Remove/install A-pillar outer section

AR63.20-P-1102SR

Remove/install A-pillar outer section

05.03.2019

Model

450.4 (except 450.418)

Section of A-pillar outer section

1

Section of A-pillar outer section

2

Spot weld removing tool

1

Section of A-pillar outer section



Remove

 Danger

The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases

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

AS00.00-Z-0007-01A

Topical note

Notes on performing repair, body work and welding on vehicles with airbags and RTE units

AH91.00-P-0002-01M

Topical note

General information on body repair

AH60.00-N-0001-01A

Topical note

Measures for preventing damage to vehicles or components when performing electric welding work

AH00.00-N-0005-01A

Notes on replacing body parts

AH60.00-P-0027-01FF

1

Mark specified cutting interface in hatched area on section of A-pillar outer section (1)

 See Fig. A.

2

Open up cutting interface using a body saw

 When cutting, pay attention to the sheet metal panels underneath.

3

Drill out spot welds on welding flange of section of A-pillar outer section (1) using a spot weld removing tool (2)

 See Fig. B.

4

Remove section of A-pillar outer section (1)



Install

5

Smooth welding edges and remove paint in welding area of separating point

6

Apply weldable primer to bare weld points in repair area

Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint

*BR00.45-Z-1001-07A

7

Cut new part to the required dimension

 See fig. C.
The cutting area for the butt welding must be made very precisely.

8

Remove protective paint from the welding areas of the new section of the A-pillar outer section (1) and apply weldable priming to the blank welding areas

Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint

*BR00.45-Z-1001-07A

9

Use hole punching pliers to punch welding flanges onto section of A-pillar outer section (1) at specified spot weld distances

Not in case of resistance spot welding.

 See fig. D.

10

Fit section of A-pillar outer section (1)

 When fitting observe correct distances.
Place body on the straightening bench if necessary.
The straightening bench and straightening set of the companies Celette, Car Bench, Car-O-Liner or Blackhawk can be optionally used.

11

Weld in section of A-pillar outer section (1) using the inert gas or resistance spot welding method

 See fig. E.

12

Slightly smooth spot welds and unevennesses

 Rework bluntly welded spots using an angle grinder.

13

Tin bluntly welded points

14

Clean repair areas with wire brush and then apply primer

15

Supplement standard sealants with body sealant

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

16

Paint repair area adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02SM

17

Add cavity preserving agent

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint

A 000 986 34 42

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20