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

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-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)

REPAIR MATERIALS

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

Scribe separation line on upper inner A-pillar (1) (area A).
Transfer separation line on upper inner A-pillar (1) from vehicle (area A).
Separate upper inner A-pillar (1) at separation point using body saw (area A).
Grind mating surfaces on upper inner A-pillar (1) in cross-hatched areas using round wire brush.

Fig 2: Identifying Upper Inner A-Pillar Mating Surfaces
Courtesy of MERCEDES-BENZ USA
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 B, C, D, E and F).

Observe pretreatment of bonding surfaces.

Grind spot weld flanges down to bare metal on both sides.

Fig 3: Identifying Inner Outer Longitudinal Member Spot Welding Areas
Courtesy of MERCEDES-BENZ USA
Scribe separation line on inner outer longitudinal member (2) (areas G and H).
Separate inner outer longitudinal member (2) at separation point using body saw (areas G and H).
Do not damage underlying sheet metal panel (area H).
Expose spot welds on inner outer longitudinal member (2) (area J).
Cut out spot welds on inner outer longitudinal member (2) using spot weld milling cutter
Dimensions:

Fig 4: Identifying Inner Outer Longitudinal Member Mating Surfaces
Courtesy of MERCEDES-BENZ USA
Grind mating surfaces on inner outer longitudinal member (2) in cross-hatched areas using round wire brush.
Grind spot weld flanges down to bare metal on both sides.
Using zinc dust paint, coat insides of spot weld flanges that were not additionally bonded (area T).
To prevent adhesion problems, do not coat bonding surfaces with zinc dust paint. (areas K, L, M, N, O, P, Q, R and S).

Observe pretreatment of bonding surfaces.
Scribe separation line on outer longitudinal member (3) (area U).
Transfer separation line on outer longitudinal member (3) from vehicle (area U).
Separate outer longitudinal member (3) at separation point using cutting disk (area U).

Fig 5: Identifying Outer Longitudinal Member Separation Point
Courtesy of MERCEDES-BENZ USA
Grind mating surfaces on outer longitudinal member (3) in cross-hatched areas using round wire brush.
Grind spot weld flanges down to bare metal on both sides.
Using zinc dust paint, coat insides of spot weld flanges that were not additionally bonded.

Fig 6: Identifying Outer Longitudinal Member Mating Surfaces

Courtesy of MERCEDES-BENZ USA

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

Observe pretreatment of bonding surfaces.