Replace complete A-pillar

AR63.20-P-1100EL

Replace complete A-pillar

17.3.11



Removing

 Danger!

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding splatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes.

Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system.

AS00.00-Z-0007-01A

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

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

 Danger!

Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.

No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A



General information on repair of vehicles with ultra-strength steels.

Failure to observe instructions when straightening/repairing, separating, preparing adhesive points, joining/connecting, resistance spot welding, MIG welding, MIG brazing can lead to considerable damage to ultra-strength steels and their joints.

AH60.00-P-0024-01N



Measures for preventing damage to components when performing electric welding and soldering work

AH60.00-P-0001-02A



General information on body repair

AH60.00-N-0001-01A



Pretreatment of bonding surfaces

AH60.00-P-0008-01SX



General information on riveting

AH60.00-P-0003-01N

1

Remove all detachable parts in area to be repaired

2

Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket

Welding protective blanket

gotis://K_60-65_23.0

3

Equip straightening bench with module members, cross members and straightening tool set.

 Observe setup plans provided.

Straightening systems, passenger cars (Celette)

gotis://K_60-65_02.0

Straightening system, passenger cars ( Car Bench)

gotis://K_60-65_03.0

4

Place vehicle on straightening bench lift and fasten

Two-column lift 3.0 - -3.5 t electromechanical

gotis://H_00.1_01.0

Two-post lifting platform, 2.5 - 3.5 t electrohydraulic

gotis://H_00.1_01.1

5

Remove complete center roof paneling

Vehicles without code (413) Panoramic glass sunroof with top sliding sunroof

AR65.10-P-1000EW

6

Cut off upper front longitudinal member

AR62.20-P-1286-01EW

 Spot weld milling cutter

*201589005100

Weld-spot milling machine

gotis://K_58.1_02.0

Body jig saw

gotis://K_58.1_01.0

Hot-air gun

gotis://K_60-65_11.0

Round wire brush

gotis://K_58.3_06.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

7

Remove A-pillar outer section (1), A-pillar reinforcement (2) and A-pillar inner section (3)

Body jig saw

gotis://K_58.1_01.0

AR63.20-P-1100-01EL

Weld-spot milling machine

gotis://K_58.1_02.0

Round wire brush

gotis://K_58.3_06.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

8

Prepare upper front longitudinal member

Round wire brush

gotis://K_58.3_06.0

AR62.20-P-1286-02EW

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

9

Prepare A-pillar outer section (1), A-pillar reinforcement (2) and A-pillar inner section (3) for installation

Body jig saw

gotis://K_58.1_01.0

AR63.20-P-1100-09EL

Round wire brush

gotis://K_58.3_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

10

Set up side portal frame with portal bracket

 Observe setup plans provided.

Celette portal straightening set

gotis://K_60-65_02.0

Portal straightening set, Car Bench

gotis://K_60-65_03.0

 Side portal frame

*210589172300

11

Install A-pillar outer section (1), A-pillar reinforcement (2) and A-pillar inner section (3)

Portal straightening set (Celette)

gotis://K_60-65_02.0

AR63.20-P-1100-10EL

Portal straightening set (Car Bench)

gotis://K_60-65_03.0

Multifunction unit (spot welding)

gotis://K_60-65_15.0

MIG-MAG inert gas welder

gotis://K_60-65_17.1

Pneumatic-mechanical blind rivet tool

gotis://K_58.3_10.2

Vice grip pliers (standard)

gotis://K_58.3_04.2

Round wire brush

gotis://K_58.3_06.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

 Side portal frame

*210589172300

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Countersunk head rivet

*BR00.45-Z-1002-13A

Blind rivet

*BR00.45-Z-1012-13A

Sealant

*BR00.45-Z-1003-01A

12

Install welding device

AR62.20-P-1286-05CW

 Welding device

*204589012300

 Adapter

*212589012300

13

Install upper front longitudinal member

Multifunction unit (spot welding)

gotis://K_60-65_15.0

AR62.20-P-1286-03EW

Inert gas welder

gotis://K_60-65_17.0

Pneumatic-mechanical blind rivet tool

gotis://K_58.3_10.2

Vice grip pliers (standard)

gotis://K_58.3_04.2

Manual temporary fastener

gotis://K_58.3_10.0

Round wire brush

gotis://K_58.3_06.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

 Welding device

*204589012300

 Adapter

*212589012300

Adhesive

*BR00.45-Z-1092-02A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Blind rivet

*BR00.45-Z-1001-13A

Countersunk head rivet

*BR00.45-Z-1002-13A

14

Install complete center roof paneling

Vehicles without code (413) Panoramic glass sunroof with top sliding sunroof

AR65.10-P-1000EW

15

Release vehicle from straightening bench, lift vehicle and remove straightening bench

Two-column lift 3.0 - -3.5 t electromechanical

gotis://H_00.1_01.0

Two-post lifting platform, 2.5 - 3.5 t electrohydraulic

gotis://H_00.1_01.1

16

Clean weld joints and sheet metal flanges with rotary wire brush

Round wire brush

gotis://K_58.3_06.0

17

Clean repair area

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

18

Remove welding protection blankets

 On all covered parts remaining in vehicle.

19

Prime repair area with primer filler

 Only use approved primer filler from

Daimler AG:

http://portal.aftersales.i.daimler.com

20

Carry out seam sealing after repairs

 Supplement standard seam seal.

AR97.10-P-4000EL

21

Paint repair area adjacent surfaces

 Use only paints approved by Daimler AG.

http://portal.aftersales.i.daimler.com

22

Apply additional cavity preservation

AR97.20-P-1500EL

23

Install all removed detachable parts

Number

Designation

Order number

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1092-02A

Adhesive kit, body, 2-component adhesive

A 009 989 36 71

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42

BR00.45-Z-1001-13A

Blind rivet 6.414

A 003 990 35 97

BR00.45-Z-1002-13A

Polygrip countersunk-head rivet, 6.414

A 003 990 86 97 05

BR00.45-Z-1012-13A

Blind rivet 6.512.5

A 004 990 16 97