Replace Complete A-Pillar - Ar63.20-P-1100LF

Model 222 

except code Z07 (B7 armoring on special protection version) 

Fig 1: A-Pillar, A-Pillar Reinforcement, Inner A-Pillar And Adjacent Component Locations (Model 222)

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 death  when working on component parts and systems with U >= 30 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.	AS60.00-Z-0007-01N
	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
Notice	General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment		AH00.00-Z-0300-01A
Notice	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
Notice	Notes on battery		AH54.10-P-0001-01A
Notice	General information on body repair		AH60.00-P-0001-01KOA
Notice	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	General information on repair of vehicles with ultra-strength steels.		AH60.00-P-0024-01N
	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 blankets
3.1	Remove center roof paneling	Model 222 except code 413 (Panoramic sliding sunroof/glass roof) except code Z07 (B7 armoring on special protection version)
			AR65.10-P-1000LF
3.2	Remove reinforcement for panoramic sliding roof	Model 222 with code 413 (Panoramic sliding sunroof/glass roof) except code Z07 (B7 armoring on special protection version)
4	Remove upper front longitudinal member (4) and strut (5)		AR62.20-P-1286-01LF
	000 588 02 39 00 Rivet press tool		WS60.00-P-0010B
		Commercially available devices/tools  Torx EPL 12 Round wire brush Spot weld milling machine Body power jigsaw Drill bits and milling cutters for high-strength steels Heat gun Body and aluminum workplace Aluminum tools Wet/dry vacuum cleaner
5	Set up straightening bench with module members, crossmember and straightening set
	000 588 01 23 00 Body straightening system		WS60.00-P-0023K
		Observe set-up plans provided.
6	Place vehicle on straightening bench and fasten
7	Separate A-pillar paneling (1), A-pillar reinforcement (2) and A-pillar inner panel (3)		AR63.20-P-1100-01LF
		Commercially available devices/tools  Round wire brush Body power jigsaw Spot weld milling machine Drill bits and milling cutters for high-strength steels Metal needle template Heat gun Wet/dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
8	Prepare A-pillar paneling (1), A-pillar reinforcement (2) and A-pillar inner panel (3)		AR63.20-P-1100-09LF
		Commercially available devices/tools  Round wire brush Body power jigsaw Spot weld milling machine Drill bits and milling cutters for high-strength steels
		White sealing compound, 310 ml, DBL 6069.20	*BR00.45-Z-1003-01A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
9	Prepare upper front longitudinal member (4) and strut (5)		AR62.20-P-1286-02LF
		Use complete replacement part. Cuts and detachment of weld joints not required. Commercially available devices/tools  Round wire brush Aluminum tools
	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
	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
Notice	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A
Notice	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
10	Install A-pillar paneling (1), A-pillar reinforcement (2), A-pillar inner panel (3), front upper longitudinal member (4) and strut (5) and weld in		AR63.20-P-1100-10LF
	000 588 01 84 00 Welder		WS60.00-P-0021K
	000 588 02 84 00 Welder		WS60.00-P-0022K
	000 588 01 23 00 Body straightening system		WS60.00-P-0023K
		Commercially available devices/tools  Round wire brush Drill bit for high-strength steels, 0 6.7 mm Manual temporary fastener, 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Body and aluminum workplace Aluminum tools Wet/dry vacuum cleaner
		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 Y2 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	*BR00.45-Z-1012-13A
		Blind rivet Y3 6.5X14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)	*BR00.45-Z-1016-13A
		Flow-form rivet structure W3 3.35 mm up to 4.1 mm clamping range (S2)	*BR00.45-Z-1027-13A
		Blind rivet Y1 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN)	*BR00.45-Z-1035-13A
		Cleaner	*BR00.45-Z-1025-04A
		2-component adhesive for reinforcements	*BR00.45-Z-1152-02A
		White sealing compound, 310 ml, DBL 6069.20	*BR00.45-Z-1003-01A
		Adhesive kit, body, 2-component adhesive	*BR00.45-Z-1092-02A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Side portal frame	Fig 2
11	Release vehicle from straightening bench, lift vehicle and remove straightening bench
12	Clean welds and sheet metal flanges	Commercially available devices/tools  Round wire brush Aluminum tools
13	Install reinforcement for panoramic sliding roof	Model 222 with code 413 (Panoramic sliding sunroof/glass roof) except code Z07 (B7 armoring on special protection version)
14	Remove spark protection blankets	Model 222 with code 413 (Panoramic sliding sunroof/glass roof) except code Z07 (B7 armoring on special protection version)
15	Clean repair area	Model 222 with code 413 (Panoramic sliding sunroof/glass roof) except code Z07 (B7 armoring on special protection version) Commercially available devices/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 t
16	Prime repair area using primer filler	Model 222 with code 413 (Panoramic sliding sunroof/glass roof) except code Z07 (B7 armoring on special protection version)
	Notes on paintwork repairs		AH98.00-P-9408-02A
	General information on operation items and work procedures for painting		AH98.00-P-0003-01A
		Use only primer fillers approved by manufacturer. See guidelines for paint technology in the workshop portal.
17	Seal seam following repairs	Model 222 with code 413 (Panoramic sliding sunroof/glass roof) except code Z07 (B7 armoring on special protection version)
		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
18	Paint repair areas and adjacent surfaces	Model 222 with code 413 (Panoramic sliding sunroof/glass roof) except code Z07 (B7 armoring on special protection version)
Notice	Notes on paintwork repairs		AH98.00-P-9408-02A
	General information on operation items and work procedures for painting		AH98.00-P-0003-01A
		Only use paints approved by the manufacturer. See guidelines for paint technology in the workshop portal.
19	Add cavity preserving agent	Model 222 with code 413 (Panoramic sliding sunroof/glass roof) except code Z07 (B7 armoring on special protection version)
			AR97.20-P-1500LF
20	Install all detachable body components in area to be repaired	Model 222 with code 413 (Panoramic sliding sunroof/glass roof) except code Z07 (B7 armoring on special protection version)
21	Install center roof paneling	Model 222 except code 413 (Panoramic sliding sunroof/glass roof) except code Z07 (B7 armoring on special protection version)
			AR65.10-P-1000LF

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

Courtesy of MERCEDES-BENZ USA