Remove/Install A-Pillar Outer Section - Ar63.20-P-1102LW

Model 205.0/1/2 

Model 253 

Model 293 

Fig 1: Inner And Outer A-Pillar, A-Pillar Reinforcement, Upper Front Longitudinal Member And Components Locations

Courtesy of MERCEDES-BENZ USA

	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.	See AS00.00-Z-0017-01A .
	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.	See AS00.00-Z-0010-01A .
	Risk of death  when working on component parts and systems with U >= 25 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.	AS00.00-Z-0035-01A
	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 a suitable, grounded dust extraction system.	See AS60.00-Z-0007-01N .
	Information on preventing damage to electronic components due to electrostatic discharge		See AH54.00-P-0001-01A .
	Note on high-voltage on-board electrical system		See AH54.00-P-0010-01A .
	Note on high-voltage battery		See AH54.10-P-0006-01MEV .
	General information on body repair		See AH60.00-N-0001-01A .
	Pretreatment of bonding surfaces		See AH60.00-P-0008-01SX .
	General information on crack diagnosis of aluminum parts		See AH60.00-P-0014-01N .
	Evaluation of high-voltage components		See AH54.00-P-6500-01SXH .
	General information on repair of vehicles with ultra-strength steels.		See AH60.00-P-0024-01N .
	Note on working on aluminum components and vehicles		See AH60.00-P-0034-01LW .
	General information on MB materials		See 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 (1), strut (2), reinforcement (3) and bracket (4)	Model 205.0/1/2, 253, 293 Model 205.0/1/2, 253	AR62.20-P-1286-01LW
	000 588 00 84 00 Heat gun		See WS54.00-P-0049B .
		Commercially available devices/tools  Round wire brush Body power jigsaw Spot weld milling machine Torx EPL 12 Aluminum tools Aluminum workplace Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding	See *BR00.45-Z-1001-07A .
4	Set up straightening bench with straightening bench crossmembers and straightening tool set 000 588 01 23 00 Body straightening system		See WS60.00-P-0023K .
5	Place vehicle on straightening bench and fasten
6	Remove A-pillar paneling (5), A-pillar reinforcement (6) and A-pillar inner panel (7)	Model 205.0/1/2, 253, 293 Model 205.0/1/2, 253	See AR63.20-P-1102-01LW .
	000 588 00 84 00 Heat gun		See WS54.00-P-0049B .
		Commercially available devices/tools  Round wire brush Metal needle template Body power jigsaw Spot weld milling machine Drill bits and milling cutters for high-strength steels Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding	See *BR00.45-Z-1001-07A .
7	Prepare A-pillar paneling (5), A-pillar reinforcement (6) and A-pillar inner panel (7)	Model 205.0/1/2 Model 253 Model 293 Model 205.0/1/2 Model 253	See AR63.20-P-1102-02LW .
		Commercially available devices/tools  Round wire brush Body power jigsaw Spot weld milling machine Zinc dust paint suitable for spot welding	See *BR00.45-Z-1001-07A .
8	Prepare upper front longitudinal member (1), strut (2), reinforcement (3) and bracket (4)		See AR62.20-P-1286-02LW .
		Cuts "A" on upper front longitudinal member (1) and "E" at reinforcement (3) are not required. Commercially available devices/tools  Round wire brush Body power jigsaw Zinc dust paint suitable for spot welding	See *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.	See AS00.00-Z-0007-01A .
		Measures for preventing damage to components when performing electric welding and soldering work	See AH60.00-P-0001-02A .
	General information on riveting		See AH60.00-P-0003-01N .
9	Install welding device		See AR62.20-P-1286-05LW .
		Model 205.0/1/2 Welding device	See Fig 3.
		Model 253 Model 293 Welding device	See Fig 4.
10	Install upper front longitudinal member (1), strut (2), reinforcement (3), bracket (4), A-pillar paneling (5), A-pillar reinforcement (6) and A-pillar inner panel (7)	Model 205.0/1/2, 253, 293
		Model 205.0/1/2 Model 253	See AR63.20-P-1102-03LW .
		000 588 01 84 00 Welder	See WS60.00-P-0021K .
	000 588 02 84 00 Welder		See WS60.00-P-0022K .
		Commercially available devices/tools  Round wire brush Drill bits and milling cutters for high-strength steels Manual temporary fastener, 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Aluminum tools Aluminum workplace Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding	See *BR00.45-Z-1001-07A .
		White sealing compound, 310 ml, DBL 6069.20	See *BR00.45-Z-1003-01A .
		Parts kit for 2-component adhesive for body	See *BR00.45-Z-1162-02A .
		Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	See *BR00.45-Z-1012-13A .
		Blind rivet 6.5X14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)	See *BR00.45-Z-1016-13A .
		Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN)	See *BR00.45-Z-1035-13A .
		Side portal frame	See Figure.
		Model 205.0/1/2 Welding device	See Fig 3.
		Model 253, 293 Welding device	See Fig 4.
11	Remove welding device
12	Release vehicle from straightening bench, lift vehicle and remove straightening bench
13	Clean welds and sheet metal flanges	Commercially available devices/tools  Round wire brush
14	Remove spark protection blankets
15	Clean repair area	Commercially available devices/tools  Wet/dry vacuum cleaner
16	Prime repair area using primer filler Notes on paintwork repairs	Use only primer filler approved by Daimler AG.	See AH98.00-P-9408-02A .
17	Seal seam following repairs		See AR97.10-P-4000LW .
18	Paint repair areas and adjacent surfaces Notes on paintwork repairs	Use only primer filler approved by Daimler AG.	See AH98.00-P-9408-02A .
19	Add cavity preserving agent		AR97.20-P-1500LW
20	Install all detachable body components in area to be repaired

Fig 2: Side Portal Frame (210 589 17 23 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Welding Device (205 589 00 23 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Welding Device (253 589 00 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-1003-01A	White sealing compound, 310 ml, DBL 6069.20	A 001 989 63 20
BR00.45-Z-1012-13A	Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	A 004 990 16 97
BR00.45-Z-1016-13A	Blind rivet 6.5X14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)	A 004 990 17 97
BR00.45-Z-1035-13A	Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN)	A 000 991 76 32
BR00.45-Z-1162-02A	Parts kit for 2-component adhesive for body	A 012 989 17 71