Preparing Complete A-Pillar For Installation - Ar63.20-P-1100-09LWR

Model 205.4 

The following operation steps 1 to 28 are shown on the left side of the vehicle and must be performed in the same way on the right side of the vehicle in the event of damage.

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1. Grind mating surfaces on A-pillar paneling (5) down to bare metal in crosshatched areas.

   Sand down spot weld flanges to bare metal on both sides.

2. Remove grinding dust.
3. Coat insides of spot weld flanges with zinc dust paint.
4. Mark and cut separating point on mounting rail (10) (area A).

   Transfer separation point from vehicle.

5. Expose spot welds on mounting rail (10) and drill with Ø 6.5 mm bit (areas B).
6. Remove section of mounting rail (10).

   The section of mounting rail (10) is reused.

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7. Grind mating surfaces of mounting rail (10) down to bare metal in cross-hatched areas.
8. Remove grinding dust.
9. Coat insides of mounting rail (10) with zinc dust paint.

   Courtesy of MERCEDES-BENZ USA

10. Mark separating point on A-pillar reinforcement (6) and cut (area C).

    Transfer separation point from vehicle.

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

11. Grind mating surfaces on A-pillar reinforcement (6) down to bare metal in cross-hatched areas.

    Sand down spot weld flanges to bare metal on both sides.

12. Remove grinding dust.
13. Coat insides of spot weld flanges with zinc dust paint.

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

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

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14. Mark separating point on A-pillar inner panel (7) and cut (area E).

    Transfer separation point from vehicle.

15. Cut laser seams on A-pillar inner panel (7) (area H).
16. Expose spot welds on A-pillar inner panel (7) and cut out (areas F).
17. Expose spot welds on A-pillar inner panel (7) and drill with Ø 6.5 mm bit (area G).
18. Remove A-pillar inner panel (7) from replacement part.
19. Grind mating surfaces on A-pillar inner panel (7) down to bare metal in crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

20. Remove grinding dust.
21. Coat insides of spot weld flanges with zinc dust paint.

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

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

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22. Fabricate duplicator (11) from A-pillar inner panel remaining piece.

    Dimensions:

    k = approx. 120 mm

23. Separate duplicator (11) in center (area J).
24. Grind insides of duplicator halves down to bare metal.
25. Remove grinding dust.

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26. Grind mating surfaces on mounting console (9) down to bare metal in the crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

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

    Do not coat bonding surfaces with zinc dust paint (area L).

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

29. Grind mating surfaces on roof frame (8) down to bare metal in crosshatched areas.
30. Remove grinding dust.
31. Coat insides of spot weld flanges with zinc dust paint.