Completely replacing A-pillar - AR63.20-P-1100P

MODEL 203.0/ 2/ 7 

Fig 1: Identifying Upper/Bottom Front Reinforcement, Inner/Outer A-Pillar And A-Pillar Reinforcement

	Remove
	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
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of death  caused by high voltage used for arc welding. Risk of explosion  caused by welding in the area of highly inflammable materials. Injury hazard  from welding spatter and UV-light while welding. Risk of poisoning  caused by inhaling welding vapors.	Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor.	AS00.00-Z-0007-01A
	General information on repairs to body	All models	AH60.00-N-0001-01A
	Measures for preventing damage to vehicles or components when performing arc welding work	All models	AH00.00-N-0005-01A
	Notes on paintwork repairs	All models	AH98.00-P-9408-02A
	Notes on repairing A-pillar with side longitudinal member	Model 203.7	AH63.20-P-1150-01PB
1	Remove engine hood		AR88.40-P-3000P
2	Remove left front fender		AR88.10-P-1000P
3	Remove left front door		AR72.10-P-0500P
4	Remove left front seat		AR91.10-P-1000P
5	Remove foot mats
6	Remove instrument panel carrier	Protect heater housing or AC housing against damage	AR68.10-P-1111P
7	Remove pedal assembly for parking brake		AR42.20-P-0510P
8	Remove or loosen electric lines and vacuum lines in area to be repaired
9	Remove windshield		AR67.10-P-1000P
10	Remove sliding roof water drain hose
11	Cover vehicle passenger compartment
12	Remove damping on inside on firewall, floor and A-pillar
13	Remove detachable parts in area to be repaired
14	Cover all detachable body components remaining in vehicle (area to be repaired)	Tarpaulin (fire-resistant)	*WH58.30-Z-1001-40A
15	Equip straightening bench with modular or crossmembers and straightening tools	Observe the assembly plans provided.
		Celette straightening bench M8S	*WE58.40-Z-1001-01E
		Celette straightening bench Sevenne	*WE58.40-Z-1001-01E
		Set of Celette modular members 955.940	*WE58.40-Z-1007-01E
		Celette additional member 955.908	*WE58.40-Z-1008-01E
		Celette straightening bench 7203.300 (for model 203)	*WE58.40-Z-1029-01A
		Car-Bench straightening bench BT 17	*WE58.40-Z-1003-01E
		Car-Bench straightening bench BT 43/1	*WE58.40-Z-1003-01E
		Celette straightening bracket set 7203.309 (for model 203), as supplement to 7203.300	*WE58.40-Z-1031-01A
		Celette straightening set 7203.310 (for model 203), only for new orders, includes supplement 7203.309	*WE58.40-Z-1032-01A
		Car-Bench universal crossmember set A 296	*WE58.40-Z-1010-01E
		Car-bench straightening set 82434 (for model 203)	*WE58.40-Z-1030-01A
		Multi-Z straightening set system MZ 450.000	*WE58.40-Z-1006-01E
16	Set vehicle onto straightening bench using two-column lift and fasten	Two-post lift	*WE58.40-Z-1001-05A
17	Cut out A-pillar		AR63.20-P-1100-01P
		Cutting templates	Figure
		Spot weld milling cutter	Figure
		Test and welding device	Figure
		Ball cutter, Ø 12 mm	*WH58.30-Z-1002-01A
		Vario Drill WS 91 spot weld removing tool	*WH58.30-Z-1006-01A
		Round wire brush, braided, Ø 70 mm	*WH58.30-Z-1001-03A
		Cutting disk, Ø 65 mm, 80 m/s (max. 23,500 rpm)	*WH58.30-Z-1021-04A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Straight grinder (electric/pneumatic)	*WE58.40-Z-1002-03A
		Angular grinder (electric/pneumatic)	*WE58.40-Z-1003-03A
		Body saw (electric/pneumatic)	*WE58.40-Z-1004-03A
		Hot-air gun	*WH58.30-Z-1004-20A
18	Prepare connection points on body		AR63.20-P-1100-02P
		Round wire brush, braided, Ø 70 mm	*WH58.30-Z-1001-03A
		Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 rpm)	*WH58.30-Z-1024-04A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Angular grinder (electric/pneumatic)	*WE58.40-Z-1003-03A
		Wet/dry vacuum cleaner	*WE58.40-Z-1005-03A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
19	Prepare inner section, console and paneling		AR63.20-P-1100-03P
		Cutting templates	Figure
		Round wire brush, braided, Ø 70 mm	*WH58.30-Z-1001-03A
		Hole punching pliers, Ø 7 mm	*WH58.30-Z-1002-02A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Body saw (electric/pneumatic)	*WE58.40-Z-1004-03A
		Wet/dry vacuum cleaner	*WE58.40-Z-1005-03A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
20	Weld in inner section and console		AR63.20-P-1100-04P
		Test and welding device	Figure
		Side portal frame	Figure
		Electrode miller	*WH58.30-Z-1003-01A
		Round wire brush, braided, Ø 70 mm	*WH58.30-Z-1001-03A
		Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 rpm)	*WH58.30-Z-1024-04A
		Cutting disk, Ø 65 mm, 80 m/s (max. 23,500 rpm)	*WH58.30-Z-1021-04A
		Clamping pliers	*WH58.30-Z-1003-02A
		Inert gas welder	*WE58.40-Z-1001-02A
		Spot welder	*WE58.40-Z-1002-02A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Straight grinder (electric/pneumatic)	*WE58.40-Z-1002-03A
		Angular grinder (electric/pneumatic)	*WE58.40-Z-1003-03A
		Body saw (electric/pneumatic)	*WE58.40-Z-1004-03A
		Wet/dry vacuum cleaner	*WE58.40-Z-1005-03A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
21	Weld in paneling		AR63.20-P-1100-05P
		Test and welding device	Figure
		Side portal frame	Figure
		Electrode miller	*WH58.30-Z-1003-01A
		Round wire brush, braided, Ø 70 mm	*WH58.30-Z-1001-03A
		Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 rpm)	*WH58.30-Z-1024-04A
		Cutting disk, Ø 65 mm, 80 m/s (max. 23,500 rpm)	*WH58.30-Z-1021-04A
		Clamping pliers	*WH58.30-Z-1003-02A
		Inert gas welder	*WE58.40-Z-1001-02A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Straight grinder (electric/pneumatic)	*WE58.40-Z-1002-03A
		Angular grinder (electric/pneumatic)	*WE58.40-Z-1003-03A
		Body saw (electric/pneumatic)	*WE58.40-Z-1004-03A
		Wet/dry vacuum cleaner	*WE58.40-Z-1005-03A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
22	Release vehicle from straightening bench and lift with two-column lift, remove straightening bench	Two-post lift	*WE58.40-Z-1001-05A
23	Clean areas to be repaired and prime with priming filler	Notes on paintwork repairs
24	Seam sealing following repair	Supplement standard seals with MB preservative.	AR97.10-P-4000P
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
25	Paint A-pillar and adjacent surfaces	Notes on paintwork repairs
26	Apply additional cavity preservation		AP97.20-P-0640-01A
	Notes on cavity preservation	Model 124, 126, 129, 140, 170, 201, 202, 203, 208, 210, 215, 220, 463, 671	AH97.20-P-0001-01B
27	Install sliding roof water drain hose
28	Install dampenings on inside on firewall, floor and A-pillar
29	Install electrical leads and vacuum lines in area repaired
30	Install instrument panel carrier		AR68.10-P-1111P
31	Install parking brake pedal assembly		AR42.20-P-0510P
32	Install windshield		AR67.10-P-1000P
33	Install left front seat		AR91.10-P-1000P
34	Install left front door		AR72.10-P-0500P
35	Install left front fender		AR88.10-P-1000P
36	Install engine hood		AR88.40-P-3000P
37	Reinstall all removed assembly parts

