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

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

Courtesy of MERCEDES-BENZ USA

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-1007-01A	BTR Usibor drill bit, dia. 6.7 mm
WH58.30-Z-1008-01A	BTR Usibor milling cutter, dia. 8 mm
WH58.30-Z-1009-01A	BTR Usibor milling cutter, dia. 8 x44 mm
WH58.30-Z-1010-01A	BTR Usibor center punch Ø 8 x80 mm
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

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

Dimensions:

Fig 2: Identifying Outer Longitudinal Member Spot Welds & Separation Line

Courtesy of MERCEDES-BENZ USA

Scribe separation line on outer longitudinal member (2) (area A).
Separate outer longitudinal member (2) at separation point using cutting disk (area A).
Do not damage underlying sheet metal panel (area A).
Expose spot welds on outer longitudinal member (2) (areas B, B₁ , C, D, E, F and G).
Cut out spot welds on outer longitudinal member (2) using ball cutter (areas B and B ₁ ).
Cut out spot welds on outer longitudinal member (2) using Vario Drill spot weld removing tool (area C).
Cut out spot welds on outer longitudinal member (2) using BTR Usibor milling cutter, dia. 8 mm or BTR Usibor milling cutter, dia. 8x44 mm (areas D, E, F and G).
Heat outer longitudinal member (2) in cross-hatched areas using hot air gun.
Cross-hatched areas are additionally bonded.
Remove damaged outer longitudinal member (2).

Fig 3: Identifying Outer Longitudinal Member Heating Areas
Courtesy of MERCEDES-BENZ USA
Scribe separation lines on inner A-pillar (1) and inner longitudinal member section (3) (areas H, I and J).
Separate inner A-pillar (1) and inner longitudinal member section (3) at separation points using cutting saw (areas H, I and J).
Do not damage underlying sheet metal panel (areas I and J).

Dimensions:

Fig 4: Identifying Inner A-Pillar Separation Point Dimensions
Courtesy of MERCEDES-BENZ USA
Expose weld seams on inner A-pillar (1) (area T).
Separate welds on inner A-pillar (1) using cutting disk (area T).

Fig 5: Identifying Inner A-Pillar Spot Welding Areas
Courtesy of MERCEDES-BENZ USA
Expose spot welds on inner A-pillar (1) (areas K, L, L ₁ , M, N, O, P, Q, R and S).
Cut out spot welds on inner A-pillar (1) using spot weld milling cutter or ball cutter (areas K, L, L ₁ , M, N, O, P, Q and R).
Cut through two sheet metal layers (areas L ₁ and Q).
Drill dia. 6.5 mm spot welds in inner A-pillar (1) (area S).
Heat inner A-pillar (1) in cross-hatched areas using hot air gun.

Fig 6: Identifying Inner A-Pillar Heating Areas
Courtesy of MERCEDES-BENZ USA

Cross-hatched areas are additionally bonded.
Remove damaged inner A-pillar (1).

Fig 7: Identifying Inner A-Pillar Mating Surfaces
Courtesy of MERCEDES-BENZ USA
Grind mating surfaces in cross-hatched areas down to bare metal using round wire brush.
Grind spot weld flanges down to bare metal on both sides.
Remove grinding and drill shavings using wet/dry vacuum cleaner.
Using zinc dust paint, coat insides of spot weld flanges and riveted joints that were not additionally bonded.

To prevent adhesion problems, do not coat bonding surfaces with zinc dust paint. (areas U, V, W, X and Y).

Observe pretreatment of bonding surfaces.