Remove/install A-pillar outer section - AR63.20-P-1102SX
MODEL 221
| Removing | |||
|---|---|---|---|
| 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 | |
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes | Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only. | AS00.00-Z-0016-01A | |
| 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 | |
| General notes on repair of vehicles with ultra-high-strength steel. | Failure to observe instructions when straightening/repairing, separating, preparing adhesive points, joining/connecting, resistance spot welding, MAG welding, MAG brazing can lead to considerable damage to ultra high-strength steels and their joints. | AH60.00-P-0024-01N | |
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-N-0005-01A | ||
| General information on repairs to body | AH60.00-N-0001-01A | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1 | Remove front door | Vehicles without code (Z07) Top protection | AR72.10-P-0500SX |
| Vehicles with code (Z07) Top protection | AR72.10-P-0500SXS | ||
| 2 | Remove front fender | AR88.10-P-1000SX | |
| 3 | Remove engine hood | AR88.40-P-3000SX | |
| 4 | Remove door sill molding | Vehicles without code (Z07) Top protection |
AR68.30-P-4100SX |
| Vehicles with code (Z07) Top protection | AR68.30-P-4100SXS | ||
| 5 | Remove windshield | Vehicles without code (Z07) Top protection | AR67.10-P-1000SX |
| Vehicles with code (Z07) Top protection | AR67.10-P-1000SXS | ||
| 6 | Cover all detachable parts remaining in vehicle with tarp. | ||
| 7 | Equip straightening bench with module members or crossmembers and straightening bracket set | Celette straightening bench Set of Celette module members 955.940 Celette auxiliary member, 955.908 Multi-Z straightening set system MZ 450.000 Celette straightening bracket set 7221.300 Car-Bench straightening bracket set 82456, see GOTIS http://gotis.aftersales.mercedes-benz.com |
|
| 8 | Lift vehicle with two-post lift | Two-post lift, see GOTIS http://gotis.aftersales.mercedes-benz.com | |
| 9 | Remove stop plugs from jack support points | ||
| 10 | Set vehicle onto straightening bench | ||
| 11 | Fasten vehicle to straightening bench | ||
| 12 | Set up side portal frame with inspection and welding device | ||
| Figure | |||
| Figure | |||
| 13 | Check installation position of A-pillar, align | ||
| 14 | Remove side portal frame with inspection and welding device | ||
| 15 | Separate A-pillar outer paneling (1) and A-pillar reinforcement (2) | BTR-Usibor drill bit, dia. 6.7 m, BTR-Usibor dia. 8x80 mm center punch Drill, straight grinder, angle grinder, body saw, dry vacuum cleaner, see GOTIS http://gotis.aftersales.mercedes-benz.com | AR63.20-P-1102-01SX |
| Figure | |||
| Figure | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 16 | Prepare A-pillar outer paneling (1) and A-pillar reinforcement (2) for installation | Drill, straight grinder, angle grinder, body saw, see GOTIS http://gotis.aftersales.mercedes-benz.com | AR63.20-P-1102-02SX |
| Figure | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 17 | Set up side portal frame with inspection and welding device | ||
| Figure | |||
| Figure | |||
| 18 | Install A-pillar outer paneling (1) and A-pillar reinforcement (2) | BTR-Usibor drill bit, dia. 6.7 m, BTR-Usibor dia. 8x80 mm center punch Taurus 4 blind rivet tool, inert gas welder, spot welder, drill, straight grinder, angle grinder, dry vacuum cleaner, see GOTIS http://gotis.aftersales.mercedes-benz.com | AR63.20-P-1102-03SX |
| Figure | |||
| 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 | ||
| Adhesive | *BR00.45-Z-1092-02A | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| 19 | Unfasten vehicle from straightening bench | ||
| 20 | Install stop plugs in jack support points | ||
| 21 | Lift vehicle with two-post lift | Two-post lift, see GOTIS http://gotis.aftersales.mercedes-benz.com | |
| 22 | Remove straightening bench. | ||
| 23 | Clean repair areas | ||
| 24 | Prime area to be repaired using primer filler | ||
| 25 | Paint repair areas and adjacent surfaces | ||
| 26 | Carry out seam sealing after repairs | AR97.10-P-4000SX | |
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 27 | Apply additional cavity preservation | Cavity preservation gun HRS no. 11072, see GOTIS http://gotis.aftersales.mercedes-benz.com | AR97.20-P-1500SX |
| MB cavity wax preservation, 1 l | *BR00.45-Z-1003-05A | ||
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| 28 | Remove tarp | ||
| 29 | Install windshield | Vehicles without code (Z07) Top protection | AR67.10-P-1000SX |
| Vehicles with code (Z07) Top protection | AR67.10-P-1000SXS | ||
| 30 | Install door sill molding | AR68.30-P-4100SX | |
| Vehicles with code (Z07) Top protection | AR68.30-P-4100SXS | ||
| 31 | Install engine hood | AR88.40-P-3000SX | |
| 32 | Install front fender | AR88.10-P-1000SX | |
| 33 | Install front door | Vehicles without code (Z07) Top protection | AR72.10-P-0500SX |
| Vehicles with code (Z07) Top protection | AR72.10-P-0500SXS |
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-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |
| 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-1002-13A | Polygrip countersunk head rivet, 6.4 x14 | A 003 990 86 97 05 |
| BR00.45-Z-1012-13A | Blind rivet 6.5x12.5 | A 004 990 16 97 |
| BR00.45-Z-1001-13A | Blind rivet 6.4x14 | A 003 990 35 97 |