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

	Risk of injury . Skin or eye injuries may result when handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	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
Notice	General information on body repair		AH60.00-P-0001-01KOA
Notice	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
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
	Notes on acoustic foam and structural foam in the vehicle		AH60.00-P-0039-01LWO

Model 238.4

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1056-07A	1K-zinc dust paint	A 000 986 28 00

The following operation steps are shown on the left side of the vehicle. This must be similarly performed for damage to the right side of the vehicle.

Use following repair materials:

Zinc dust paint

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Expose spot welds on mounting support (9) and drill out with Ø 6.5 mm (area A).
Expose spot welds on mounting support (9) and cut off (area B).

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Mark separating point on A-pillar outer panel (7) and cut (area C).
Do not cut too deeply.

Component parts located behind this will otherwise be damaged and the strength affected.

Dimension : f = approx. 65 mm (measured from Y-marking)
Expose spot welds on A-pillar outer panel (7) and cut off (area D).
Cut off common spot welds on panels that are located one behind the other through two panel thicknesses.
Expose solder seams on A-pillar outer panel (7) and cut (area E).
Expose spot welds on A-pillar outer panel (7) and cut off (areas F and G).

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Heat cross-hatched areas on A-pillar outer panel (7).
Cross-hatched areas are bonded.

Heat cross-hatched areas from inside (area H).
Remove A-pillar outer panel (7).

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Mark separating point on A-pillar inner panel (5) and cut (area I).
Do not cut too deeply.

Component parts located behind this will otherwise be damaged and the strength affected.

Dimensions:

i = approx. 120 mm
Expose spot welds on A-pillar reinforcement (6) and cut off (area J).
Remove A-pillar reinforcement (6).

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Expose solder seam on A-pillar inner panel (5) and cut (area K).
Expose spot welds on A-pillar inner panel (5) and cut off (areas L₁ and L₂ ).
Expose spot welds on A-pillar inner panel (5) and drill out with a diameter of 6.5 mm (areas L₃ and L ₄ ).
Drill out spot welds from inside (area L₃ ).
Heat A-pillar inner panel (5) in cross-hatched areas.
Cross-hatched areas are bonded.
Remove A-pillar inner panel (5).

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Grind mating surfaces down to bare metal in cross-hatched areas.
Grind spot weld flanges down to bare metal on both sides.
Remove grinding dust and chips from drilling.
Apply zinc dust paint to insides of spot weld flanges.
Do not coat bonding surfaces with zinc dust paint (area M).

Otherwise adhesion problems can occur.

Observe pretreatment of bonding surfaces.

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