Replace complete A-pillar · ar6320s1100e · Mercedes-Benz WIS

AR63.20-S-1100E

Replace complete A-pillar

20.03.2020

Model

447, 448

Modification notes

11.03.2020

Work procedure revised

The whole document

S63.20-4767-09

1	A-pillar outer section		3	Inner A-pillar
2	Inner A-pillar reinforcement		4	Door hinge strap

 Danger	Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)	Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.Model 447 with engine 780	AS00.00-Z-0035-01A
 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
 Danger	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
 Caution	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
Topical note	Notes on battery		AH54.10-P-0001-01A
Topical note	General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment	Model 447 with engine 780	AH00.00-Z-0300-01A
Topical note	Special instructions for lifting and supporting vehicle		AH00.60-N-0100-01A
Topical note	General information on body repair		AH60.00-N-0001-01A
Topical note	Notes on resistance spot welding of multiple-layer sheet metal flange		AH60.00-N-0028-01S
Topical note	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A
Topical note	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	General information on riveting		AH60.00-P-0003-01N
	General information on MB materials		AH98.00-P-9409-03A
	Remove
1	Remove all detachable parts in area of repair point.
2	Remove soundproofing.		AR60.00-S-1752E
		 Only in repair area.
3	Cover all detachable parts remaining in vehicle with welding protection blankets.	 Commercially available devices/tools Welding protection blanket
4	Set up straightening bench with crossbars and straightening tool set.
	000 588 01 23 00 Body straightening system		WS60.00-P-0023K
5	Place vehicle on straightening bench and fasten.
	000 588 01 80 00 Swivel arm vehicle lift		WS00.00-P-0041B
6	Remove upper front longitudinal member.		AR62.20-S-1286-01E
	000 588 00 84 00 Heat gun		WS54.00-P-0049B
		 Commercially available devices/tools Spot weld milling machine Rotary wire brush Wet and dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
7	Cut off the A-pillar outer section (1).		AR63.20-S-1102-01E
	000 588 00 84 00 Heat gun		WS54.00-P-0049B
		 Commercially available devices/tools Body power jigsaw Rotary wire brush Angle grinder Spot weld milling machine
8	Remove outer paneling of upper A-pillar.		AR63.20-S-1105-01E
		 Commercially available devices/tools Body power jigsaw Spot weld milling machine Rotary wire brush Wet and dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
9	Partially remove reinforcement of inner upper A-pillar.		AR63.20-S-1111-01E
	000 588 00 84 00 Heat gun		WS54.00-P-0049B
		 Commercially available devices/tools Body power jigsaw Hand drill Spot weld milling machine Rotary wire brush Wet and dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
10	Separate reinforcement of inner A-pillar (2).		AR63.20-S-1115-01E
	000 588 00 84 00 Heat gun		WS54.00-P-0049B
		 Commercially available devices/tools Spot weld milling machine Rotary wire brush
11	Separate inner A-pillar (3).		AR63.20-S-1106-01E
	000 588 00 84 00 Heat gun		WS54.00-P-0049B
		 Commercially available devices/tools Spot weld milling machine Rotary wire brush Wet and dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
12	Prepare upper front longitudinal member for installation.		AR62.20-S-1286-02E
		 Commercially available devices/tools Rotary wire brush Wet and dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
13	Prepare A-pillar outer section (1) for installation.		AR63.20-S-1102-02E
		 Commercially available devices/tools Body power jigsaw Hole punching pliers Hand drill Rotary wire brush Wet and dry vacuum cleaner Clamping pliers (Standard)
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
14	Install the dowels for the longitudinal member panel holder.	Model 447.8, 448.8	AR88.80-S-6005-01CH
Topical note	General notes on touch-up applicators and paint spray cans		AH98.00-P-9409-06A
Topical note	Notes on removing adhesive residues and foils on paint and metal surfaces with surface conditioning disks		AH00.00-P-0013-01AK
		 Commercially available devices/tools Surface conditioning disk Ø 100 mm
		Primer Teroson 150 (Terokal 150)	*BR00.45-Z-1179-02A
		Teromix 6700 adhesive	*BR00.45-Z-1147-02A
		Cleaner	*BR00.45-Z-1025-04A
		Primer stick	*BR00.45-Z-1012-07A
15	Prepare outer paneling of upper A-pillar for installation.		AR63.20-S-1105-02E
		 Commercially available devices/tools Body power jigsaw Rotary wire brush Hole punching pliers Wet and dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
16	Prepare partial reinforcement of inner upper A-pillar for installation.		AR63.20-S-1111-02E
	000 588 01 84 00 Welder		WS60.00-P-0021K
		 Commercially available devices/tools Body power jigsaw Clamping pliers (Standard) Rotary wire brush Wet and dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
17	Prepare reinforcement of inner A-pillar (2) for installation.		AR63.20-S-1115-02E
		 Commercially available devices/tools Rotary wire brush Wet and dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
18	Prepare inner A-pillar (3).		AR63.20-S-1106-02E
