Partially remove/install A-pillar

AR63.20-S-1107E

Partially remove/install A-pillar

04.05.2020

Model

447, 448

Shown on right side of vehicle

1

A-pillar outer section

2

Inner A-pillar reinforcement

3

Door hinge strap

 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

 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

 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

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

Measures for preventing damage to components when performing electric welding and soldering work

AH60.00-P-0001-02A

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

Cut off A-pillar outer section (1) in segments.

AR63.20-S-1108-01E



000 588 00 84 00 Heat gun

WS54.00-P-0049B

 Commercially available devices/tools
Rotary wire brush
Spot weld milling machine
Body power jigsaw

7

Cut off inner A-pillar reinforcement (2) in segments.

AR63.20-S-1109-01E

 Commercially available devices/tools
Spot weld milling machine
Body power jigsaw
Rotary wire brush
Wet and dry vacuum cleaner

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

8

Prepare A-pillar outer section (1) for installation in segments.

AR63.20-S-1108-02E

 Commercially available devices/tools
Body power jigsaw
Hole punching pliers
Hand drill
Rotary wire brush
Wet and dry vacuum cleaner

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

9

Install dowels for the mounting rail of the longitudinal member panel.

Model 447.8, 448.8

AR88.80-S-6005-01CH

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

10

Prepare inner A-pillar reinforcement (2) for installation in segments.

AR63.20-S-1109-02E

 Commercially available devices/tools
Body power jigsaw
Rotary wire brush
Wet and dry vacuum cleaner

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

11

Weld in inner A-pillar reinforcement (2) section.

AR63.20-S-1109-03E



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
Angular grinder
Blind riveting tool (setting force > 19 kN)
Rotary wire brush
Wet and dry vacuum cleaner

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

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

12

Install and weld in A-pillar outer section (1) and door hinge holder (3).

AR63.20-S-1108-03E



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
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

13

Release vehicle from straightening bench, lift and remove straightening bench.

14

Remove welding protection blankets.

 Commercially available devices/tools
Welding protection blanket

 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

15

Prime repair area with a primer filler.

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A


Repair area must be free of dust and grease.
Otherwise adhesion problems may occur.

 Use only primer filler approved by Daimler AG:
http://xentry.daimler.com

16

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

17

Paint repair area and adjacent surfaces.

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

 Use only paints approved by Daimler AG, see:
http://xentry.daimler.com

18

Supplement cavity preservation.

AR97.20-S-1500E

19

Install soundproofing.

AR60.00-S-1752E

 Only in repair area.

20

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-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

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-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-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