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

	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 238.3

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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Mark separating points on A-pillar paneling (5) and cut (areas A and B).
Do not make the cuts too deep.

Damage to the component parts located behind this can otherwise occur and the strength is affected.

Dimensions:

a = approx. 100 mm

b = approx. 80 mm

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Expose spot welds on A-pillar paneling (5) and cut off (area C).
Cut off common spot welds on panels that are located one behind the other through two panel thicknesses.
Heat A-pillar paneling (5) in cross-hatched areas.
Cross-hatched areas are bonded.
Remove A-pillar paneling (5).

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Expose spot welds on roof frame reinforcement (9) and cut off (area D).
Remove roof frame reinforcement (9).

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Mark separating point on A-pillar reinforcement (6) and cut (area E).
Do not cut too deeply.

Damage to the component parts located behind this can otherwise occur and the strength is affected.

Mark separating point along Y-marking.
Expose spot welds on A-pillar reinforcement (6) and cut off (area F).
Cut off common spot welds on panels that are located one behind the other through two panel thicknesses.
Expose solder seams on A-pillar reinforcement (6) and cut (area G).

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Expose spot welds on A-pillar reinforcement (6) and drill out with Ø 6.5 mm (area H).
Expose spot welds on A-pillar reinforcement (6) and cut off (area I).

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Heat A-pillar reinforcement (6) in cross-hatched areas.
Cross-hatched areas are bonded.
Remove A-pillar reinforcement (6).

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Mark separating points on A-pillar inner panel (7) and roof frame inner panel (8) and cut (areas K and L).
Do not make the cuts too deep.

Damage to the component parts located behind this can otherwise occur and the strength is affected.

Dimensions:

k = approx. 160 mm

l = approx. 120 mm

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Expose solder seam on roof frame inner panel (8) and cut (area N).
Expose spot welds on A-pillar inner panel (7) and roof frame inner panel (8) and cut off (areas M₁ and M₂ ).
Expose spot weld on A-pillar inner panel (7) and drill out with a diameter of 6.5 mm (area M₃ ).
Cut off spot weld from inside (area M₂ ).
Heat A-pillar inner panel (7) in cross-hatched areas.
Cross-hatched areas are bonded.
Remove A-pillar inner panel (7) and roof frame inner panel (8) together.

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA
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 O).

Otherwise adhesion problems can occur.

Observe pretreatment of bonding surfaces.