Cut off outer paneling on A-pillar with reinforcement for A-pillar

D63.20-1232-04

 The following operation steps are shown on model 906.733 on the left side of the vehicle and must be performed analogously on the right side in the event of damage.

1 Drill off rivet to strut (2) (areas A, B and C).

2 Remove strut (2) from wheel well paneling and A-pillar outer section (1).

D63.20-1235-06

3 Mark separation lines on A-pillar outer section (1) (areas D and E).

 Mark separation line (area E) depending on damage.

To mark the separation line (area D) the dimension (d) must not exceed
370 mm.

4 Cut A-pillar outer section (1) at separating points (areas D and E).

 Do not cut too deeply. Otherwise the reinforcement panel below can be damaged.

Dimensions:

d approx. 320 mm

D63.20-1270-06

5 Make rough saw incision on A-pillar outer section (1) (area O).

6 Expose spot welds on element of A-pillar outer section (3) (area P).

7 Cut out spot welds on A-pillar outer section (3)(area P).

 Through two sheet metal thicknesses (area P).

8 Remove A-pillar outer section (3)

D63.20-1268-06

9 Expose spot welds on A-pillar outer section (1) (areas F1, F2, F3 and F4).

10 Cut out spot welds on A-pillar outer section (1)(areas F1, F2, F3 and F4).

 Cut off through two panel thicknesses (areas F2 and F4).

D63.20-1271-06

11 Expose spot welds on A-pillar outer section (1) (areas M1, M2, M3, N1, N2, N3 and N4).

12 Cut out spot welds on A-pillar outer section (1) (areas M1, M2, M3, N1, N2, N3 and N4).

 Cut off through two panel thicknesses (areas M2, N2 and N3).

D63.20-1275-06

13 Expose weld seams on A-pillar reinforcement (4) (areas Q, R, S and T).

14 Grind open weld seams on A-pillar reinforcement (4) (areas Q, R, S and T).

15 Expose weld seam on inner A-pillar (5) (area G).

16 Grind open weld seam on inner A-pillar (5) (area G).

17 Remove A-pillar outer section with A-pillar reinforcement (4)

D63.20-1278-09

18 Grind mating surfaces down to bare metal in the crosshatched areas.

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

Grind down to bare metal from inside the vehicle (area U).

19 Remove shavings and drill chips.

20 Coat insides of spot weld flanges with zinc dust paint.