Remove A-pillar together with side longitudinal member - AR63.20-P-1150-01T

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Cutting Templates (211 589 05 23 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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-1024-04A	Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 RPM)

WORKSHOP EQUIPMENT

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

REPAIR MATERIALS

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

Fig 3: Identifying Separation Points (Areas A, B, C, D) (Dimension w, x, y and y1)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Mark separation points and cut (areas A, B, C and D).
Dimension w approx. 200 mm. Dimension x approx. 150 mm.

Dimension y approx. 100 mm.

Dimension y1 approx. 130 mm. Dimension z approx. 630 mm.

Do not damage floor located behind (area D).
Remove section.

Fig 4: Identifying Areas K, L, AV And BN
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Expose spot welds and cut out with spot weld cutter (areas K, L, AV and BN).
Expose spot welds and cut out with spot weld cutter (area AW).
separate (areas BI and BL).
Unscrew door hinges.
Remove section from A-pillar

Fig 5: Identifying Area AW, BI & BL
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Areas O, AO, AQ, BF And BS
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Expose spot welds and cut out with spot weld cutter (areas O, AO, AQ, BF and BS).
Remove reinforcements for hinges.

Fig 7: Identifying Areas K1, L1, M, X1, AQ, AR And AV
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Mark separation point (area M).
Dimension x1 approx. 50 mm.
Separate paneling and longitudinal member (area M).
Expose spot welds and cut out with spot weld cutter (areas K1, L1, AQ, AR and AV).
Remove inner A-pillar and section from longitudinal member.

Fig 8: Identifying Areas AA, AB, K2, P, Q, R, S, T, U, V, xx & xy
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Mark separation points (areas P, Q, T and U).
Dimension v approx. 50 mm. Dimension xx approx. 50 mm.

Dimension xy approx. 100 mm.
Separate paneling (areas P and T).
Cut reinforcement (area Q).
Separate paneling and center A-pillar (area U).
Expose spot welds and cut out with spot weld cutter (areas K2, R, S, AA and AB).
Remove sections

Fig 9: Identifying Areas BJ, BK And BR
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Expose spot welds and cut out with spot weld cutter (areas BJ, BK and BR).
Remove section from longitudinal member.

Fig 10: Identifying Connection Surfaces Shaded Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind connection surfaces down to bare metal in shaded areas. Sand spot weld flanges to bare metal on both sides

Fig 11: Identifying Connection Surfaces Shaded Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind connection surfaces down to bare metal in shaded areas. Sand spot weld flanges to bare metal on both sides
Remove grinding and drilling chips using wet/dry vacuum cleaner.
Coat insides of spot weld flanges with zinc dust paint.