A-Pillar Complete Replacement - Ar63.20-S-1100E

Model 447, 448

Fig 1: Outer Front Pillar, Inner Front Pillar, Inner Front Pillar Reinforcement And Adjacent Component Locations

Courtesy of MERCEDES-BENZ USA

	Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)	Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines. Model 447 with engine 780	AS00.00-Z-0035-01A
	The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases	Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system.	AS00.00-Z-0007-01A
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of injury caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
Notice	Notes on battery		AH54.10-P-0001-01A
Notice	General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment	Model 447 with engine 780	AH00.00-Z-0300-01A
Notice	Special instructions for lifting and supporting vehicle		AH00.60-S-0100-01KOA
Notice	General information on body repair		AH60.00-P-0001-01KOA
Notice	Notes on resistance spot welding of multiple-layer sheet metal flange		AH60.00-S-0028-01KOS
Notice	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A
Notice	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	General information on riveting		AH60.00-P-0003-01N
	General information on MB materials		AH98.00-P-9409-03A
	Remove
1	Remove all detachable parts in area of repair point.
2	Remove soundproofing.	Only in repair area.	AR60.00-S-1752E
3	Cover all detachable parts remaining in vehicle with welding protection blankets.	Commercially available devices/tools Welding protection blanket
4	Set up straightening bench with crossbars and straightening set. 000 588 50 23 00 Body straightening system		WS60.00-P-0439K
5	Place vehicle on straightening bench and fasten. 000 588 01 80 00 Swivel arm vehicle lift		WS00.00-P-0041B
6	Remove upper front longitudinal member.		AR62.20-S-1286-01E
	000 588 15 84 00 Heat gun	Commercially available devices/tools Spot weld milling machine Rotary wire brush Wet and dry vacuum cleaner	WS54.00-P-0125B
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
7	Cut off the A-pillar outer section (1).		AR63.20-S-1102-01E
	000 588 15 84 00 Heat gun	Commercially available devices/tools Body power jigsaw Rotary wire brush Spindle grinder Spot weld milling machine	WS54.00-P-0125B
8	Remove outer trim of upper A-pillar.	Commercially available devices/tools Body power jigsaw Spot weld milling machine Rotary wire brush Wet and dry vacuum cleaner	AR63.20-S-1105-01E
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
9	Partially remove reinforcement of inner upper A-pillar.		AR63.20-S-1111-01E
	000 588 15 84 00 Heat gun	Commercially available devices/tools Body power jigsaw Hand drill Spot weld milling machine Rotary wire brush Wet and dry vacuum cleaner	WS54.00-P-0125B
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
10	Separate reinforcement of inner A-pillar (2).		AR63.20-S-1115-01E
	000 588 15 84 00 Heat gun	Commercially available devices/tools Spot weld milling machine Rotary wire brush	WS54.00-P-0125B
11	Separate inner A-pillar (3).		AR63.20-S-1106-01E
	000 588 15 84 00 Heat gun	Commercially available devices/tools Spot weld milling machine Rotary wire brush Wet and dry vacuum cleaner	WS54.00-P-0125B
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
12	Prepare upper front longitudinal member for installation.	Commercially available devices/tools Rotary wire brush Wet and dry vacuum cleaner	AR62.20-S-1286-02E
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
13	Prepare A-pillar outer section (1) for installation.	Commercially available devices/tools Body power jigsaw Hole punching pliers Hand drill Rotary wire brush Wet and dry vacuum cleaner Clamping pliers (Standard)	AR63.20-S-1102-02E
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
14	Prepare outer trim of upper A-pillar for installation.	Commercially available devices/tools Body power jigsaw Rotary wire brush Hole punching pliers Wet and dry vacuum cleaner	AR63.20-S-1105-02E
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
15	Prepare partial reinforcement of inner upper A-pillar for installation.		AR63.20-S-1111-02E
	000 588 13 84 00 Welder	Commercially available devices/tools Body power jigsaw Clamping pliers (Standard) Rotary wire brush Wet and dry vacuum cleaner	WS60.00-P-0437K
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
16	Prepare reinforcement of inner A-pillar (2) for installation.	Commercially available devices/tools Rotary wire brush Wet and dry vacuum cleaner	AR63.20-S-1115-02E
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
17	Prepare inner A-pillar (3).	Commercially available devices/tools Rotary wire brush Wet and dry vacuum cleaner	AR63.20-S-1106-02E
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
18	Install and weld in inner A-pillar (3).		AR63.20-S-1106-03E
	000 588 12 84 00 Welder		WS00.00-P-0318K
	000 588 13 84 00 Welder		WS60.00-P-0437K
	000 588 50 23 00 Body straightening system	Commercially available devices/tools Clamping pliers (Standard) Hand drill Angular grinder Rotary wire brush Wet and dry vacuum cleaner	WS60.00-P-0439K
