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Install and weld in complete A-pillar - AR63.20-P-1100-10SX

Fig 1: Identifying Side Portal Frame (210 589 17 23 00)
G07583624Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Inspection And Welding Device (210 589 00 23 00)
G07583625Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1092-02A Adhesive kit, body, 2-component adhesive A 009 989 36 71
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
BR00.45-Z-1012-13A Blind rivet 6.5x12.5 A 004 990 16 97
BR00.45-Z-1001-13A Blind rivet 6.4x14 A 003 990 35 97
  1. SPECIAL TOOL Set up side portal frame (9).
  2. Fit upper inner A-pillar (10) and inner outer longitudinal member (2) and fasten using SPECIAL TOOL inspection and welding device (6) and as well as bolts (8) and COMMERCIALLY AVAILABLE TOOLS clamping pliers
  3. Drill dia. 6.5 mm rivet holes in upper inner A-pillar (10) and inner outer longitudinal member (2) (area A).
  4. Fasten upper inner A-pillar (10) and inner outer longitudinal member (2) with COMMERCIALLY AVAILABLE TOOLS manual temporary fastener (area A).
    Fig 3: Fastening Upper Inner A-Pillar And Inner Outer Longitudinal Member
    G07583626Courtesy of MERCEDES-BENZ USA
  5. Install doubler panel (14) and outer longitudinal member (3), fit and fasten using COMMERCIALLY AVAILABLE TOOLS clamping pliers.

    IMPORTANT Align doubler panel (14) with outer longitudinal member (3) using center punch (13)

    IMPORTANT Fasten doubler panel (14) from bottom at through hole with COMMERCIALLY AVAILABLE TOOLS clamping pliers.

    Fig 4: Installing Doubler Panel And Outer Longitudinal Member
    G07583627Courtesy of MERCEDES-BENZ USA
  6. Drill dia. 6.5 mm rivet holes in upper inner A-pillar (10) and inner outer longitudinal member (2) (areas B and C).
    Fig 5: Identifying Upper Inner A-Pillar And Inner Outer Longitudinal Member Riveting Areas
    G07583628Courtesy of MERCEDES-BENZ USA

    Dimensions: 

    Fig 6: Identifying Outer Longitudinal Member Dimensions
    G07583629Courtesy of MERCEDES-BENZ USA
  7. Scribe rivet holes on outer longitudinal member (3) (areas D1 and E1 ).
  8. Center punch rivet holes at top on outer longitudinal member (3) using COMMERCIALLY AVAILABLE TOOLS BTR Usibor center punch, dia. 8x80 mm (areas D1 and E1 ).
  9. Drill rivet holes at top on outer longitudinal member (3) using COMMERCIALLY AVAILABLE TOOLS dia. 6.7 mm BTR Usibor drill bit (areas D1 and E1 ).

    Dimensions: 

    Fig 7: Identifying Outer Longitudinal Member Dimensions
    G07583630Courtesy of MERCEDES-BENZ USA
  10. Scribe rivet holes at center on outer longitudinal member (3) (area F1 ).
  11. Center punch rivet holes at center on outer longitudinal member (3) using COMMERCIALLY AVAILABLE TOOLS BTR Usibor center punch, dia. 8 x80 mm (area F1 ).
  12. Drill rivet holes at center on outer longitudinal member (3) with COMMERCIALLY AVAILABLE TOOLS dia. 6.7 mm BTR Usibor drill bit (area F 1 ).

    Dimensions: 

    Fig 8: Identifying Outer Longitudinal Member Dimensions
    G07583631Courtesy of MERCEDES-BENZ USA
  13. Scribe rivet holes at bottom on outer longitudinal member (3) (area G1 ).
  14. Center punch rivet holes at bottom on outer longitudinal member (3) using COMMERCIALLY AVAILABLE TOOLS BTR Usibor center punch, dia. 8 x80 mm (area G1 ).
  15. Drill rivet holes at bottom on outer longitudinal member (3) with COMMERCIALLY AVAILABLE TOOLS dia. 6.7 mm BTR Usibor drill bit (area G 1 ).
  16. Remove outer longitudinal member (3) and doubler panel (14).
  17. Deburr rivet holes on outer longitudinal member (3) and doubler panel (14) on both sides.
  18. Coat insides of riveted joints with zinc dust paint.
  19. Remove upper inner A-pillar (10) and inner outer longitudinal member (2).
  20. Deburr rivet holes on upper inner A-pillar (10) and inner outer longitudinal member (2) on both sides.
  21. Apply 2-component adhesive on inner outer longitudinal member (2) in shaded areas.

