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

	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 238.3 

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

Courtesy of MERCEDES-BENZ USA

1. Mark separating point on A-pillar paneling (5.1) and cut (area B).

   Take over separating point from vehicle.

2. Grind mating surfaces on A-pillar paneling (5.1) down to bare metal in cross-hatched area.

   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 surface with zinc dust paint (area C).

   Otherwise adhesion problems can occur.

   Observe pretreatment of bonding surfaces.

5. Mark separating points on roof frame paneling (5.2) and cut (area A).

   Transfer separation points from vehicle

6. Grind mating surfaces on roof frame paneling (5.2) down to bare metal in cross-hatched area.

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

7. Remove grinding dust.
8. Apply zinc dust paint to insides of spot weld flanges.

   Courtesy of MERCEDES-BENZ USA

9. Grind mating surfaces on roof frame reinforcement (9) down to bare metal in cross-hatched areas.
10. Remove grinding dust.

    Observe pretreatment of bonding surfaces.

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

11. Mark separating point on A-pillar reinforcement (6) and cut (area E).

    Take over separating point from vehicle.

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

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

13. Remove grinding dust.
14. Apply zinc dust paint to insides of spot weld flanges.

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

    Otherwise adhesion problems can occur.

    Observe pretreatment of bonding surfaces.

    Courtesy of MERCEDES-BENZ USA

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

    Take over separating point from vehicle.

16. Cut off spot welds on A-pillar inner panel (7) (area G).
17. Drill off spot welds on A-pillar inner panel (7) with Ø 6.5 mm (area H).
18. Remove A-pillar inner panel (7) from replacement part.

    Courtesy of MERCEDES-BENZ USA

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

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

20. Remove grinding dust.
21. Apply zinc dust paint to insides of spot weld flanges.

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

    Otherwise adhesion problems can occur.

    Observe pretreatment of bonding surfaces.

22. Mark separating point on roof frame inner panel (8) and cut (area K).

    Take over separating point from vehicle.

23. Grind mating surfaces on roof frame inner panel (8) down to bare metal in cross-hatched areas.

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

24. Remove grinding dust.
25. Apply zinc dust paint to insides of spot weld flanges.

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

    Otherwise adhesion problems can occur.

    Observe pretreatment of bonding surfaces.

    Courtesy of MERCEDES-BENZ USA

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

    Dimensions: 

    k = approx. 120 mm

27. Cut duplicator (11) in center (area J).
28. Grind insides of duplicator halves down to bare metal.
29. Remove grinding dust.

Courtesy of MERCEDES-BENZ USA