Prepare A-pillar with side longitudinal member for installation - AR63.20-P-1150-06T

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1002-02A	Hole punching pliers, dia. 7 mm
WH58.30-Z-1001-03A	Round wire brush, braided, dia. 70 mm
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-1003-03A	Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A	Body saw (electric/pneumatic)

REPAIR MATERIALS

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

1. Transfer separation points from vehicle to new part and cut (areas C, D and Q).

   Observe reinforcement (area D).

2. Expose spot welds and cut out with spot weld cutter (area S).
3. Remove section.
   Fig 2: Identifying Separation Points (Areas C, D And Q) & Spot Welds (Area S)

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
   Fig 3: Identifying Connection Surfaces Shaded Areas

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Grind connection surfaces down to bare metal in shaded areas. Sand spot weld flanges to bare metal on both sides.
5. Coat insides of spot weld flanges with zinc dust paint.
   Fig 4: Identifying Separation Point (Area U) & Connection Surfaces

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. Transfer separation point from vehicle to new part and cut (area U).
7. Remove section.
8. Grind connection surfaces down to bare metal in shaded areas. Sand spot weld flanges to bare metal on both sides.
9. Coat insides of spot weld flanges with zinc dust paint.
   Fig 5: Identifying Separation Point (Area T), Holes (Areas AP & BR) & Connection Surfaces

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
10. Transfer separation point from vehicle to new part and cut (area T).
11. Remove section.
12. Punch holes (area AP).
13. Drill 7 mm dia. holes (area BR).
14. Grind connection surfaces down to bare metal in shaded areas. Sand spot weld flanges to bare metal on both sides.
15. Coat insides of spot weld flanges with zinc dust paint.
    Fig 6: Identifying Separation Point (Area M) & Connection Surfaces

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
16. Transfer separation point from vehicle to new part and separate (area M).
17. Remove section.
18. Grind connection surfaces down to bare metal in shaded areas. Sand spot weld flanges to bare metal on both sides.
19. Coat insides of spot weld flanges with zinc dust paint.