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

Fig 1: Identifying Side Portal Frame (210 589 17 23 00)

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Fig 2: Identifying Inspection And Welding Device (221 589 00 23 00)

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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-1001-13A	Blind rivet 6.4x14	A 003 990 35 97
BR00.45-Z-1012-13A	Blind rivet 6.5x12.5	A 004 990 16 97
BR00.45-Z-1002-13A	Polygrip countersunk head rivet, 6.4 x14	A 003 990 86 97 05

Set up side portal frame (3).
Install A-pillar outer paneling (1) and A-pillar reinforcement (2), fit and fasten using inspection and welding device (4 and 5), bolts (6) and clamping pliers.

Fig 3: Installing A-Pillar Outer Paneling And A-Pillar Reinforcement
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Fig 4: Identifying A-Pillar Outer Paneling And A-Pillar Reinforcement Drilling Areas
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Drill dia. 6.5 mm rivet holes in A-pillar outer paneling (1) and A-pillar reinforcement (2) (areas A and D).
Center punch rivet holes on A-pillar outer paneling (1) and A-pillar reinforcement (2) using BTR Usibor center punch, dia. 8 x 80 mm (areas B and C).
Drill rivet holes in A-pillar outer paneling (1) and A-pillar reinforcement (2) with BTR Usibor drill bit, dia. 6.7 mm (areas B, C and C 1).
Countersink rivet holes on A-pillar outer paneling (1) (area C ₁ ).
To drill rivet holes in A-pillar outer paneling (1) transfer every second spot welds from old A-pillar outer paneling to new part.

When replacing A-pillar outer paneling (1) and A-pillar reinforcement (2) transfer rivet holes from removed part (area B).
Fasten A-pillar reinforcement (2) using manual temporary fasteners.
Remove inspection and welding device (4 and 5) and side portal frame (3).
Remove A-pillar outer paneling (1).
Deburr rivet holes on A-pillar outer paneling (1) on both sides.
Coat insides of riveted joints with zinc dust paint.
To prevent adhesion problems, do not coat bonding surfaces with zinc dust paint.
Drill dia. 6.5 mm rivet holes in A-pillar reinforcement (2) (area F).
Scribe rivet holes on A-pillar reinforcement (2) (area E).
Center punch rivet holes on A-pillar reinforcement (2) using BTR Usibor center punch, dia. 8 x 80 mm (area E).
Drill rivet holes in A-pillar reinforcement (2) with BTR Usibor drill bit, dia. 6.7 mm (area E).
Remove A-pillar reinforcement (2).
Dimensions:

Fig 5: Identifying A-Pillar Reinforcement Riveting Areas
Courtesy of MERCEDES-BENZ USA
Deburr rivet holes on A-pillar reinforcement (2) on both sides.
Coat insides of riveted joints with zinc dust paint.
To prevent adhesion problems, do not coat bonding surfaces with zinc dust paint.
Apply 2-component adhesive material in shaded areas.
Apply glue from inside (area G).

Observe pretreatment of bonding surfaces.

Refer to manufacturer specifications for adhesive curing and application times.

Fig 6: Identifying A-Pillar Reinforcement 2-Component Adhesive Material Application Area
Courtesy of MERCEDES-BENZ USA

To prevent adhesion problems, do not coat bonding surfaces with zinc dust paint.
Install A-pillar reinforcement (2) and fasten using manual temporary fasteners and clamping pliers.
Rivet A-pillar reinforcement (2) and side longitudinal member (7) using blind rivet, steel/steel, dia. 6.5 x 12.5 (area H).
Rivet A-pillar reinforcement (2) using Polygrip flat round head rivet, dia. 6.4 x 14 mm (area I).

Fig 7: Identifying A-Pillar Reinforcement Riveting Area
Courtesy of MERCEDES-BENZ USA
Apply 2-component adhesive in shaded areas on A-pillar reinforcement (2) and outer longitudinal member (7).
Observe pretreatment of bonding surfaces.

Refer to manufacturer specifications for adhesive curing and application times.

Fig 8: Identifying A-Pillar Reinforcement And Outer Longitudinal Member Adhesive Application Area
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Install A-pillar outer paneling (1) and fasten using manual temporary fasteners and clamping pliers.

Fig 9: Identifying A-Pillar Outer Paneling & A-Pillar Reinforcement Spot Weld Areas
Courtesy of MERCEDES-BENZ USA
A-pillar outer paneling (1) and A-pillar reinforcement (2) (areas J and K).
Rivet A-pillar outer paneling (1) and A-pillar reinforcement (2) using Polygrip flat round head rivet, dia. 6.4 x 14 mm (areas L ₁ and M).

Fig 10: Identifying A-Pillar Outer Paneling And A-Pillar Reinforcement Riveting Area
Courtesy of MERCEDES-BENZ USA
Rivet A-pillar outer paneling (1) and A-pillar reinforcement (2) using blind rivet, steel/steel, dia. 6.5 x 12.5 (areas L and L ₁ ).
Rivet A-pillar outer paneling (1) using Polygrip countersunk head rivet, dia. 6.4 x 14 (area L ₂ ).
A-pillar outer paneling (1) (areas N, O, P, Q and R).

Fig 11: Identifying A-Pillar Outer Paneling Seam Weld Areas
Courtesy of MERCEDES-BENZ USA

Weld in intervals, allow to cool down in between to minimize heat distortion (areas N and R).
Grind A-pillar outer paneling (1) down flat in cross-hatched areas using abrasive disk.
Restore surface on A-pillar outer paneling (1) and smooth.
Remove grinding and drill shavings using wet/dry vacuum cleaner.

Fig 12: Identifying A-Pillar Outer Paneling Grinding Areas

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