Cut Off A-Pillar - Ar63.20-P-1100-01LF

Model 222 

except code Z07 (B7 armoring on special protection version) 

The following steps are shown on the left side of the vehicle and must be accomplished analogously on the right side in the event of damage.

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1. Mark separating point on A-pillar paneling (1) and cut (areas A and B).

   Do not make the cuts too deep.

   Otherwise the components below can be damaged and weakened.

   Dimensions:

   a = approx 60 mm

   b = approx 50 mm

2. Expose spot welds on A-pillar paneling (1) and cut out (areas C, D and E).

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

   Cut out spot welds through three panel thicknesses (areas E)

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3. Heat A-pillar paneling (1) in crosshatched areas.
4. Remove A-pillar paneling (1).

   Cross-hatched areas are bonded.

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5. Mark separating point on A-pillar reinforcement (2) and cut (area F).

   Do not cut too deeply.

   Otherwise the components below can be damaged and weakened.

   Dimensions:

   f = approx. 75 mm

6. Expose MIG solder seam on A-pillar reinforcement (2) and cut (area G).
7. Expose spot welds on A-pillar reinforcement (2) and cut out (areas H and I).

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

8. Expose spot welds on A-pillar reinforcement (2) and drill with Ø 6.5 mm bit (area Q).

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9. Heat A-pillar reinforcement (2) in crosshatched areas.

   Cross-hatched areas are bonded.

10. Remove A-pillar reinforcement (2).

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11. Mark separation point on offset reinforcement and cut (area J).

    Do not cut too deeply.

    Otherwise the components below can be damaged and weakened.

    Dimensions: 

    j = approx. 75 mm

12. Cut laser seams on offset reinforcement (areas K).
13. Expose MIG solder seam on A-pillar inner panel (3) and cut (area L).
14. Expose spot welds on A-pillar inner panel (3) and cut (areas M, N and O).

    Cut out spot welds through two panel thicknesses (area N).

    Cut out spot welds from rear (area O).

15. Expose spot welds on A-pillar inner panel (3) and drill with Ø 6.5 mm bit (area P).
16. Heat A-pillar inner panel (3) in crosshatched areas.

    Cross-hatched areas are bonded.

17. Remove A-pillar inner panel (3).

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18. 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.

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

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

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

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