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Home >> Mercedes Benz >> 2015 >> Sprinter 3500 Van Cargo Extended, RWD >> Repair and Diagnosis >> Collision >> General Collision Information >> Side Wall - Testing & Repair Part 2 - 906 Chassis >> Testing & Repair >> Remove A-Pillar Inner Section - Ar63.20-D-1104-01H

Remove A-Pillar Inner Section - Ar63.20-D-1104-01H

G10888779Courtesy of MERCEDES-BENZ USA
  1. Scribe cut on A-pillar (1) and cut (area A).

    NOTES Do not cut too deeply. Otherwise the components below can be damaged and weakened.

    IMPORTANT To mark the separation line (area A) the dimension (a) must not exceed 370 mm.

  2. Scribe cut on A-pillar (1) and cut (area B).

    IMPORTANT Cut through A-pillar (1) and inner A-pillar (area B).

  3. Scribe cut on A-pillar (1) and cut (area C).

    NOTES Do not cut too deeply. Otherwise the components below can be damaged and weakened.

  4. Scribe cut on A-pillar (1) and cut (area D).

    NOTES Do not cut too deeply. Otherwise the components below can be damaged and weakened.

    IMPORTANT Cut through A-pillar (1) and longitudinal member reinforcement (area D).

    G10888780Courtesy of MERCEDES-BENZ USA
  5. Expose spot welds on A-pillar (1) and cut out (areas E, F and G).
  6. Remove section (1.1).
  7. Expose spot welds on A-pillar (1) and cut out (areas J, K and L).
  8. Scribe cut on A-pillar (1) and cut (area H).

    NOTES Do not cut too deeply. Otherwise the components below can be damaged and weakened.

  9. Remove section (1.2).
    G10888781Courtesy of MERCEDES-BENZ USA
    G10888782Courtesy of MERCEDES-BENZ USA
  10. Pry open sheet metal lug (1.3) in direction of arrow.
  11. Expose spot welds on A-pillar (1) and cut out (areas M, N, O, P and Q).

    IMPORTANT Cut out spot welds through two panel thicknesses (area N). It is necessary to feel some of the spot welds from the inside (area Q).

    G10888783Courtesy of MERCEDES-BENZ USA
  12. Expose spot welds on A-pillar (1) and cut out (areas R and S).
  13. Expose spot welds on A-pillar (1) and cut out (area T).
  14. Remove section (1.4).
  15. Remove damaged A-pillar (1).
    G10888784Courtesy of MERCEDES-BENZ USA
    G10888785Courtesy of MERCEDES-BENZ USA
  16. Grind mating surfaces down to bare metal in the crosshatched areas.

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

  17. Remove drilling chips/savings.
  18. Coat inside of spot welding flanges with zinc dust paint.
  19. Grind mating surfaces down to bare metal in the crosshatched areas.

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

  20. Remove drilling chips/savings.
  21. Coat inside of spot welding flanges with zinc dust paint.
    G10888786Courtesy of MERCEDES-BENZ USA
    G10888787Courtesy of MERCEDES-BENZ USA
  22. Grind mating surfaces down to bare metal in the crosshatched areas.

    IMPORTANT Grind spot weld flanges down to bare metal on both sides. Grind down to bare metal from inside (area T).

  23. Remove shavings and drill chips.
  24. Coat insides of spot weld flanges with zinc dust paint.