Install A-pillar outer section - AR63.20-P-1102-03CW

The following operation steps are shown on model 204.0.

1. Center-punch hole for subsequent cavity preservation on inner A-pillar (3) (area A₁ ).
2. Drill Ø 8 mm hole for subsequent cavity preservation through inner A-pillar (3) and A-pillar reinforcement (2) (area A₁ ).

   Do not damage water drain hose below, otherwise water can penetrate into interior compartment.

   Dimensions: 

   Fig 1: Identifying Cavity Dimensions On Inner A-Pillar

   Courtesy of MERCEDES-BENZ USA
3. Set up side portal frame.

   Observe setup plans.

4. Install A-pillar reinforcement (2), fit and fix in place with welding device.

   Use spacer of welding device (see setup plan).

5. Drill Ø 6.7 mm rivet holes on A-pillar reinforcement (2) (area A).
6. Remove welding device and A-pillar reinforcement (2).
7. Deburr rivet holes on A-pillar reinforcement (2) on both sides.
8. Coat insides of riveted joints with zinc dust paint.
   Fig 2: Identifying Drill Area On Pillar Reinforcement

   Courtesy of MERCEDES-BENZ USA
   Fig 3: Identifying A-Pillar Reinforcement Weld & Rivet Areas

   Courtesy of MERCEDES-BENZ USA
9. Slide protective tube over water drain hose and position on area to be welded on A-pillar (area P).

   Manual temporary fastener

10. Apply MB body sealant to foam parts on A-pillar reinforcement (2).
11. Install A-pillar reinforcement (2), fit and fix in place with welding device and manual temporary fasteners.

    Use spacer of welding device (see setup plan).

12. Guide water drain hose through hole on A-pillar reinforcement (2) and fasten.
13. Rivet A-pillar reinforcement (2) with steel/steel blind rivet, Ø 6.5 x12.5 (area A).
14. A-pillar reinforcement (2) (areas B, C, D and E).

    To ensure the minimum strength of the welds, the new resistance spot welds must be located in exactly the same position as resistance spot welds located at the factory, because these areas are glued beneath (areas B, C, D and E).

    When replacing upper front longitudinal member, areas (F, G, H, I, J, K, L, M, N and O) are replaced by joints from the repair method for the upper front longitudinal member.

15. A-pillar reinforcement (2) (areas F, G, H, I, J, K, L, M and N).
16. A-pillar reinforcement (2) (areas O, P, Q and R).
17. Remove welding device
18. Grind inert gas weld on A-pillar reinforcement (2) down flat on mating surfaces (arrows).
19. Grind inert gas weld and MIG plug welds down flat on A-pillar reinforcement (2) (areas F, G and R).
20. Install outer A-pillar paneling (1), fit and fix in place with welding device.

    Observe setup plans.

    When replacing upper front longitudinal member, this is fitted before the A-pillar outer paneling (1).

21. Drill Ø 6.7 mm rivet holes on A-pillar outer paneling (1) (areas S, T, U and V).
22. Countersink rivet holes on A-pillar outer paneling (1) (area S).
    Fig 4: Identifying A-Pillar Outer Panelling Rivet Areas

    Courtesy of MERCEDES-BENZ USA
23. Remove welding device and A-pillar outer paneling (1).
24. Deburr rivet holes on A-pillar outer paneling (1) on both sides.
25. Coat insides of riveted joints with zinc dust paint.
    Fig 5: Identifying A-Pillar Outer Panelling Weld & Rivet Areas

    Courtesy of MERCEDES-BENZ USA
26. Install outer A-pillar paneling (1), fit and fix in place with welding device and manual temporary fasteners.
27. Rivet A-pillar outer paneling (1) with Polygrip flat round head rivet, Ø 6.4 x14 (areas T, U and V).
28. Rivet A-pillar outer paneling (1) with Polygrip countersunk rivet, Ø 6.4 x14 (area S).
29. A-pillar outer paneling (1) (areas W and X).
30. A-pillar outer paneling (1) (areas Y and Z).

    Weld in intervals, allow to cool down in between to minimize heat distortion (areas Y and Z).

31. A-pillar outer paneling (1) (areas AA and AB).
32. Remove welding device and side portal frame.
33. Grind inert gas welds and MIG plug welds down flat on A-pillar outer paneling (1) (areas Y, Z, AA and AB).
34. Clean weld joints.
35. Finish surface on outer A-pillar paneling (1) and smooth.
36. Remove drill shavings.