Fig 2: Identifying Side Portal Frame (210 589 17 23 00)

Fig 3: Identifying Inspection And Welding Device (203 589 00 23 00)

Fig 4: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Fig 5: 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-1003-01A	Electrode miller
WH58.30-Z-1006-01A	Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1002-02A	Hole punching pliers, dia. 7 mm
WH58.30-Z-1003-02A	Clamping pliers
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-1024-04A	Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)
WH58.30-Z-1004-20A	Hot-air gun
WH58.30-Z-1001-40A	Tarp (fire-resistant)

WORKSHOP EQUIPMENT

WE58.40-Z-1029-01A	Celette straightening bracket set 7203.300 (model 203)
WE58.40-Z-1030-01A	Car bench straightening bracket set 82434, (model 203)
WE58.40-Z-1031-01A	Celette straightening bracket set 7203.309 (model 203), as supplement to 7203.300
WE58.40-Z-1032-01A	Celette straightening bracket set 7203.310 (model 203), only with new ordering contains addition 7203.309
WE58.40-Z-1001-01E	Celette straightening bench
WE58.40-Z-1003-01E	Car-Bench straightening bench
WE58.40-Z-1006-01E	Celette Multi-Z straightening set system
WE58.40-Z-1007-01E	Celette module crossmember set 955.940
WE58.40-Z-1008-01E	Celette additional member 955.908
WE58.40-Z-1010-01E	Car-Bench universal cross member set A 296
WE58.40-Z-1001-02A	Inert gas welder
WE58.40-Z-1002-02A	Spot welder
WE58.40-Z-1001-03A	Drill (electric/pneumatic)
WE58.40-Z-1002-03A	Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A	Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A	Body saw (electric/pneumatic)
WE58.40-Z-1005-03A	Wet/dry vacuum cleaner
WE58.40-Z-1001-05A	Two-post lifting platform

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-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42