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

	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	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	General information on repair of vehicles with ultra-strength steels.		AH60.00-P-0024-01N

Model 238.4 

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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1. Mark separating point on A-pillar outer panel (7) and cut (area A).

   Take over separating point from vehicle.

2. Grind mating surfaces on A-pillar outer panel (7) down to bare metal in cross-hatched areas.

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

3. Remove grinding dust.
4. Apply zinc dust paint to insides of spot weld flanges.

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

   Otherwise adhesion problems can occur.

   Observe pretreatment of bonding surfaces.

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5. Grind mating surfaces on A-pillar reinforcement (6) down to bare metal in cross-hatched areas.
6. Apply zinc dust paint to insides of spot weld flanges.
7. A-pillar reinforcement (6) in A-pillar outer panel (7) (area C).
8. Clean weld joints that can no longer be accessed after installation of A-pillar outer panel (7) with installed A-pillar reinforcement (6) and coat with zinc dust paint.

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9. Mark separating point on A-pillar inner panel (5) and cut (area D).

   Take over separating point from vehicle.

10. Cut off spot welds on A-pillar inner panel (5) (area E).
11. Drill off spot welds on A-pillar inner panel (5) with Ø 6.5 mm (area F).
12. Remove A-pillar inner panel (5) from replacement part.

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13. Expose spot welds on A-pillar inner panel (5) and drill out with a diameter of 6.5 mm (area G₁ ).
14. Cut off spot welds on A-pillar inner panel (5) (area G₂ ).
15. Remove mounting support (9) from A-pillar inner panel (5).

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16. Grind mating surfaces on A-pillar inner panel (5) down to bare metal in cross-hatched areas.

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

17. Remove grinding dust.
18. Apply zinc dust paint to insides of spot weld flanges.

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

    Otherwise adhesion problems can occur.

    Observe pretreatment of bonding surfaces.

19. Fabricate a duplicator (10) from A-pillar inner panel remaining piece.

    Dimensions: 

    i = approx. 120 mm

20. Cut duplicator (10) in center (area I).
21. Grind insides of duplicator halves down to bare metal.
22. Remove grinding dust.

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