Replace Complete A-Pillar Together With Side Longitudinal Member - Ar63.20-P-1150GQ
Model 166, 292
Illustrated on model 166.0
Fig 1: Inner A-Pillar, Outer A-Pillar And A-Pillar Reinforcement Component Locations (Model 166) (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 . | |
| Topical note | General information on body repair | AH60.00-N-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 . | ||
| 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 . | |
| 4 | Place vehicle on straightening bench and fasten | ||
| 5 | Remove A-pillar outer section (1), A-pillar reinforcement (2) and A-pillar inner section (3) | AR63.20-P-1150-01GQ . | |
Wet/dry vacuum cleaner |
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| Zinc dust paint suitable for spot welding | *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 . | |
| Zinc dust paint suitable for spot welding | *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 . | |
| Topical note | 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 . | |||
| WS60.00-P-0022K . | |||
Wet/dry vacuum cleaner |
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| Gap dimension | *BE60.00-P-1001-01Z . | ||
| Gap dimension | *BE60.00-P-1002-01Z . | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A . | ||
| Blind rivet with polygrip countersunk head 6.4 X14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN) | *BR00.45-Z-1002-13A . | ||
| Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A . | ||
| 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 | ||
| 10 | Remove fire-resistant welding blankets | ||
| 11 | Clean repair area | ||
| 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 | ||
| Topical note | Notes on paintwork repairs | AH98.00-P-9408-02A . | |
| Use only primer filler approved by Daimler AG | |||
| 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 . | |
| Topical note | 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 | ||
| Topical note | Notes on paintwork repairs | AH98.00-P-9408-02A . | |
| Use only paints approved by Daimler AG | |||
| 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 headlamp | Dimension "B" | mm | 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 | 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-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 |