		 Commercially available devices/tools Rotary wire brush Wet and dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
19	Install and weld in inner A-pillar (3).		AR63.20-S-1106-03E
	000 588 01 84 00 Welder		WS60.00-P-0021K
	000 588 02 84 00 Welder		WS60.00-P-0022K
	000 588 01 23 00 Body straightening system		WS60.00-P-0023K
		 Commercially available devices/tools Clamping pliers (Standard) Hand drill Angular grinder Rotary wire brush Wet and dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Adhesive kit, body, 2-component adhesive	*BR00.45-Z-1092-02A
		 Side portal frame	*210589172300
20	Install and weld in reinforcement of inner A-pillar (2).		AR63.20-S-1115-03E
	000 588 01 84 00 Welder		WS60.00-P-0021K
	000 588 01 23 00 Body straightening system		WS60.00-P-0023K
		 Commercially available devices/tools Clamping pliers (Standard) Hand drill Blind riveting tool (setting force > 19 kN) Rotary wire brush Wet and dry vacuum cleaner Squeeze gun
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		White sealing compound, 310 ml, DBL 6069.20	*BR00.45-Z-1003-01A
		Blind rivet with polygrip countersunk head 6.414 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)	*BR00.45-Z-1002-13A
		 Side portal frame	*210589172300
21	Install and weld in partial reinforcement of inner upper A-pillar.		AR63.20-S-1111-03E
	000 588 01 84 00 Welder		WS60.00-P-0021K
	000 588 02 84 00 Welder		WS60.00-P-0022K
		 Commercially available devices/tools Clamping pliers (Standard) Hand drill Blind rivet tool (setting force > 19 kN) Wet and dry vacuum cleaner Squeeze gun
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		White sealing compound, 310 ml, DBL 6069.20	*BR00.45-Z-1003-01A
		Adhesive kit, body, 2-component adhesive	*BR00.45-Z-1092-02A
		Blind rivet with polygrip countersunk head 6.414 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)	*BR00.45-Z-1002-13A
22	Install and weld in outer paneling of upper A-pillar.		AR63.20-S-1105-03E
	000 588 01 84 00 Welder		WS60.00-P-0021K
	000 588 02 84 00 Welder		WS60.00-P-0022K
		 Commercially available devices/tools Clamping pliers (Standard) Rotary wire brush Angular grinder Wet and dry vacuum cleaner
		Gap dimensions	*BE60.00-N-1002-01J
		Gap dimensions	*BE60.00-N-1004-01J
		 Feeler gauge	*129589032100
23	Install corresponding welding fixture.	Model 447 with engine 622, 780	AR62.20-S-1286-05EFA
Topical note	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
		Model 447 with engine 274, 651, 654 Model 448 with engine 274	AR62.20-S-1286-05EFE
		 Bolt, suspension strut to body	*BA32.25-N-1004-04C
		 Model 447 with engine 274, 651, 654 Model 448 with engine 274 Welding device	*447589022300
		 Model 447 with engine 622, 780 Welding device	*447589032300
24	Install and weld in upper front longitudinal member with welding fixture.		AR62.20-S-1286-03E
	000 588 01 84 00 Welder		WS60.00-P-0021K
		 Commercially available devices/tools Clamping pliers (Standard) Hand drill Blind riveting tool (set force > 19 kN) Rotary wire brush Wet and dry vacuum cleaner Squeeze gun
		Adhesive kit, body, 2-component adhesive	*BR00.45-Z-1092-02A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)	*BR00.45-Z-1001-13A
		 Model 447 with engine 274, 651, 654 Model 448 with engine 274 Welding device	*447589022300
		 Model 447 with engine 622, 780 Welding device	*447589032300
	Remove
25	Remove corresponding welding fixture.	 Model 447 with engine 274, 651, 654 Model 448 with engine 274 Welding device	*447589022300
		 Model 447 with engine 622, 780 Welding device	*447589032300
26	Install and weld in A-pillar outer section (1).		AR63.20-S-1102-03E
	000 588 01 84 00 Welder		WS60.00-P-0021K
	000 588 02 84 00 Welder		WS60.00-P-0022K
	000 588 01 23 00 Body straightening system		WS60.00-P-0023K
		 Commercially available devices/tools Clamping pliers (Standard) Rotary wire brush Angular grinder Wet and dry vacuum cleaner Squeeze gun
		Gap dimensions	*BE60.00-N-1004-01J
		White sealing compound, 310 ml, DBL 6069.20	*BR00.45-Z-1003-01A
		 Feeler gauge	*129589032100
		 Side portal frame	*210589172300
27	Release vehicle from straightening bench, lift and remove straightening bench.
28	Remove welding protection blankets.
 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 protective skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
29	Prime repair areas with a primer filler.
Topical note	Notes on paintwork repairs		AH98.00-P-9408-02A
		 The repair area must be free of dust and grease. Otherwise adhesion problems may occur.
		 Use only primer filler approved by Daimler AG: https://xentry.daimler.com
30	Seal seam after repair.		AR97.10-S-4000E
		 Supplement standard seals with sealant.
 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 protective skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
31	Paint repair area and adjacent surfaces.
Topical note	Notes on paintwork repairs		AH98.00-P-9408-02A
		 Use only paints approved by Daimler AG: https://xentry.daimler.com
32	Supplement cavity preservation.		AR97.20-S-1500E
33	Install soundproofing.		AR60.00-S-1752E
		 Only in repair area.
34	Install all detachable parts in area of repair point.

