Separate A-Pillar Outer Section - Ar63.20-P-1102-01LW

Model 205.0/1/2 

Model 253 

The following steps are shown on the left side of the vehicle and must be performed on the right side in the same way in the event of damage.

1. Model 253

   Mark separating point on A-pillar paneling (5) and cut (area B).

   Do not cut too deeply.

   Otherwise the components below can be damaged and weakened.

   Dimensions: 

   b = approx. 40 mm (measured from Y-marking on A-pillar reinforcement)

   Fig 1: Outer A-Pillar Removal Cut Lines And Measurement Locations (Model 205.0/1/2 & 253) (1 Of 2)

   Courtesy of MERCEDES-BENZ USA
2. Model 205.0/1/2

   Mark separating point on A-pillar paneling (5) and cut (area B).

   Do not cut too deeply.

   Otherwise the components below can be damaged and weakened.

   Dimensions: 

   b = approx. 238 mm

3. Mark separating point on A-pillar paneling (5) and cut (area A).

   Do not cut too deeply.

   Otherwise the components below can be damaged and weakened.

   Dimensions: 

   a = approx. 50 mm

4. Expose spot welds on A-pillar paneling (5) and cut out (areas C and D).

   Cut out spot welds through two panel thicknesses (areas D).

   Fig 2: Outer A-Pillar Removal Cut Lines And Measurement Locations (Model 205.0/1/2 & 253) (2 Of 2)

   Courtesy of MERCEDES-BENZ USA
5. Model 205.0/1/2

   Heat A-pillar paneling (5) in crosshatched areas.

   Cross-hatched areas are bonded.

6. Remove A-pillar paneling (5).

   Courtesy of MERCEDES-BENZ USA

   Fig 3: A-Pillar Reinforcement Removal Cut Lines And Measurement Locations (Model 205.0/1/2 & 253)

   Courtesy of MERCEDES-BENZ USA
7. Mark separating point on A-pillar reinforcement (6) and cut (area E).

   Do not cut too deeply.

   Otherwise the components below can be damaged and weakened.

   Dimensions: 

   e₁ = approx. 12 mm

   e₂ = approx. 30 mm

   f = approx. 253 mm

8. 1. 8.1 Model 205.0/1/2

      Mark separating point on A-pillar reinforcement (6) and cut (area F).

   2. 8.2 Model 253

      Mark separating point on Y-marking on A-pillar reinforcement (6) and cut (area F).

9. Expose spot welds on A-pillar reinforcement (6) and cut out (areas G and H).

   Cut out spot welds through two panel thicknesses (areas H).

10. Expose spot weld on A-pillar reinforcement (6) and drill with Ø 6.5 mm bit (area I).

    Dimensions: 

    f = approx. 253 mm

    Courtesy of MERCEDES-BENZ USA

11. Heat A-pillar reinforcement (6) in cross-hatched areas.

    Cross-hatched areas are bonded.

12. Remove A-pillar reinforcement (6).
    Fig 4: Inner A-Pillar Removal Cut Lines And Measurement Locations (Model 205.0/1/2 & 253)

    Courtesy of MERCEDES-BENZ USA
13. Mark separating points on A-pillar inner panel (7) and cut (areas J and K).

    Do not make the cuts too deep.

    Otherwise the components below can be damaged and weakened.

    Dimensions: 

    j = approx. 90 mm

    k = approx. 40 mm

14. Expose spot welds on A-pillar inner panel (7) and cut out (areas L and M).

    Cut out spot welds through two panel thicknesses (areas M).

15. Expose spot welds on A-pillar inner panel (7) and drill with Ø 6.5 mm bit (areas N).
16. Remove A-pillar inner panel (7).
17. Grind mating surfaces down to bare metal in the cross-hatched inner C-pillar sidewall.

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

18. Remove grinding dust and drill chips.
19. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas P).

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

    Courtesy of MERCEDES-BENZ USA