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Replace complete A-pillar - AR63.20-P-1100M

MODEL 220 (except 220.8) 

Fig 1: Identifying Inner A-Pillar, Rear Reinforcement And Bracket
G10128122Courtesy of MERCEDES-BENZ USA
REMOVING Remove     
NOTES General information on repairs to body All models  
1 Remove engine hood    
2 Remove front fender    
3 Remove front door    
4 Remove front seat Model 220.0/1 up to 31.8.02  
Models 220.0/1 as of 1.9.02 with code (803)
Model year 2003		  
5 Remove foot mats    
6 Remove instrument panel    
7 Remove jacket tube    
Models 220.026/028/063/065/070/075/083/084/087/128/165/170/175/178/183/184/187  
8 Remove pedal assembly for parking brake   AR42.20-P-0510I
9 Remove attached parts in engine compartment and on firewall    
10 Remove or loosen electric lines and vacuum lines in area to be repaired    
11 Remove windshield    
12 Remove sliding roof water drain hose    
13 Cover vehicle passenger compartment    
14 Remove damping on inner firewall, floor and A-pillar    
15 Remove detachable parts in area to be repaired    
16 Cover all attached parts remaining in vehicle (area to be repaired) Tarpaulin (fireproof) *WH58.30-Z-1001-40A 
17 Equip Celette or Car-Bench straightening bench with modular members or cross members and straightening bracket set IMPORTANT Observe design plans provided  
Celette straightening bench (MUF 5, MUF 7) *WE58.40-Z-1001-01E 
Celette straightening bench (M8S) *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 
Car-Bench straightening bench BT 17 *WE58.40-Z-1003-01E 
Car-Bench universal cross member set A 296 *WE58.40-Z-1010-01E 
Car-Bench universal cross member set A 296/15 (all cross members 1500 mm long) *WE58.40-Z-1011-01E 
Celette straightening bracket set 7220.300 (for model 220) *WE58.40-Z-1018-01A 
Celette additional straightening bracket set 7220.309, (for model 220) *WE58.40-Z-1019-01A 
Celette additional straightening set 7220.307 for Celette straightening bracket set 7220.310 (for model 220 4MATIC) *WE58.40-Z-1049-01A 
Car-Bench straightening bracket set 82 430, (model 220) *WE58.40-Z-1020-01A 
Car-Bench additional straightening set 82446 for Car-Bench straightening bracket set 82430 (for model 220 4MATIC) *WE58.40-Z-1050-01A 
DANGER Risk of death  . Death may result if vehicle slips or topples from the lifting platform. Align vehicle between the pillars of the lifting platform and position the four support plates at the lifting platform mounting points specified by the vehicle manufacturer.  
18 Place vehicle on straightening bench using two-column lift and fasten Two-column lift *WE58.40-Z-1001-05A 
19 Cut out A-pillar   AR63.20-P-1100-01M
SPECIAL TOOL Spot weld cutter Figure
SPECIAL TOOL Template for side longitudinal member Figure
20 Prepare connection points on body   AR63.20-P-1100-02M
INSTALLING Install     
DANGER The high voltage used for arc welding presents a lethal hazard. Explosion hazard  when welding in area of materials easily inflammable. Injury hazard  from welding spatter and UV-light while welding. Risk of poisoning  when 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.  
NOTES Measures for preventing damage to vehicles or components when performing arc welding work All models  
21 Prepare inner section, console and paneling   AR63.20-P-1100-03M
22 Set up side portal straightening bracket set IMPORTANT Observe design plans provided  
SPECIAL TOOL Multi-Z element MZ 260 Fig 5
SPECIAL TOOL Side portal frame Figure
SPECIAL TOOL Check and welding gauges Fig 6
23 Welding in inner section and console   AR63.20-P-1100-04M
24 Welding in paneling   AR63.20-P-1100-05M
DANGER Risk of death  . Death may result if vehicle slips or topples from the lifting platform. Align vehicle between the pillars of the lifting platform and position the four support plates at the lifting platform mounting points specified by the vehicle manufacturer.  
25 Release vehicle from straightening bench and lift with two-column lift, remove straightening bench Two-column lift *WE58.40-Z-1001-05A 
26 Clean areas repaired and prime with primer/filler    
NOTES Notes on paintwork repairs Models 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463  
27 Supplement standard sealing with MB body sealant IMPORTANT See paintwork manual  
28 Add MB permanent underfloor protection as a supplement to underbody protection installed as standard   AR97.20-P-0500-03A
29 Paint A-pillar and adjacent surfaces    
NOTES Notes on paintwork repairs Models 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463  
30 Supplement hollow cavity preservation    
REFER TO MAINTENANCE Preservation    
31 Reinstall all detachable parts removed    

Special tools 

Fig 2: Identifying Weld Spot Miller (201 589 00 51 00)
G07648025Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Template (220 589 09 23 00)
G10128103Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Side Portal Frame (210 589 17 23 00)
G07321115Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Multi-Z Elements MZ 260 (140 589 26 23 00)
G10111572Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Check And Welding Gauges (220 589 02 23 00)
G10128098Courtesy of MERCEDES-BENZ USA
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-1031-02A C-clamp
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-1010-06A Socket SW19 for hexagon head screws
WH58.30-Z-1015-06A SW17 socket wrench bit, 1/2 inch drive
WH58.30-Z-1001-11A Double end box wrench, offset, 17 x 19 mm
WH58.30-Z-1002-11A Double end box wrench, offset, 22 x 24 mm
WH58.30-Z-1001-40A Tarp (fire-resistant)
WORKSHOP EQUIPMENT

WE58.40-Z-1018-01A Celette straightening set 7220.300 (model 220)
WE58.40-Z-1019-01A Celette supplementary straightening bracket set 7220.309 (short straightening bench, model 220)
WE58.40-Z-1020-01A Car bench straightening set 82 430, (model 220)
WE58.40-Z-1049-01A Celette 7220.307 supplementary straightening set for Celette straightening bracket set 7220.310 (model 220 4MATIC)
WE58.40-Z-1050-01A Car-Bench 82446 supplementary straightening set for Car Bench straightening bracket set 82430 (model 220 4MATIC)
WE58.40-Z-1001-01E Celette straightening bench
WE58.40-Z-1002-01E Celette straightening unit
WE58.40-Z-1003-01E Car-Bench straightening bench
WE58.40-Z-1004-01E Car-Bench straightening lifting platform
WE58.40-Z-1005-01E Car-Bench straightening equipment
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-1011-01E Car-Bench Universal crossmember set A 296/15 (all crossmembers 1500 mm long)
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-1008-03A Pneumatic ratchet
WE58.40-Z-1001-05A Two-post lifting platform
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