    IMPORTANT serve pretreatment of bonding surfaces.

    IMPORTANT Refer to manufacturer specifications for adhesive curing and application times.

    Fig 9: Fitting Upper Inner A-Pillar On Inner Outer Longitudinal Member
    G07583632Courtesy of MERCEDES-BENZ USA
  22. Fit upper inner A-pillar (10) on inner outer longitudinal member (2) and fasten using COMMERCIALLY AVAILABLE TOOLS manual temporary fastener and COMMERCIALLY AVAILABLE TOOLS clamping pliers.
  23. Upper inner A-pillar (10) on inner outer longitudinal member (2) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area F).
  24. Rivet upper inner A-pillar (10) on inner outer longitudinal member (2) using Polygrip flat round head rivet, dia. 6.4 x14 mm (area A).
  25. Apply 2-component adhesive to vehicle in shaded areas.

    IMPORTANT Observe pretreatment of bonding surfaces.

    IMPORTANT Refer to manufacturer specifications for adhesive curing and application times.

    Fig 10: Identifying 2-Component Adhesive Application Areas
    G07583633Courtesy of MERCEDES-BENZ USA
  26. Install complete inner A-pillar (1), fit using SPECIAL TOOL inspection and welding devices (6) and fasten using COMMERCIALLY AVAILABLE TOOLS manual temporary fastener and COMMERCIALLY AVAILABLE TOOLS clamping pliers.
  27. Complete inner A-pillar (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas G, H, I, J, K and L).
  28. Rivet complete inner A-pillar (1) using Polygrip flat round head rivet, dia. 6.4 x 14 mm (areas B and C).
    Fig 11: Identifying Inner A-Pillar Spot Weld & Riveting Areas
    G07583634Courtesy of MERCEDES-BENZ USA
  29. Complete inner A-pillar (1) SHIELDED GAS SEAM WELD (areas M, N and O).
  30. Grind MIG welds down flat on mating surfaces.
  31. Clean welds using COMMERCIALLY AVAILABLE TOOLS round wire brush.
  32. Remove grinding and drill shavings using wet/dry vacuum cleaner.
  33. Coat insides of welds with zinc dust paint.

    NOTES To prevent adhesion problems, do not coat bonding surfaces with zinc dust paint.

    Fig 12: Identifying Inner A-pillar Welding Areas
    G07583635Courtesy of MERCEDES-BENZ USA
  34. Install doubler panel (14), fit and fasten using COMMERCIALLY AVAILABLE TOOLS manual temporary fasteners.
  35. Apply 2-component adhesive to complete inner A-pillar (1) in shaded areas.
    Fig 13: Identifying Inner A-Pillar Adhesive Application Area
    G07583636Courtesy of MERCEDES-BENZ USA

    IMPORTANT Observe pretreatment of bonding surfaces.

    IMPORTANT Refer to manufacturer specifications for adhesive curing and application times.

  36. Install outer longitudinal member (3), fit and fasten using COMMERCIALLY AVAILABLE TOOLS manual temporary fasteners, COMMERCIALLY AVAILABLE TOOLS clamping pliers and COMMERCIALLY AVAILABLE TOOLS C-clamps.
  37. Outer longitudinal member (3) with POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas P, Q, R, S, T and U).
    Fig 14: Identifying Outer Longitudinal Member Spot Welding Areas
    G07583637Courtesy of MERCEDES-BENZ USA
  38. Clean welds using COMMERCIALLY AVAILABLE TOOLS round wire brush.
  39. Coat inside of weld with zinc dust paint (area T).
  40. Rivet doubler panel (14) on side longitudinal member and outer longitudinal member (3) using blind rivet, steel/steel, dia. 6.5x12.5 (areas D and E).
  41. Route water drain hose (11) on complete inner A-pillar (1), insert into passage and fasten using brackets (12).
Fig 15: Identifying Side Longitudinal Member And Outer Longitudinal Member Riveting Areas & Water Drain Hose
G07583638Courtesy of MERCEDES-BENZ USA
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