A-Pillar Partial Removal And Installation - Ar63.20-S-1107E
Model 447, 448
MODIFICATION NOTES
| 28.10.2021 | Sequence of operation steps revised. | Operation steps 11 to 19 | |
| 28.10.2021 | Method extended. | Operation steps 21 to 24 | AR63.20-S-1108-03E |
Shown on right side of vehicle
| 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 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 | |
| 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 | 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 | Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | |
| 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. | AR60.00-S-1752E | |
| 3 | Cover all detachable parts remaining in vehicle with welding protection blankets. | ||
| 4 |
Set up straightening bench with crossbars and straightening tool 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 | Cut off A-pillar outer section (1) in segments. | AR63.20-S-1108-01E | |
| 000 588 15 84 00 Heat gun | Spot weld milling machine Body power jigsaw |
WS54.00-P-0125B | |
| 7 | Cut off inner A-pillar reinforcement (2) in segments. | Body power jigsaw Rotary wire brush Wet and dry vacuum cleaner |
AR63.20-S-1109-01E |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 8 | Prepare A-pillar outer section (1) for installation in segments. | Hole punching pliers Hand drill Rotary wire brush Wet and dry vacuum cleaner |
AR63.20-S-1108-02E |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 9 | Prepare inner A-pillar reinforcement (2) for installation in segments. | Rotary wire brush Wet and dry vacuum cleaner |
AR63.20-S-1109-02E |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 10 | Weld in inner A-pillar reinforcement (2) section. | AR63.20-S-1109-03E | |
| 000 588 13 84 00 Welder | 000 588 12 84 00 Welder WS00.00-P-0318K Hand drill Angle grinder Blind riveting tool (setting force > 19 kN) Rotary wire brush Wet and dry vacuum cleaner |
WS60.00-P-0437K | |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 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 | ||
| Fig 1 | |||
| 11 | Install and weld in A-pillar outer section (1) and door hinge holder (3). | AR63.20-S-1108-03E | |
| 000 588 13 84 00 Welder | WS60.00-P-0437K | ||
| 000 588 12 84 00 Welder | Hand drill Rotary wire brush Angle grinder Wet and dry vacuum cleaner Squeeze gun |
WS00.00-P-0318K | |
| *BE60.00-Z-1004-01KOJ | |||
| Seam seal 300 ml in black or white | *BR00.45-Z-1003-01A | ||
| Fig 2 | |||
| Fig 1 | |||
| 12 | Release vehicle from straightening bench, lift and remove straightening bench. | ||
| 13 | 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 | |
| 14 | Prime repair area with a primer filler. | ||
| Notice | Notes on paintwork repairs | See guidelines for paint technology in the workshop portal. |
AH98.00-P-9408-02A |
| 15 | Seal seam after repair. | 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 | |
| 16 | Paint repair area and adjacent surfaces. | ||
| Notice | Notes on paintwork repairs | See guidelines for paint technology in the workshop portal. |
AH98.00-P-9408-02A |
| 17 | Supplement cavity preservation. | AR97.20-S-1500E | |
| 18 | Install soundproofing. | AR60.00-S-1752E | |
| 19 | Install dowels for the mounting rail of the longitudinal member panel. | Model 447, 448.8 with code CN1 (Exterior rocker panel) |
AR88.80-S-6005-01CH |
| Primer Teroson 150 (Terokal 150) | *BR00.45-Z-1179-02A | ||
| Teroson PU 6800 adhesive | *BR00.45-Z-1147-02A | ||
| 20 | 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-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) | ||
| For picture, see | AR60.00-S-0700-01E | AR60.00-S-0700-01E | ||||
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-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-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 |