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Renew complete A-pillar - AR63.20-P-1100CW: Notes

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MODEL 204.0/2 

Shown on model 204.0 

Fig 1: Identifying A-Pillar Outer Section Components
G07069828Courtesy of MERCEDES-BENZ USA
REMOVING Removing     
DANGER 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
DANGER 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
DANGER 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
NOTES Measures for preventing damage to vehicles or components when performing electric welding work   AH00.00-N-0005-01A 
NOTES General information on repairs to body   AH60.00-N-0001-01A
NOTES Notes on paintwork repairs   AH98.00-P-9408-02A
NOTES Notes on cavity preservation   AH97.20-P-0001-01B
IMPORTANT General information on MB materials   AH98.00-P-9409-03A
IMPORTANT General information on riveting   AH60.00-P-0003-01N
1 Prepare required workshop equipment and commercially available tools for repair    
2 Remove all detachable parts in area to be repaired    
3 Cover all detachable parts remaining vehicle with fireproof tarpaulin    
4 Equip straightening bench with module members, cross members and straightening bracket set. IMPORTANT Observe body plans provided.  
5 Lift vehicle with two-post lifting platform  
6 Set vehicle onto straightening bench    
7 Fasten vehicle to straightening bench    
8 Set up side portal frame with welding device IMPORTANT Observe body plans provided.  
    SPECIAL TOOL Side portal frame Figure
    SPECIAL TOOL Welding device Figure
9 Check installation position of A-pillar, align    
10 Remove side portal frame with welding device    
11 Separate upper front longitudinal member (6)   AR62.20-P-1286-01CW
    SPECIAL TOOL Spot weld milling cutter Figure
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
12 Remove A-pillar outer section (1) with A-pillar reinforcement (2).   AR63.20-P-1102-01CW 
    SPECIAL TOOL Spot weld milling cutter Figure
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
13 Remove A-pillar inner section (5), side longitudinal member (3) and offset reinforcement (4)   AR63.20-P-1100-01CW 
    SPECIAL TOOL Spot weld milling cutter Figure
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
14 Prepare upper front longitudinal member (6)   AR62.20-P-1286-02CW
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
15 Prepare A-pillar outer section (1) with A-pillar reinforcement (2) for installation   AR63.20-P-1102-02CW 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
16 Prepare A-pillar inner section (5) and side longitudinal member (3) with offset reinforcement (4) for installation.   AR63.20-P-1100-09CW
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install     
17 Set up side portal frame with welding device IMPORTANT Observe body plans provided.  
    SPECIAL TOOL Side portal frame Figure
    SPECIAL TOOL Welding device Figure
18 Install A-pillar inner section (5) and side longitudinal member (3) with offset reinforcement (4).   AR63.20-P-1100-10CW
    SPECIAL TOOL Side portal frame Figure
    SPECIAL TOOL Welding device Figure
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
    Rivet *BR00.45-Z-1012-13A 
19 Install A-pillar outer section (1) with A-pillar reinforcement (2). IMPORTANT Before installing A-pillar outer section (1), install upper front longitudinal member (6). AR63.20-P-1102-03CW
    SPECIAL TOOL Side portal frame Figure
    SPECIAL TOOL Welding device Figure
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
    Rivet *BR00.45-Z-1001-13A 
    Polygrip countersunk head rivet, 6.4 X14 *BR00.45-Z-1002-13A 
    Rivet *BR00.45-Z-1012-13A 
    Protective tube *BR00.45-Z-1003-15A 
20 Install welding device   AR62.20-P-1286-05CW
21 Install upper front longitudinal member (6)   AR62.20-P-1286-03CW
    SPECIAL TOOL Welding device Figure
    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 
    Adhesive *BR00.45-Z-1011-02B 
22 Remove side portal frame with welding device    
23 Unfasten vehicle from straightening bench    
24 Lift vehicle with two-post lifting platform  
25 Remove straightening bench.    
26 Clean weld joints and sheet metal flanges with round wire brush    
27 Clean repair areas    
28 Prime area to be repaired using primer filler    
29 Carry out seam sealing after repairs IMPORTANT Supplement standard sealant with sealant. AR97.10-P-4000CW
    Sealant *BR00.45-Z-1003-01A 
    Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
30 Paint repair areas and adjacent surfaces    
31 Apply additional cavity preservation   AR97.20-P-1500CW
     
NOTES Notes on cavity preservation   AH97.20-P-0001-01B
    Preservation agent *BR00.45-Z-1003-05A 
32 Remove tarp IMPORTANT On all covered parts remaining in vehicle.  
33 Install all removed detachable body components    
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G07069829Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Side Portal Frame (210 589 17 23 00)
G07069830Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Welding Device (204 589 00 23 00)
G07069831Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1003-01A Sealant, white, 310 ml, DB supply specification 6069.20 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 Cavity preservation, solvent-free (1 l container) 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 Blind rivet 6.4x14 A 003 990 35 97
BR00.45-Z-1002-13A Polygrip countersunk head rivet, 6.4x14 A 003 990 86 97 05
BR00.45-Z-1012-13A Blind rivet 6.5x12.5 A 004 990 16 97
BR00.45-Z-1003-15A Protective tube A 169 611 01 46
BR00.45-Z-1011-02B Sealant Omnifit FD10-1042 A 002 989 23 20
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