Remove/Install A-Pillar Outer Section - Ar63.20-P-1102LW
Model 205.0/1/2
Model 253
Model 293
Fig 1: A-Pillar Outer Panel, A-Pillar Reinforcement And Upper Side Member Component Locations (Model 205.0/1/2)
| 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 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 . | |
| 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 . | |
| Topical note | General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system | AH00.00-Z-0300-01A . | |
| Topical note | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A . | |
| Topical note | Notes on battery | AH54.10-P-0001-01A . | |
| Topical note | General information on body repair | AH60.00-N-0001-01A . | |
| Topical note | Pretreatment of bonding surfaces | AH60.00-P-0008-01SX . | |
| Topical note | General information on crack diagnosis of aluminum parts | AH60.00-P-0014-01N . | |
| 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-0034-01LW . | ||
| 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 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 | Round wire brush Body power jigsaw Spot weld milling machine Torx EPL 12 Aluminum tools Aluminum workplace Wet/dry vacuum cleaner |
WS54.00-P-0049B . | |
| Zinc dust paint suitable for spot welding | *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 | 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 | AR63.20-P-1102-01LW . | ||
| 000 588 00 84 00 Heat gun | 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 |
WS54.00-P-0049B . | |
| Zinc dust paint suitable for spot welding | *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 |
AR63.20-P-1102-02LW . |
Round wire brush Body power jigsaw Spot weld milling machine Zinc dust paint suitable for spot welding |
*BR00.45-Z-1001-07A . | ||
| 8 | Prepare upper front longitudinal member (1), strut (2), reinforcement (3) and bracket (4) | Round wire brush Body power jigsaw |
AR62.20-P-1286-02LW . |
| 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 . | |
| 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 . | ||
| 9 | Install welding device | AR62.20-P-1286-05LW . | |
Model 293 Welding device |
|||
| 10 | Install upper front longitudinal member (1), strut (2), reinforcement (3), bracket (4), A-pilla 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 | AR63.20-P-1102-03LW . | ||
| 2 |
000 588 01 84 00 Welder | WS60.00-P-0021K . | |
| 2 |
000 588 02 84 00 Welder | 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 |
WS60.00-P-0022K . |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A . | ||
| White sealing compound, 310 ml, DBL 6069.20 | *BR00.45-Z-1003-01A . | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A . | ||
| Blind rivet 6.5X 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A . | ||
| Blind rivet 6.5X 14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1016-13A . | ||
| Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1035-13A . | ||
| 11 | Remove welding device | ||
| 12 | Release vehicle from straightening bench, lift vehicle and remove straightening bench | ||
| 13 | Clean welds and sheet metal flanges | Round wire brush |
|
| 14 | Remove spark protection blankets | ||
| 15 | Clean repair area | Wet/dry vacuum cleaner |
|
| 16 | Prime repair area using primer filler | ||
| Topical note | Notes on paintwork repairs | AH98.00-P-9408-02A . | |
| 17 | Seal seam following repairs | AR97.10-P-4000LW . | |
| 18 | Paint repair areas and adjacent surfaces | ||
| Topical note | Notes on paintwork repairs | 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 |
A-PILLAR OUTER PANEL REPAIR MATERIALS (Model 205.0/1/2)
| 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 6.5X 12.5 (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 6.5X 14.5 (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 |