Install And Weld In Complete A-Pillar - Ar63.20-P-1100-10LWE

Model 213 

The following steps are shown on the left side of the vehicle and must be performed analogously on the right side in the event of damage.

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1. Install A-pillar inner panel (7) and A-pillar reinforcement with portal bracket, fit and fix in place.

   Use spacers.

2. Drill rivet holes on A-pillar inner panel (7) with Ø 6.7 mm bit (areas A and A₁ ).

   Drill rivet holes through present holes in body (areas A).

3. Remove portal bracket, A-pillar reinforcements and A-pillar inner panel (7).
4. Deburr rivet holes on A-pillar inner panel (7) and body on both sides.
5. Remove drilling chips.
6. Coat insides of riveted joints with zinc dust paint.
7. Apply 2-component adhesive to body in cross-hatched area.

   Apply 2-component adhesive to inside (area A₂ ).

   Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

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   Courtesy of MERCEDES-BENZ USA

8. Install A-pillar inner panel (7) and fix in place.
9. Rivet A-pillar inner panel (7) with Ø 6.5x12.5 rivet (areas B).
10. A-pillar inner panel (7) (area s F).
11. A-pillar inner panel (7) (areas C and E).

    Inert gas weld in intervals and allow welding area to cool down in between. Reduces heat distortion.

12. Grind inert gas weld on A-pillar inner panel (7) down flat (area E).
13. Clean welding areas which are no longer accessible after installing upper front longitudinal member and A-pillar reinforcement and coat with zinc dust paint.

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14. Install inner connecting panel (9), fit and fix in place.
15. Drill rivet holes on inner connecting panel (9) with Ø 6.7 mm bit (areas G and H).
16. Countersink rivet holes on inner connecting panel (9) (area G).
17. Remove inner connecting panel (9).
18. Deburr rivet holes in inner connecting panel (9) and body on both sides.
19. Remove drilling chips.
20. Apply 2-component adhesive to inner connecting panel (9) in cross-hatched area.

    Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

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21. Install inner connecting panel (9) and fix in place.
22. Rivet inner connecting panel (9) with Ø 6.4x15.5 countersunk head rivet (area I).

    After painting countersunk head rivet mask with suitable felt strips (area I).

23. Rivet inner connecting panel (9) with Ø 6.5x12.5 countersunk head rivet (area J).

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24. Install A-pillar inner panel (6) with portal bracket, fit and fix in place.

    Use spacers.

25. Drill rivet holes on A-pillar reinforcement (6) with Ø 6.7 mm bit (area K).
26. Remove portal bracket and A-pillar reinforcement (6).
27. Deburr rivet holes on A-pillar inner panel (6) and body on both sides.

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28. Apply sealant to foam parts on A-pillar reinforcement (6) in crosshatched areas.

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29. Apply 2-component adhesive to A-pillar inner panel (7) in crosshatched areas.

    Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

30. Install A-pillar reinforcement (6) and fix in place.
31. Rivet A-pillar reinforcement (6) with Ø 6.5x12.5 rivet (area K₁ ).
32. A-pillar reinforcement (6) (area M).

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33. A-pillar reinforcement (6) (areas O₁ ).
34. A-pillar reinforcement (6) (areas N₁ , N₂ and N₃ ).

    Inert gas weld in intervals and allow welding area to cool down in between. Reduces heat distortion.

35. Grind inert gas welds down flat on A-pillar reinforcement (6) (areas N₁ and N₂ ).

    Grind down flat beaded areas and contact surfaces on B-pillar paneling only.

36. Clean welding areas which are no longer accessible after installing upper front longitudinal member and A-pillar paneling and coat with zinc dust paint.
37. Install outer connecting panel (8), fit and fix in place.

    Center outer connecting panel (8) above inert gas weld on A-pillar reinforcement.

38. Drill rivet holes on outer connecting panel (8) through present holes with Ø 6.7 mm (areas O₂ and O₃ ).

    When drilling, ensure that the bit does not reach too far into the A-pillar reinforcement. Otherwise the water drain hose in the A-pillar reinforcement can be damaged.

