Replace Complete A-Pillar Together With Side Longitudinal Member - AR63.20-P-1150GQ
MODEL 166, 292
Shown on model 166.0
| 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 | |
| General information on body repair | AH60.00-P-0001-01A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| Remove | |||
| 1 | Remove all detachable parts in area to be repaired | ||
| 2 | Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket | ||
| 3 |
Equip straightening bench with module members, cross members and straightening tool set 000 588 01 23 00 Body straightening system |
WS60.00-P-0023K | |
| 4 | Risk of death
caused by vehicle slipping or toppling off of the lifting platform. Place vehicle on straightening bench and fasten |
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 |
| 5 | Remove A-pillar outer section (1), A-pillar reinforcement (2) and A-pillar inner section (3) | AR63.20-P-1150-01GQ | |
Round wire brush Spot weld milling machine Drill bits and milling cutters for high-strength steels Body jig saw Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint |
*BR00.45-Z-1001-07A | ||
| 6 | Prepare A-pillar outer section (1), A-pillar reinforcement (2) and A-pillar inner section (3) for installation | AR63.20-P-1150-06GQ | |
Body jig saw Round wire brush Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint |
*BR00.45-Z-1001-07A | ||
| 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 inflammable materials from the hazard area. Use air extraction system. | AS00.00-Z-0007-01A | |
| 7 | Install A-pillar outer section (1), A-pillar reinforcement (2) and A-pillar inner section (3), fit in place and install | AR63.20-P-1150-04GQ | |
| 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 | ||
| WS60.00-P-0021K | |||
| Blind rivet tool | WS60.00-P-0022K | ||
| Manual temporary fastener 6.35 mm | *BE60.00-P-1001-01Z | ||
| Hand drill Wet/dry vacuum cleaner |
*BE60.00-P-1002-01Z | ||
| Gap dimension | *BR00.45-Z-1001-07A | ||
| Gap dimension Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint |
*BR00.45-Z-1002-13A | ||
| Blind rivet with polygrip countersunk head 6.4 14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN) | *BR00.45-Z-1012-13A | ||
| Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) Feeler gauge |
Figure | ||
| 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 | |
| 8 | Release vehicle from straightening bench and remove straightening bench | ||
| 9 | Clean welds and sheet metal flanges | Round wire brush |
|
| 10 | Remove fire-resistant welding blankets | ||
| 11 | Clean repair area | 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 | |
| 12 | Prime repair area using primer filler Notes on paintwork repairs |
Use only primer filler approved by Daimler AG. | AH98.00-P-9408-02A |
| Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents | Never spray corrosion protection on flames or hot, glowing objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection. | AS97.00-Z-0001-01A | |
| 13 | Seal seam following repairs | AR97.10-P-4000GQ | |
| Notes on sprayable joint sealant | AH97.10-P-0002-01A | ||
| Notes on seam seal | AH97.10-P-0002-02A | ||
| 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 | Paint repair areas and adjacent surfaces Notes on paintwork repairs |
Use only paints approved by Daimler AG. | AH98.00-P-9408-02A |
| 15 | Add cavity preserving agent | AR97.20-P-1500GQ | |
| 16 | Install detachable parts in area to be repaired |
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 166 | Model 292 | |||
|---|---|---|---|---|---|---|
| BE60.00-P-1001-01Z | Gap dimension | Engine hood to fender | Dimension "A" | mm | 3, 8 (± 1) | 3, 0 (± 0, 5) |
| Engine hood to | Dimension "B" | mm headlamp | 3, 9 (± 1) | 3, 5 (± 1) | ||
| Engine hood to bumper | Dimension "C" | mm | 5, 4 (± 1, 5) | 4, 5 (± 1, 5) | ||
| Fender to A-pillar | Dimension "D" | mm | 3, 5 (± 1) | 3, 0 (± 0, 5) | ||
| Front door to fender | Dimension "E" | mm | 4, 3 (± 0, 7) | 4, 0 (+1/-0, 5) | ||
| Front door to rear door | Dimension "F" | mm | 4, 8 (± 0, 7) | 4, 5 (+1/-0, 5) | ||
| Rear door to rear fender | Dimension "I" | mm | 4, 3 (± 0, 7) | 3, 5 (+1/-0, 5) | ||
| For picture, see | AR60.00-P-0700-01GQ | AR60.00-P-0700-01GQ | ||||
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 166 | Model 292 | |||
|---|---|---|---|---|---|---|
| BE60.00-P-1002-01Z | Gap dimension | Bumper to headlamp | Dimension "S1" | mm | 3, 0 (± 0, 5) | 2, 0 (± 1) |
| Dimension "S2" | mm | 3, 0 (± 0, 5) | 2, 0 (± 1) | |||
| Dimension "S3" | mm | 3, 0 (± 0, 5) | 3, 0 (± 1) | |||
| Fender to headlamp | Dimension "R" | mm | 3, 9 (± 1) | 3, 0 (± 1) | ||
| Engine hood to A-pillar | Dimension "Q" | mm | 3, 5 (± 1) | 4, 0 (+1, 5/-1, 0) | ||
| For picture, see | AR60.00-P-0700-01GQ | AR60.00-P-0700-01GQ | ||||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint | A 000 986 34 42 |
| BR00.45-Z-1002-13A | Blind rivet with polygrip countersunk head 6.4 14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN) | A 003 990 86 97 05 |
| BR00.45-Z-1012-13A | Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | A 004 990 16 97 |