Replace inner A-pillar

AR63.20-P-1106V

Replace inner A-pillar

18.11.11



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 the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the 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



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

All models

AH00.00-N-0005-01A



General information on body repair

All models

AH60.00-N-0001-01A



Notes on paintwork repairs

Model 124, 126, 129, 140, 163, 168, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463, 639

AH98.00-P-9408-02A



General information on MB materials

Model 124, 126, 129, 140, 163, 168, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463, 639

AH98.00-P-9409-03A

1

Remove detachable parts in area to be repaired

2

Cover all detachable parts remaining in vehicle

Tarp (fire-resistant)

3

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

 Observe set-up plans provided.

Passenger car straightening system (Celette)

gotis://K_60-65_02.0

Accessories for straightening system (Celette)

gotis://K_60-65_04.1

Straightening systems for passenger cars (Car Bench)

gotis://K_60-65_03.0

Accessories for straightening system (Car Bench)

gotis://K_60-65_04.2

4

Raise vehicle

AR00.60-P-1000V

5

Set vehicle onto straightening bench

6

Remove stop plugs from jack support points

7

Fasten vehicle to straightening bench

8

Remove A-pillar with side longitudinal member

AR63.20-P-1150V

9

Separate inner A-pillar (1)

AR63.20-P-1106-01V

 Spot weld milling cutter

*201589005100

Ball cutter, dia. 12 mm

Round wire brush, braided, dia. 70 mm

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

Drill
gotis://K_58.1_04.0

Straight grinder
gotis://K_58.0_03.0

Angle grinder
gotis://K_58.1_07.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

10

Prepare inner A-pillar (1)

AR63.20-P-1106-02V

Round wire brush, braided, dia. 70 mm

Drill
gotis://K_58.1_04.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

11

Install inner A-pillar (1)

AR63.20-P-1106-03V

 Portal frame

*129589032300

 Multi-Z element MZ 260

*140589262300

 Welding device

*171589002300

Electrode miller

Clamping pliers

Round wire brush, braided, dia. 70 mm

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

Inverter spot welder
gotis://K_60-65_16.0

Drill
gotis://K_58.1_04.0

Angle grinder
gotis://K_58.1_07.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

12

Install A-pillar with side longitudinal member

AR63.20-P-1150V

13

Unfasten vehicle from straightening bench

14

Install stop plugs in jack support points

15

Raise vehicle

AR00.60-P-1000V

16

Remove straightening bench.

17

Clean weld joints and sheet metal flange with round wire brush

Round wire brush, braided, dia. 70 mm

Drill
gotis://K_58.1_04.0

18

Clean repair areas

19

Prime repair area using primer filler

20

Carry out seam sealing after repairs

 Supplement standard sealants with MB body sealant.

AR97.10-P-4000V

Sealant

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

21

Paint repair areas and adjacent surfaces

22

Apply additional cavity preservation

AR97.20-P-1500V



Notes on cavity preservation

Model 124, 126, 129, 140, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 463, 639, 671, 690.6, 901, 902, 903, 904, 905

Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7

AH97.20-P-0001-01B

Combination pressure spray gun (corrosion protection)
gotis://K_91-97_01.0

MB cavity wax preservation, 1 l

*BR00.45-Z-1003-05A

23

Remove tarp

 On all covered parts remaining in vehicle.

24

Install all detachable body components in area to be repaired

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-1041-01A

Seam sealant, sprayable 310 ml

A 002 989 84 20

BR00.45-Z-1003-05A

Cavity sealant, solvent-free (1 l container)

A 000 986 72 70 05

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42