Remove/install A-pillar outer section - AR63.20-P-1102LF

MODEL 222

without CODE Z07 (Top protection)

Fig 1: A-Pillar Outer Section Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	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
	Risk of death when touching components on vehicles with high-voltage on-board electrical system	Do not touch components and open lines of the high-voltage on-board electrical system. Persons who wear electronic implants (e.g. cardiac pacemakers), must not carry out any work on high-voltage on-board electrical systems.	AS54.00-Z-0001-01A
	Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust	Wear dust filter mask, safety glasses and protective gloves. Use suitable, grounded dust extractor	AS60.00-Z-0007-01N
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Note on high-voltage on-board electrical system		AH54.00-P-0010-01A
	Note on high-voltage battery		AH54.10-P-0006-01MEV
	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	General information on repair of vehicles with ultra-strength steels.		AH60.00-P-0024-01N
	Evaluation of high-voltage components		AH54.00-P-6500-01SXH
	General information on body repair		AH60.00-P-0001-01A
	Note on working on aluminum components and vehicles		AH60.00-P-0034-01LF
	Notes on acoustic foam and structural foam in the vehicle		AH60.00-P-0039-01A
	General information on MB materials		AH98.00-P-9409-03A
	Remove
1	Remove detachable parts in area to be repaired
2	Cover all detachable parts remaining on vehicle with spark protection blanket
3	Remove upper front longitudinal member (4) and strut (5)	Commercially available tools Torx EPL 12 Round wire brush Weld-spot milling machine Body power jig saw Drill bits and milling cutters for high-strength steels Heat gun Wet/dry vacuum cleaner	AR62.20-P-1286-01LF
4	Set up straightening bench with module members, crossmember and straightening set	Observe set-up plans provided.
5	Place vehicle on straightening bench and fasten
6	Remove longitudinal member paneling (1) and A-pillar reinforcement (2)	Commercially available tools Round wire brush Body power jig saw Weld-spot milling machine Drill bits and milling cutters for high-strength steels Metal needle template Heat gun Wet/dry vacuum cleaner	AR63.20-P-1102-01LF
6		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
7	Prepare longitudinal member paneling (1) and A-pillar reinforcement (2)		AR63.20-P-1102-02LF
7		Commercially available tools Round wire brush Body power jig saw Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
8	Prepare upper front longitudinal member (4) and strut (5)	Use complete replacement part. Cuts and detachment of weld joints not required. Commercially available tools Round wire brush	AR62.20-P-1286-02LF
	Install
	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 flammable materials from the hazard area. Use air extraction system.	AS00.00-Z-0007-01A
	Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes	Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only.	AS00.00-Z-0016-01A
	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A
	Notes on processing of 2-K structural foam adhesive during body repairs		AH60.00-P-0040-01A
	General information on riveting		AH60.00-P-0003-01N
9	Install longitudinal member paneling (1), A- pillar reinforcement (2), upper front longitudinal member (4) and strut (5) and weld in		AR63.20-P-1102-03LF
		Commercially available tools Round wire brush Drill bit for high-strength Ø 6.7 mm steels Manual temporary fastener, 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Wet/dry vacuum cleaner Polygrip countersunk-head rivet, 6.4x14	*BR00.45-Z-1002-13A
		Blind rivet 6.5x12.5	*BR00.45-Z-1012-13A
		Blind rivet, 6.5 x 14.5	*BR00.45-Z-1016-13A
		Flow-form rivet structure 3.35 mm up to 4.1 mm clamping range (S2)	*BR00.45-Z-1027-13A
		Blind rivet 6.4x12 (clamping range 1 mm to 3.5 mm)	*BR00.45-Z-1035-13A
		Cleaner	*BR00.45-Z-1025-04A
		2-component adhesive for reinforcements	*BR00.45-Z-1152-02A
		Body adhesive kit, 2-component adhesive	*BR00.45-Z-1092-02A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Side portal frame	Figure
10	Release vehicle from straightening bench, lift vehicle and remove straightening bench
11	Clean welds and sheet metal flange	Commercially available tools Round wire brush
12	Remove spark protection blankets
13	Clean repair area	Commercially available tools Wet/dry vacuum cleaner
	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 using primer filler
	Notes on paintwork repairs		AH98.00-P-9408-02A
		Use only primer filler approved by Daimler AG.
15	Carry out seam sealing after repairs	Supplement standard seals with sealant.	AR97.10-P-4000LF
	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
	Paint repair areas and adjacent surfaces
	Notes on paintwork repairs	Use only paints approved by Daimler AG.	AH98.00-P-9408-02A
17	Apply additional cavity preservation		AR97.20-P-1500LF
18	Install all detachable body components in area to be repaired

Fig 2: Identifying Side Portal Frame (210 589 17 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-1002-13A	Polygrip countersunk-head rivet, 6.4 x 14	A 003 990 86 97 05
BR00.45-Z-1012-13A	Blind rivet 6.5x12.5	A 004 990 16 97
BR00.45-Z-1016-13A	Blind rivet, 6.5 x 14.5	A 004 990 17 97
BR00.45-Z-1025-04A	Cleaner	A 005 989 19 71
BR00.45-Z-1027-13A	Flow-form rivet structure 3.35 mm up to 4.1 mm clamping range (S2)	A 000 991 10 33
BR00.45-Z-1035-13A	Blind rivet 6.4x12 (clamping range 1 mm to 3.5 mm)	A 000 991 76 32
BR00.45-Z-1092-02A	Body adhesive kit, 2-component adhesive	A 009 989 36 71
BR00.45-Z-1152-02A	2-component adhesive for reinforcements	A 011 989 99 71