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Adhesive kit, body, 2-component adhesive	*BR00.45-Z-1092-02A
		Side portal frame	Fig 3
19	Install and weld in reinforcement of inner A-pillar (2).		AR63.20-S-1115-03E
	000 588 13 84 00 Welder		WS60.00-P-0437K
	000 588 50 23 00 Body straightening system	Commercially available devices/tools Clamping pliers (Standard) Hand drill Blind riveting tool (setting force > 19 kN) Rotary wire brush Wet and dry vacuum cleaner Squeeze gun	WS60.00-P-0439K
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Seam seal 300 ml in black or white	*BR00.45-Z-1003-01A
		Blind rivet with polygrip countersunk head 6.4x14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)	*BR00.45-Z-1002-13A
		Side portal frame	Fig 3
20	Install and weld in partial reinforcement of inner upper A-pillar.		AR63.20-S-1111-03E
	000 588 12 84 00 Welder		WS00.00-P-0318K
	000 588 13 84 00 Welder	Commercially available devices/tools Clamping pliers (Standard) Hand drill Blind riveting tool (set force > 19 kN) Wet and dry vacuum cleaner Squeeze gun	WS60.00-P-0437K
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Seam seal 300 ml in black or white	*BR00.45-Z-1003-01A
		Adhesive kit, body, 2-component adhesive	*BR00.45-Z-1092-02A
		Blind rivet with polygrip countersunk head 6.4x14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)	*BR00.45-Z-1002-13A
21	Install and weld in outer trim of upper A-pillar.		AR63.20-S-1105-03E
	000 588 12 84 00 Welder		WS00.00-P-0318K
	000 588 13 84 00 Welder	Commercially available devices/tools Clamping pliers (Standard) Rotary wire brush Angular grinder Wet and dry vacuum cleaner	WS60.00-P-0437K
		Adjust gap dimensions	*BE60.00-Z-1002-01KOJ
		Adjust gap dimensions	*BE60.00-Z-1004-01KOJ
		Feeler gauge	Fig 4
22	Install corresponding welding fixture.	Model 447 with engine 622, 780	AR62.20-S-1286-05EFA
Notice	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
		Model 447 with engine 254, 274, 651, 654 Model 448 with engine 254, 274	AR62.20-S-1286-05EFE
		Screw/bolt, suspension strut to body	*BA32.25-Z-1004-04KOC
		Model 447 with engine 254, 274, 651, 654 Model 448 with engine 254, 274 Welding device	Fig 2
		Model 447 with engine 622, 780 Welding device	Fig 5
23	Install and weld in upper front longitudinal member with welding fixture.		AR62.20-S-1286-03E
	000 588 13 84 00 Welder	Commercially available devices/tools Clamping pliers (Standard) Hand drill Blind riveting tool (set force > 19 kN) Rotary wire brush Wet and dry vacuum cleaner Squeeze gun	WS60.00-P-0437K
		Adhesive kit, body, 2-component adhesive	*BR00.45-Z-1092-02A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Blind rivet 6.4x14 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)	*BR00.45-Z-1001-13A
		Model 447 with engine 254, 274, 651, 654 Model 448 with engine 254, 274 Welding device	Fig 2
		Model 447 with engine 622, 780 Welding device	Fig 5
	Remove
24	Remove corresponding welding fixture.	Model 447 with engine 254, 274, 651, 654 Model 448 with engine 254, 274 Welding device	Fig 2
		Model 447 with engine 622, 780 Welding device	Fig 5
25	Install and weld in A-pillar outer section (1).		AR63.20-S-1102-03E
	000 588 12 84 00 Welder		WS00.00-P-0318K
	000 588 13 84 00 Welder		WS60.00-P-0437K
	000 588 50 23 00 Body straightening system	Commercially available devices/tools Clamping pliers (Standard) Hand drill Rotary wire brush Angular grinder Wet and dry vacuum cleaner Squeeze gun	WS60.00-P-0439K
		Adjust gap dimensions	*BE60.00-Z-1004-01KOJ
		Seam seal 300 ml in black or white	*BR00.45-Z-1003-01A
		Feeler gauge	Fig 4
		Side portal frame	Fig 3
26	Release vehicle from straightening bench, lift and remove straightening bench.
27	Remove welding protection blankets.
	Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.	No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
28	Prime repair areas with a primer filler.
Notice	Notes on paintwork repairs	Repair area must be free of dust and grease. Otherwise adhesion problems may occur Use only primer fillers approved by manufacturer. See guidelines for paint technology in the workshop portal.	AH98.00-P-9408-02A
29	Seal seam after repair.	Supplement standard seals with sealant.	AR97.10-S-4000E
	Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.	No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
30	Paint repair area and adjacent surfaces.
Notice	Notes on paintwork repairs	Repair area must be free of dust and grease. Otherwise adhesion problems may occur Only use paints approved by the manufacturer. See guidelines for paint technology in the workshop portal.	AH98.00-P-9408-02A
31	Supplement cavity preservation.		AR97.20-S-1500E
32	Install soundproofing.	Only in repair area.	AR60.00-S-1752E
33	Install dowels for the mounting rail of the longitudinal member panel.	Model 447, 448.8 with code CN1 (Exterior rocker panel) Only perform operation steps for installing the dowel.	AR88.80-S-6005-01CH
		Primer Teroson 150 (Terokal 150)	*BR00.45-Z-1179-02A
		Teroson PU 6800 adhesive	*BR00.45-Z-1147-02A
34	Install all detachable parts in area of repair point.

