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

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Cutting Templates (211 589 05 23 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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-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)

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

Fig 3: Identifying Separation Points (Areas A, B, C And D)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Mark separation points and cut (areas A, B, C and D).
Dimension w approx. 200 mm. Dimension x approx. 150 mm. Dimension y approx. 100 mm.

Dimension y1 approx. 130 mm. Dimension z approx. 630 mm.

Do not damage floor located behind (area D).
Remove section.

Fig 4: Identifying Spot Welds (Areas K, L, AV And BN)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Expose spot welds and cut out with spot weld cutter (areas K, L, AV and BN).
Expose spot welds and cut out with spot weld cutter (area AW).
separate (areas BI and BL).
Unscrew door hinges.
Remove section from A-pillar

Fig 5: Identifying Spot Welds (Area AW)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Spot Welds (Areas O, AO, AQ, BF And BS)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Expose spot welds and cut out with spot weld cutter (areas O, AO, AQ, BF and BS).
Remove reinforcements for hinges.

Fig 7: Identifying Spot Welds (Areas K1, L1, AQ, AR And AV) & Separation Point (Area M)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Mark separation point (area M).
Dimension x1 approx. 50 mm.
Separate paneling and longitudinal member (area M).
Expose spot welds and cut out with spot weld cutter (areas K1, L1, AQ, AR and AV).
Remove inner A-pillar and section from longitudinal member.

Fig 8: Locating Separation Points (Areas P, Q, T And U) & Spot Welds (Areas K2, R, S, AA & AB)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Mark separation points (areas P, Q, T and U).
Dimension v approx. 50 mm. Dimension xx approx. 50 mm.

Dimension xy approx. 100 mm.
Separate paneling (areas P and T).
Cut reinforcement (area Q).
Separate paneling and center A-pillar (area U).
Expose spot welds and cut out with spot weld cutter (areas K2, R, S, AA and AB).
Remove sections

Fig 9: Identifying Spot Welds (Areas BJ, BK And BR)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Expose spot welds and cut out with spot weld cutter (areas BJ, BK and BR).
Remove section from longitudinal member.

Fig 10: Locating Connection Surfaces Shaded Areas (1 Of 2)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind connection surfaces down to bare metal in shaded areas. Sand spot weld flanges to bare metal on both sides

Fig 11: Locating Connection Surfaces Shaded Areas (2 Of 2)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind connection surfaces down to bare metal in shaded areas. Sand spot weld flanges to bare metal on both sides
Remove grinding and drilling chips using wet/dry vacuum cleaner.
Coat insides of spot weld flanges with zinc dust paint.