Field Remedy: 1399

Remedy:

I:   Preparation of an A-pillar check link carrier and an A-pillar
     inner reinforcement plate.
II:  Replacement of the A-pillar check link carrier.
III: Repair of the crack in the A-pillar.

Note:

     For each A-pillar check link carrier repair side is required:

1 A-pillar check link carrier - left side

1 A-pillar check link carrier - right side

4 Fixing screws                       

4 Fixing nuts                          

     The A-pillar reinforcement plate must be made from the A-pillar
     carrier of the respective other side.

Working procedure:

I: Preparation of an A-pillar check link carrier and an A-pillar
   inner reinforcement plate

Important:

     When preparing the A-pillar check link carrier and the A-pillar
     inner reinforcement plate, the dimensions must be meticulously
     kept and the bores must be made exactly; otherwise, problems may
     arise during the installation of the check link to the A-pillar
     check link carrier.

 1. Scribe the A-pillar check link carrier (dimension "I" 7 mm,
    dimension "II" 8 mm, dimension "III" 6,5 mm) and punch it
    (picture I).

 2. Predrill the A-pillar check link carrier 4 times (diameter 3 mm).
 3. Rebore the A-pillar check link carrier 4 times (diameter 6,5 mm).
 4. Debur the bores.
 5. Align the A-pillar check link carrier and the A-pillar inner
    reinforcement plate to each other (the A-pillar check link
    carrier serves as drill template).
 6. Mount the A-pillar check link carrier and an A-pillar inner
    reinforcement plate into the vice of the stationary drilling
    machine.
 7. Drill the A-pillar inner reinforcement plate through the A-pillar
    check link plate (diameter 6.5 mm).
 8. Debur the bores.
 9. Remove the surface-coating in the welding area of the A-pillar
    inner reinforcement plate with emery cloth or a file.
10. Remove the surface-coating in the welding area of the fixing nuts
    with emery cloth or a file.
11. Mount the A-pillar check link carrier and the A-pillar inner
    reinforcement plate with fixing screws and fixing nuts, join these
    by screwing hand-tight.

Note:

     Locate the fixing nuts on the side of the A-pillar inner
     reinforcement plate.

12. Fix the fixing nuts with two welding points each to the A-pillar
    inner reinforcement plate (picture II).

13. Remove the fixing screws.

II: Replacement of the A-pillar check link carrier

Note:

     Be aware of the mounting position of the A-pillar check link
     carrier:
     The big bore points upwards.

     Be aware of the mounting position of the A-pillar inner
     reinforcement plate:
     The big bore points upwards.

 1. Remove the front door

     - see working procedure "Front or Rear Door, Remove and
       Install", group "A", Service Instruction Omega-B.

 2. Only driver side: Remove driver side mixed air nozzle housing

     - see working procedure "Mixed Air Nozzle Housing, Drivers Side,
     Remove and Install", group "D", Service Instruction Omega-B.

 3. Only passenger side: Remove passenger side mixed air nozzle
    housing

     - see working procedure "Mixed Air Nozzle Housing, Passengers
       Side, Remove and Install", group "D", Service Instruction
       Omega-B.

 4. Remove the front door sealing in the A-pillar area.
 5. Remove the front door wiring harness sealing through the A-pillar
    to the inside.
 6. Scribe the position of the A-pillar check link carrier on the
    A-pillar.
 7. Drill out the 4 welding points of the A-pillar check link carrier
    with a welding point drill (picture III).

 8. Remove the A-pillar check link carrier.
 9. If necessary, adjust or repair the A-pillar (A-pillar repair see
    working procedure "III").
10. Grind the A-pillar naked in the area of the A-pillar check link
    carrier using an angle grinder.
11. Install the front door.
12. Install a new A-pillar check link carrier to the check link.
13. Determine the position of the A-pillar check link carrier and fix
    the A-pillar check link carrier with three welding points to the
    A-pillar (picture IV)(prior to this, grind the welding areas of
    the A-pillar check link carrier naked).

14. Remove front door.
15. Drill 4 bores into the A-pillar through the A-pillar check link
    carrier (diameter 6.5 mm).
16. Grind the welding points off the A-pillar check link carrier.
17. Remove the A-pillar check link carrier.
18. Debur the bores.
19. Paint the A-pillar, the A-pillar check link carrier and the
    A-pillar inner reinforcement plate.
20. Remove the A-pillar lower interior lining

     - see working procedure "Inner Panelling - Lower A-pillar",
       group "C", Service Instruction Omega-B.

21. Remove the front door wiring harness from the A-pillar and pull
    it out to the inside.
22. Fix retaining band to the A-pillar inner reinforcement plate
    (in order to avoid rattling noise, do not use welding wire or
    cables) (picture V).

23. Insert the A-pillar inner reinforcement plate, through the
    opening of the front door wiring harness, into the A-pillar.
24. Install the A-pillar check link carrier to the A-pillar using
    new fixing screws – tightening torque 10 Nm (use locking
    compound).
25. Cut off as much of the retaining band as possible.
26. Apply cavity protection to the inner A-pillar.
27. Route the front door wiring harness and install it to the
    A-pillar.
28. Install the A-pillar lower interior lining

     - see working procedure "Inner Panelling - Lower A-pillar",
       group "C", Service Instruction Omega-B.

29. Install the inner and outer front door wiring harness sealing 
    to the A-pillar.

Note:

     Observe the mounting position – the arrow must point upwards.

30. Install the front door sealing.
31. Only driver side: Install driver side mixed air nozzle housing

     - see working procedure "Mixed Air Nozzle Housing, Drivers
       Side, Remove and Install", group "D", Service Instruction
       Omega-B.

32. Only passenger side: Install passenger side mixed air nozzle
    housing

     - see working procedure "Mixed Air Nozzle Housing,
       Passengers Side, Remove and Install", group "D", Service
       Instruction Omega-B.

33. Install front door

     - see working procedure "Front or Rear Door, Remove and
       install", group "A", Service Instruction Omega-B.

III: Repair of the crack in the A-pillar

 1. Bore through the ends of the crack (diameter 2.5 mm).
 2. Weld the crack and the bores.
 3. Grind the repaired area.

Parts:                                 Part-No.:     Catalog-No.: 

1 A-pillar check link carrier          90568535      90 01 095
  - left side

1 A-pillar check link carrier          90568536      90 01 094
  - right side

4 Fixing screws                        11093871      20 35 600

4 Fixing nuts                          11011418      20 64 155

Labour Times:                          TC:          Hours:

T 8 139 90    Repair of A-pillar       90           5.1
              check link carrier

T 8 139 91    Paint and finish         90           2.6
              works

                  
The costs for this repair will be covered for vehicles not
older than 3 years and a mileage lower than 100.000 km.

The regular warranty procedure should be used for claiming
Set-up-time.