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Separate A-pillar outer section - AR63.20-P-1102-01SX

Fig 1: Identifying Set Of Cutting Templates (221 589 03 23 00)
G07583651Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G07583652Courtesy 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-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
  1. Scribe separation line on A-pillar outer paneling (1) (area A).
  2. Scribe separation lines on A-pillar outer paneling (1) using SPECIAL TOOL cutting template (area B).

    IMPORTANT When replacing complete A-pillar SPECIAL TOOL position cutting template on Y-marking. Expose Y-marking if necessary (arrow).

    IMPORTANT When replacing A-pillar outer paneling (1) and A-pillar reinforcement (2), establish separation line in accordance with the damage profile using the SPECIAL TOOL cutting template (area B).

    Dimensions: 

    Fig 3: Identifying A-Pillar Outer Paneling And Cutting Template
    G07583653Courtesy of MERCEDES-BENZ USA
  3. Separate separation points on A-pillar outer paneling (1) using body saw (areas A and B) (areas A and B).

    IMPORTANT Do not damage the underlying side longitudinal member and A-pillar reinforcement (2).

  4. Expose spot welds and weld seams on A-pillar outer paneling (1) (areas C, C 1 D and E).
  5. Cut out spot welds on A-pillar outer paneling (1) using SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas C and C 1 ).

    IMPORTANT Cut through two sheet metal layers (area C).

  6. Separate weld seams on A-pillar outer paneling (1) using cutting disk (areas D and E).
    Fig 4: Identifying A-Pillar Outer Paneling Spot Weld & Weld Seam Areas
    G07583654Courtesy of MERCEDES-BENZ USA
  7. Expose spot welds on A-pillar outer paneling (1) (areas F, G, H, H1 and I).
  8. Cut out spot welds on A-pillar outer paneling (1) using SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas F, G, H, H1 and I).

    IMPORTANT Cut through two sheet metal layers (areas H1 and F).

    Fig 5: Identifying A-Pillar Outer Paneling Spot Welding Areas
    G07583655Courtesy of MERCEDES-BENZ USA
  9. Heat A-pillar outer paneling (1) in cross-hatched areas using COMMERCIALLY AVAILABLE TOOLS hot air gun.

    IMPORTANT Cross-hatched areas are bonded.

  10. Remove damaged A-pillar outer paneling (1).
    Fig 6: Identifying A-Pillar Outer Paneling Heating Area
    G07583656Courtesy of MERCEDES-BENZ USA
  11. Expose spot welds on A-pillar reinforcement (2) (areas J, K and L).
  12. Center punch holes with COMMERCIALLY AVAILABLE TOOLS BTR Usibor center punch, dia. 8 x 80 mm (area J).
  13. Drill holes with COMMERCIALLY AVAILABLE TOOLS BTR Usibor drill bit, dia. 6.7 mm (area J).
  14. Cut out spot welds on A-pillar reinforcement (2) using SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas K and L).
    Fig 7: Identifying A-Pillar Reinforcement Spot Welding Area
    G07583657Courtesy of MERCEDES-BENZ USA
  15. Expose spot welds and weld on A-pillar reinforcement (2) (areas M and N).
  16. Cut out spot welds on A-pillar reinforcement (2) using SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (area M).
  17. Cut weld on A-pillar reinforcement (2) using cutting disk (area N).
    Fig 8: Identifying A-Pillar Reinforcement Spot Welding Area
    G07583658Courtesy of MERCEDES-BENZ USA
  18. Heat A-pillar reinforcement (2) in cross-hatched areas using COMMERCIALLY AVAILABLE TOOLS hot air gun.

    IMPORTANT Cross-hatched areas are bonded.

    Fig 9: Identifying A-Pillar Reinforcement Heating Area
    G07583659Courtesy of MERCEDES-BENZ USA
  19. Remove damaged A-pillar reinforcement (2).
  20. Grind mating surfaces in cross-hatched areas down to bare metal using COMMERCIALLY AVAILABLE TOOLS round wire brush.

    IMPORTANT Grind cross-hatched area down to bare metal from inside (area U 1 ).

    IMPORTANT Grind spot weld flange down to bare metal on both sides (areas O and P).

    IMPORTANT Observe pretreatment of bonding surfaces (areas O, P, Q, R, S, T, U and U1 ).

    NOTES To prevent adhesion problems, do not coat bonding surfaces with zinc dust paint. (areas O, P, Q, R, S, T, U and U 1 ).

  21. Remove grinding and drill shavings using wet/dry vacuum cleaner.
Fig 10: Identifying A-Pillar Reinforcement Grinding Areas
G07583660Courtesy of MERCEDES-BENZ USA
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