Gap dimensions

Number	Designation				Model 447, 448 except code W64, W65, W68	Model 447, 448 with code W64, W65, W68
BE60.00-N-1002-01J	Gap dimensions	Fender to headlamp	Dimension "BA"	mm	2 (1)	2 (1)
		Fender to bumper	Dimension "BB"	mm	0,3 (0,25)	0,3 (0,25)
		Fender to A-pillar	Dimension "BC"	mm	2,6 (1)	2,6 (1)
		Fender to front door	Dimension "BD"	mm	4,5 (0,8)	4,5 (0,8)
		Fender to longitudinal member	Dimension "BE"	mm	4,5 (1,2)	4,5 (1,2)
			For picture, see		AR60.00-S-0700-01E	AR60.00-S-0700-01E

Gap dimensions

Number	Designation				Model 447, 448 except code W64, W65, W68	Model 447, 448 with code W64, W65, W68
BE60.00-N-1004-01J	Gap dimensions	Front door to longitudinal member	Dimension "DA"	mm	6 (+2/-1)	6 (+2/-1)
		Front door to sidewall	Dimension "DB"	mm	4 (1)	4 (1)
		Front door to sliding door	Dimension "DC"	mm	4 (+1,2/-0,8)	4 (+1,2/-0,8)
		Front door to A-pillar	Dimension "DD"	mm	4,5 (+1,5/-1)	4,5 (+1,5/-1)
		Front door to fuel filler door	Dimension "DE"	mm	4 (1)	4 (1)
			For picture, see		AR60.00-S-0700-01E	AR60.00-S-0700-01E

 Suspension struts

Number	Designation			Model 447, 448
BA32.25-N-1004-04C	Bolt, suspension strut to body	Stage 1	Nm	40
		Stage 2	°	90

447 589 02 23 00

Welding device

210 589 17 23 00

Side portal frame

129 589 03 21 00

Feeler gauge

447 589 03 23 00

Welding device

Repair materials

Number	Designation	Order number
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 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)	A 003 990 35 97
BR00.45-Z-1002-13A	Blind rivet with polygrip countersunk head 6.414 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)	A 003 990 86 97 05
BR00.45-Z-1003-01A	White sealing compound, 310 ml, DBL 6069.20	A 001 989 63 20
BR00.45-Z-1012-07A	Primer stick	A 000 986 27 50
BR00.45-Z-1025-04A	Cleaner	A 005 989 19 71
BR00.45-Z-1092-02A	Adhesive kit, body, 2-component adhesive	A 012 989 17 71
BR00.45-Z-1147-02A	Teromix 6700 adhesive	A 006 989 99 71
BR00.45-Z-1179-02A	Primer Teroson 150 (Terokal 150)	Henkel AG & Co. KGaA http://www.loctite.de

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