Outer A-Pillar Section Installation - Ar63.20-P-1102-03RG

	000 588 04 39 00 Rivet press tool		WS60.00-P-0440B
	000 588 12 84 00 Welder		WS00.00-P-0318K

Model 190 

Fig 1: Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

Further information can be found in the superordinate service document. Comply with safety information in superordinate customer service document.

The following operation steps are shown on the left side of the vehicle. In case of damage, these steps must be similarly performed on the right side of the vehicle.

Replace flow drill and self-tapping fillister head screws as well as self-pierce rivets installed on the vehicle with high-strength rivets in accordance with the clamping range.

1. Install and align the new A-pillar outer section part (1) and portal straightener.
2. Install and align outer side longitudinal member and longitudinal member panel.
3. Check gaps using feeler gauge and adjust.
4. Fix the new A-pillar outer section part (1).
5. Remove longitudinal member panel and outer side longitudinal member.

   Courtesy of MERCEDES-BENZ USA

   Shown on model 190.3 

6. Drill rivet holes on A-pillar outer section (1) with ø 6.5 mm (area A1).

   Transfer holes present in vehicle for flow drill bolts and selftapping fillister head bolts to new part. In the case of new part to new part connections, adapt these and drill together.

7. Prepare A-pillar outer section (1) with rivet press tool (area B1).

   Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt these and prepare together.

8. Remove A-pillar outer section (1) and portal straightener.
9. Deburr rivet holes on A-pillar outer section (1) and body on both sides (area A1).

   Observe pretreatment of bonding surfaces.

10. Remove shavings using wet/dry vacuum cleaner.
11. To the A-pillar outer section (1) apply the 2-component adhesive (cross-hatched areas).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

    Shown on model 190.3 

12. Install A-pillar outer section (1), fit and fix in place.
13. Rivet the A-pillar outer section (1) with the rivet press tool and flow-form rivets or flow-form rivets (areas B2 and B3).

    Use flow-form rivets with structure 5.0 mm to 6.1 mm clamping range (S48) or flow-form rivets with structure 7.1 mm to 8.3 mm clamping range (S68).

14. Rivet the A-pillar outer section (1) with the rivet press tool and blind rivets or blind rivet (area A2).

    Use blind rivet 6.4x14 (Klemmbereich 2.6 mm up to 6 mm, draw-off strength min. 15.5 kN) or blind rivet 6.4x17 (Klemmbereich 4.5 mm up to 7 mm, draw-off strength min. 15.5 kN).

15. Tack weld A-pillar outer section (1) with welder ( ) (area C2).

    When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Weld seams must  be tack welded at start, end and every approx. 4 cm.

16. Check weld seam gaps.

    Check all weld seam gaps before start of welding. The weld seam gap may not be greater than 1 mm, where required use a body weld.

17. Weld A-pillar outer section (1) with welder ( ) (area C2).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

18. Level welds on A-pillar outer section (1) and restore surface (area C2).
19. Remove shavings using wet/dry vacuum cleaner.