||
| Fig 6 | |||
| Fig 7 | |||
| Figure | |||
| Figure | |||
| Fig 8 | |||
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| Preservation agent | *BR00.45-Z-1003-05A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Rivet | *BR00.45-Z-1001-13A | ||
| Polygrip countersunk head rivet, 6.4x14 | *BR00.45-Z-1002-13A | ||
| 31 | Install and weld in complete A-pillar | AR63.20-P-1100-10QA | |
| Figure | |||
| Figure | |||
| Figure | |||
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| Preservation agent | *BR00.45-Z-1003-05A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Rivet | *BR00.45-Z-1001-13A | ||
| Polygrip | *BR00.45-Z-1002-13A countersunk head rivet, 6.414 | ||
| 32 | Remove portal frame with check and welding devices | ||
| 33 | Unfasten vehicle from straightening bench | ||
| 34 | Lift vehicle with two-column lifting platform | ||
| 35 | Remove straightening bench. | ||
| 36 | Clean weld joints and sheet metal flange with round wire brush | ||
| 37 | Clean repair areas | ||
| 38 | Prime area to be repaired using primer filler | ||
| 39 | Carry out seam sealing after repairs | AR97.10-P-4000Q | |
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 40 | Paint repair areas and adjacent surfaces | ||
| 41 | Apply additional cavity preservation | AR97.20-P-1500QA | |
| Preservation agent | *BR00.45-Z-1003-05A | ||
| 42 | Remove tarp | ||
| 43 | Install insulating material from inner firewall, floor and A-pillar. | ||
| 44 | Install parking brake pedal assembly | AR42.20-P-0510P | |
| 45 | Install cross member below instrument panel | AR68.10-P-1120QA | |
| 46 | Install electrical lines and vacuum lines in repair area and fasten. | ||
| 47 | Install windshield | AR67.10-P-1000P | |
| 48 | Install front seat | AR91.10-P-1000Q | |
| 49 | Install floor mats | ||
| 50 | Install engine hood | AR88.40-P-3000Q | |
| 51 | Install front door | AR72.10-P-0500Q | |
| 52 | Install front fender | AR88.10-P-1000Q | |
| 53 | Install all removed detachable body components |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | Sealant | A 001 989 63 20 |
| BR00.45-Z-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 20 |
| BR00.45-Z-1003-05A | Preservation agent A | 000 986 72 70 05 |
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
| BR00.45-Z-1001-13A | Rivet | A 003 990 35 97 |
| BR00.45-Z-1002-13A | Polygrip countersunk head rivet, 6.4x14 | A 003 990 86 97 05 |