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

Model 167 

The following operation steps are to be performed on model 167.1 on the left side of the vehicle and must be performed analogously on the right side.

The higher-level service document as well as the safety information in the service document must be observed.

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1. Mark separating points on A-pillar paneling (1) and cut (areas A, B).

   Do not make the cuts too deep.

   Otherwise the components below can be damaged and weakened.

   Dimensions: 

   a = approx. 90 mm

   b approx. 60 mm

2. Expose spot welds on A-pillar paneling (l) and cut off (areas C).

   Joint spot welds on panels that are one behind the other must be cut out through two panel thicknesses.

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3. Heat A-pillar panel (1) in cross-hatched areas.

   Cross-hatched areas are bonded with adhesive.

4. Remove A-pillar paneling (1).

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5. Mark separating points on A-pillar upper section reinforcement (4) and longitudinal member outer shell (2) and cut (areas D, E).

   Do not make the cuts too deep.

   Otherwise the components below can be damaged and weakened.

   Dimensions: 

   d = approx. 60 mm

   e = approx. 40 mm

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6. Expose solder seam on A-pillar lower section reinforcement (3) and cut (area G).
7. Expose spot welds on A-pillar upper section reinforcement (4), A-pillar lower section reinforcement (3) and longitudinal member outer shell (2) and cut off (areas F).

   Joint spot welds on panels that are one behind the other must be cut out through two panel thicknesses.

   Courtesy of MERCEDES-BENZ USA

   Courtesy of MERCEDES-BENZ USA

8. Expose spot welds on longitudinal member outer shell (2) and cut off (areas H, J).

   Joint spot welds on panels that are one behind the other must be cut out through two panel thicknesses.

9. Expose solder seam on longitudinal member outer shell (2) and cut (area I).
10. Heat A-pillar upper section reinforcement (4), A-pillar lower section reinforcement (3) and longitudinal member outer shell (2) in cross-hatched areas.

    Cross-hatched areas are bonded with adhesive.

11. Remove A-pillar upper section reinforcement (4), A-pillar lower section reinforcement (3) and longitudinal member outer shell (2) together.

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    Courtesy of MERCEDES-BENZ USA

12. Mark separating point on A-pillar inner panel (7) and reinforcement (6) and cut (areas K, L).

    Do not cut too deeply (area L).

    Otherwise the components below can be damaged and weakened.

    Dimensions: 

    k = approx. 150 mm

    l=approx.20 mm

13. Expose spot welds on reinforcement (6) and cut off (areas M).
14. Remove reinforcement (6).

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15. Expose MIG solder seams on A-pillar inner panel (7) and cut (area P).
16. Expose spot welds on A-pillar inner panel (7) and cut off (areas N).
17. Expose spot welds on A-pillar inner panel (7) and drill out with Ø 6.5 mm (area O).
18. Remove A-pillar inner panel (7).

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19. Grind mating surfaces down to bare metal in cross-hatched areas.

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

    Grind mating surface on inside down to bare metal (area Q₂ ).

20. Remove grinding dust and drill chips.
21. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas Q₁ , Q₃ ).

    Otherwise adhesion problems may occur.

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    Observe pretreatment of bonding surfaces.