39. Countersunk rivet holes on outer connecting panel (8) (area O₂ ).
40. Remove outer connecting panel (8).
41. Drill rivet holes on outer connecting panel (8) and body on both sides.

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42. Apply 2-component adhesive to body in cross-hatched area.

    Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

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43. Install outer connecting panel (8) and fix in place.
44. Rivet outer connecting panel (8) with Ø 6.4x15.5 countersunk head rivet (area O₄ ).
45. Rivet outer connecting panel (8) with Ø 6.5x12.5 rivets (area O₅ ).

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    Courtesy of MERCEDES-BENZ USA

46. Drill out connecting flange (10) on old A-pillar reinforcement section with Ø 7 mm bit.

    If connecting flange (10) is damaged

    ↓

    Fabricate connecting flange (10).

47. Install connecting flange (10), fit and fix in place.
48. Connecting flange (10) (area K₄ ).

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49. Install upper front longitudinal member (1), fit with welding device and fix in place.
50. Install reinforcement (3), fit and fix in place.
51. Drill rivet holes on upper front longitudinal member (1) and reinforcement with (3) with Ø 6.7 mm bit (areas Mi, N₁ and O).

    Drill rivet holes from inside through present hole in body (area N₁ ).

52. Remove upper front longitudinal member (1), reinforcement (3) and welding device.
53. Deburr drill holes on upper front longitudinal member (1), reinforcement (3) and body on both sides.
54. Remove drilling chips.
55. Coat inside of riveted joint with zinc dust paint (areas O).

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56. Apply 2-component adhesive to body in crosshatched areas.

    Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

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57. Install upper front longitudinal member (1), fit with welding device and fix in place.
58. Install reinforcement (3) and fix in place.
59. Rivet upper front longitudinal member (1) and reinforcement (3) with Ø 6.5x12.5 rivet (areas P₁ and P₂ ).
60. Rivet upper front longitudinal member (1) and reinforcement (3) with Ø 6.5x14.5 rivet (areas P₃ ).
61. Upper front longitudinal member (1) (areas Q).

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62. Install strut (2) and bracket (4), fit and fix in place.
63. Drill rivet holes on strut (2) and bracket (4) with Ø 6.7 mm (areas R and S).
64. Remove strut (2) and bracket (4).
65. Deburr rivet holes on strut (2), bracket (4) and body on both sides.
66. Remove drilling chips.
67. Coat insides of riveted joints with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas R).

    Otherwise adhesion problems may occur.

68. Apply 2-component adhesive to body in crosshatched areas.

    Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

69. Install strut (2) and bracket (4) and fix in place.
70. Rivet strut (2) with Ø 6.5x12.5 rivet (areas T).
71. Rivet strut (2) and bracket (4) with Ø 6.4x12 (areas U).
72. Install A-pillar paneling (5), fit and fix in place.
73. Drill rivet holes on A-pillar paneling (5) with Ø 6.7 mm (areas V₁ , V₂ and V₃ ).
74. Remove A-pillar paneling (5).
75. Deburr rivet holes on A-pillar inner panel (5) and body on both sides.
76. Remove drilling chips.
77. Coat insides of riveted joints with zinc dust paint.

    Do not apply zinc dust paint to bonding surfaces (areas V₂ ). Otherwise adhesion problems may occur.

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78. Apply sealant to foam part in crosshatched area.

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    Courtesy of MERCEDES-BENZ USA

79. Install A-pillar paneling (5) and fix in place.
80. Rivet A-pillar paneling (5) with Ø 6.4x12 rivet (areas W₁
81. Rivet A-pillar paneling (5) with Ø 6.5x12.5 (areas W₂ ).
82. Rivet A-pillar paneling (5) with Ø 6.5x14.5 rivets (area W₃ ).
83. A-pillar paneling (5) (areas X).
84. A-pillar paneling (5) (areas Y).

    Inert gas weld in intervals and allow welding area to cool down in between. Reduces heat distortion.

85. Grind inert gas welds down flat (areas Y).
86. Solder surfaces on A-pillar paneling (5) with body solder and smooth (areas Y).

    Alternatively to restorage of the surfaces with body solder, it is also possible to use a body basic spatula.