Replace complete A-pillar together with side longitudinal member

AR63.20-P-1150QA

Replace complete A-pillar together with side longitudinal member

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 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



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

AH00.00-N-0005-01A



General information on body repair

AH60.00-N-0001-01A



Notes on cavity preservation

AH97.20-P-0001-01B



Notes on paintwork repairs

AH98.00-P-9408-02A



General information on MB materials

AH98.00-P-9409-03A



General information on riveting

AH60.00-P-0003-01N

1

Prepare all workshop equipment and commercially available tools required for repair

2

Remove engine hood

AR88.40-P-3000Q

3

Remove front fender

AR88.10-P-1000Q

4

Remove front door

AR72.10-P-0500Q

5

Remove front seat

AR91.10-P-1000Q

6

Remove floor mats

7

Remove cross member under instrument panel

 Secure heater or air conditioning housing to prevent damage during removal.

AR68.10-P-1120QA

8

Remove pedal assembly for parking brake

AR42.20-P-0510P

9

Remove or disconnect electrical lines and vacuum lines in area to be repaired.

10

Remove windshield

AR67.10-P-1000P

11

Remove insulating material from inner firewall, floor and A-pillar.

12

Remove all detachable parts in area to be repaired

13

Cover all detachable parts remaining vehicle with fireproof tarpaulin

14

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

 Observe setup plans provided.

Passenger car straightening system (Celette)

gotis://K_60-65_02.0

Straightening systems for passenger cars (Car Bench)

gotis://K_60-65_03.0

15

Lift vehicle with two-post lifting platform

16

Set vehicle onto straightening bench

17

Fasten vehicle to straightening bench

18

Set up side portal frame with check and welding devices

Observe body plans provided.

Passenger car straightening system (Celette)

gotis://K_60-65_02.0

Straightening systems for passenger cars (Car Bench)

gotis://K_60-65_03.0

 Side portal frame

*210589172300

 Inspection and welding device

*203589002300

 Inspection and welding devices

*209589002300

19

Set up front portal frame with welding devices

 When mounting front portal frame, use additional set of Multi-Z elements MZ 260. Observe set-up plans provided.

Passenger car straightening system (Celette)

gotis://K_60-65_02.0

Straightening system accessories (Celette)

gotis://K_60-65_04.1

Straightening systems for passenger cars (Car Bench)

gotis://K_60-65_03.0

Straightening system accessory (Car Bench)

gotis://K_60-65_04.2

 Portal frame

*129589032300

 Multi-Z element MZ 260

*140589262300

 Welding devices

*209589052300

20

Check/straighten installation position of A-pillar

21

Remove portal frame with check and welding devices

22

Remove welding panel on side longitudinal member

Shown on model 209.3

AR63.30-P-1500Q

23

Remove outer paneling from A-pillar (1).

AR63.20-P-1105QA

24

Separate A-pillar with outer longitudinal member (2).

AR63.20-P-1150-01QA

 Spot weld milling cutter

*201589005100

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

25

Separate inner A-pillar (5)

AR63.20-P-1106-01QA

 Spot weld milling cutter

*201589005100

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

26

Prepare inner A-pillar (5)

AR63.20-P-1106-02QA

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

27

Prepare A-pillar with outer longitudinal member (2) for installation

AR63.20-P-1150-06QA

 Spot weld milling cutter

*201589005100

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

28

Set up side portal frame with check and welding devices

Observe body plans provided.

Passenger car straightening system (Celette)

gotis://K_60-65_02.0

Straightening systems for passenger cars (Car Bench)

gotis://K_60-65_03.0

 Side portal frame

*210589172300

 Inspection and welding device

*203589002300

 Inspection and welding devices

*209589002300

29

Set up front portal frame with welding devices

Observe body plans provided.

Passenger car straightening system (Celette)

gotis://K_60-65_02.0

Straightening systems for passenger cars (Car Bench)

gotis://K_60-65_03.0

 Portal frame

*129589032300

 Multi-Z element MZ 260

*140589262300

 Welding devices

*209589052300

30

Install and weld in inner A-pillar (5)

AR63.20-P-1106-03QA

 Side portal frame

*210589172300

 Portal frame

*129589032300

 Multi-Z element MZ 260

*140589262300

 Inspection and welding devices

*209589002300

 Inspection and welding device

*203589002300

 Welding devices

*209589052300

Sealant

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

Preservation agent

*BR00.45-Z-1003-05A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Rivet

*BR00.45-Z-1001-13A

Polygrip countersunk-head rivet, 6.414

*BR00.45-Z-1002-13A

31

Install and weld in complete A-pillar

AR63.20-P-1100-10QA

 Side portal frame

*210589172300

 Inspection and welding devices

*209589002300

 Inspection and welding device

*203589002300

Sealant

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

Preservation agent

*BR00.45-Z-1003-05A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Rivet

*BR00.45-Z-1001-13A

Polygrip countersunk-head rivet, 6.414

*BR00.45-Z-1002-13A

32

Remove portal frame with check and welding devices

33

Unfasten vehicle from straightening bench

34

Lift vehicle with two-post lifting platform

35

Remove straightening bench.

36

Clean weld joints and sheet metal flange with round wire brush

37

Clean repair areas

38

Prime repair area using primer filler

39

Carry out seam sealing after repairs

 Supplement standard sealant with sealant.

AR97.10-P-4000Q

Sealant

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

40

Paint repair areas and adjacent surfaces

41

Apply additional cavity preservation

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

AR97.20-P-1500QA

Preservation agent

*BR00.45-Z-1003-05A

42

Remove tarp

 On all covered parts remaining in vehicle.

43

Install insulating material from inner firewall, floor and A-pillar.

44

Install parking brake pedal assembly

AR42.20-P-0510P

45

Install cross member below instrument panel

AR68.10-P-1120QA

46

Install electrical lines and vacuum lines in repair area and fasten.

47

Install windshield

AR67.10-P-1000P

48

Install front seat

AR91.10-P-1000Q

49

Install floor mats

50

Install engine hood

AR88.40-P-3000Q

51

Install front door

AR72.10-P-0500Q

52

Install front fender

AR88.10-P-1000Q

53

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-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

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