ADJUST GAP DIMENSIONS

Number	Designation				Model 447, 448 except code W64, W65, W68	Model 447, 448 with code W64, W65, W68
BE60.00-Z-1002-01KOJ	Adjust gap dimensions	Fender to headlamp	Dimension "BA"	mm	2 (±1)	2 (±1)
		Fender to bumper	Dimension "BB"	mm	0, 3 (±0, 25)	0, 3 (±0, 25)
		Fender to A-pillar	Dimension "BC"	mm	2, 6 (±1)	2, 6 (±1)
		Fender to front door	Dimension "BD"	mm	4, 5 (±0, 8)	4, 5 (±0, 8)
		Fender to longitudinal member	Dimension "BE"	mm	4, 5 (±1, 2)	4, 5 (±1, 2)
		Fender to longitudinal member	For picture, see		AR60.00-S-0700-01E	AR60.00-S-0700-01E

ADJUST GAP DIMENSIONS

Number	Designation				Model 447, 448 except code W64, W65, W68	Model 447, 448 with code W64, W65, W68
BE60.00-Z-1004-01KOJ	Adjust gap dimensions	Front door to longitudinal member	Dimension "DA"	mm	6 (+2/-1)	6 (+2/-1)
		Front door to sidewall	Dimension "DB"	mm	4 (±1)	4 (±1)
		Front door to sliding door	Dimension "DC"	mm	4 (+1, 2/-0, 8)	4 (+1, 2/-0, 8)
		Front door to A-pillar	Dimension "DD"	mm	4, 5 (+1, 5/-1)	4, 5 (+1, 5/-1)
		Front door to fuel filler door	Dimension "DE"	mm	4 (±1)	4 (±1)
		Front door to fuel filler door	For picture, see		AR60.00-S-0700-01E	AR60.00-S-0700-01E

SUSPENSION STRUTS

Number	Designation			Model 447, 448
BA32.25-Z-1004-04KOC	Screw/bolt, suspension strut to body	Stage 1	Nm	40
BA32.25-Z-1004-04KOC	Screw/bolt, suspension strut to body	Stage 2	∠°	90

Fig 2: Identifying Welding Device (447 589 02 23 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Side Portal Frame (210 589 17 23 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Welding Device (447 589 03 23 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42
BR00.45-Z-1001-13A	Blind rivet 6.4x14 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)	A 003 990 35 97
BR00.45-Z-1002-13A	Blind rivet with polygrip countersunk head 6.4x14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)	A 003 990 86 97 05
BR00.45-Z-1003-01A	Seam seal 300 ml in black or white	A 005 989 63 20
BR00.45-Z-1092-02A	Adhesive kit, body, 2-component adhesive	A 012 989 17 71
BR00.45-Z-1147-02A	Teroson PU 6800 adhesive	A 000 989 15 02 09
BR00.45-Z-1179-02A	Primer Teroson 150 (Terokal 150)	Henkel AG & Co. KGaA http://www.loctite.de