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Install A-Pillar Outer Section - Ar63.20-P-1102-03LW

Model 205.0/1/2 

Model 253 

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

G12824112Courtesy of MERCEDES-BENZ USA
  1. Install A-pillar inner panel (7) and A-pillar reinforcement with portal bracket, fit and fix in place.

    IMPORTANT Use spacers.

  2. Drill Ø 6.7 mm rivet holes in inner A-pillar (7) (areas A and B).

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

    Drill rivet holes through present holes in A-pillar inner panel (7) (areas B).

  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.
    G12824113Courtesy of MERCEDES-BENZ USA
  7. Install A-pillar inner panel (7) and fix in place.
  8. Rivet A-pillar inner panel (7) with Ø 6.5x12.5 rivet (areas C).
  9. A-pillar inner panel (7) IMPORTANT (areas D).
  10. A-pillar inner panel (7) SHIELDED GAS SEAM WELD (areas E and F).

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

  11. Grind inert gas weld on A-pillar inner panel (7) down flat (area E).

    IMPORTANT Grind down flat only in beaded areas and contact surfaces of A-pillar reinforcement.

  12. Clean welding areas which are no longer accessible after installing upper front longitudinal member and A-pillar reinforcement and coat with zinc dust paint.
  13. Install A-pillar reinforcement (6) with portal bracket, fit and fix in place.

    IMPORTANT Use spacers.

  14. Drill Ø 6.7 mm rivet holes in A-pillar reinforcement (6) (areas G and H).

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

  15. Remove A-pillar reinforcement (6) and portal bracket.
  16. Deburr rivet holes on A-pillar inner panel (6) and body on both sides.
    G12824114Courtesy of MERCEDES-BENZ USA
  17. Apply sealant to foam parts on A-pillar reinforcement (6) in crosshatched areas.
    G12824115Courtesy of MERCEDES-BENZ USA
  18. Apply 2-component adhesive to body in crosshatched areas.

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

    G12824116Courtesy of MERCEDES-BENZ USA
    G12824117Courtesy of MERCEDES-BENZ USA
  19. Install A-pillar reinforcement (6) and fix in place.
  20. Rivet A-pillar reinforcement (6) with Ø 6.5x12.5 rivets (areas I1 and I2 ).
  21. A-pillar reinforcement (6) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas J).
  22. A-pillar reinforcement (6) SHIELDED GAS SEAM WELD (areas K and L).

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

  23. Grind inert gas welds down flat on A-pillar reinforcement (6) (areas K and L).

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

  24. Clean welding areas which are no longer accessible after installing upper front longitudinal member and A-pillar paneling and coat with zinc dust paint.
    G12824118Courtesy of MERCEDES-BENZ USA
  25. Install upper front longitudinal member (1) fit with welding device and fix in place.
  26. Install reinforcement (3), fit and fix in place.
  27. Drill Ø 6.7 mm rivet holes in upper front longitudinal member (1) and reinforcement (3) (areas M, N and O).

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

  28. Remove upper front longitudinal member (1), reinforcement (3) and welding device.
  29. Deburr drill holes on upper front longitudinal member (1), reinforcement (3) and body on both sides.
  30. Remove drilling chips.
  31. Coat inside of riveted joint with zinc dust paint (areas O).
    G12823981Courtesy of MERCEDES-BENZ USA
  32. Apply 2-component adhesive to body in crosshatched areas.

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

    G12824120Courtesy of MERCEDES-BENZ USA
  33. Install upper front longitudinal member (1) with welding device and fix in place.
  34. Install reinforcement (3) and fix in place.
  35. Rivet upper front longitudinal member (1) and reinforcement (3) with Ø 6.5x12.5 rivets (areas P1 and P2 ).
  36. Rivet upper front longitudinal member (1) and reinforcement (3) with Ø 6.5x14.5 rivets (areas P3 ).
  37. Upper front longitudinal member (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas Q).
    G12824121Courtesy of MERCEDES-BENZ USA
  38. Install strut (2) and bracket (4), fit and fix in place.
  39. Drill Ø 6.7 mm rivet holes in strut (2) and bracket (4) (areas R and S).
  40. Remove strut (2) and bracket (4).
  41. Deburr rivet holes on strut (2), bracket (4) and body on both sides.
  42. Remove drilling chips.
  43. Coat insides of riveted joints with zinc dust paint.

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

    Otherwise adhesion problems may occur.

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

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

    G12823986Courtesy of MERCEDES-BENZ USA
    G12824123Courtesy of MERCEDES-BENZ USA
  45. Install strut (2) and bracket (4) and fix in place.
  46. Rivet strut (2) with Ø 6, 5x12.5 rivets (areas T).
  47. Rivet strut (2) and bracket (4) with Ø 6.4x12 rivets (areas U).
  48. Install A-pillar paneling (5), fit and fix in place.
  49. Drill Ø 6.7 mm rivet holes on A-pillar paneling (5) ((areas V1 and V2 ).
  50. Remove A-pillar paneling (5).
  51. Deburr rivet holes on A-pillar inner panel (5) and body on both sides.
  52. Remove drilling chips.
  53. Coat insides of riveted joints with zinc dust paint.

    NOTES Do not apply zinc dust paint to bonding surfaces (areas V2).

    Otherwise adhesion problems may occur.

    G12824124Courtesy of MERCEDES-BENZ USA
  54. Model 205.0/1/2

    Apply 2-component adhesive to body in crosshatched areas.

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

    G12824125Courtesy of MERCEDES-BENZ USA
  55. Install A-pillar paneling (5) and fix in place.
  56. Rivet A-pillar paneling (5) with Ø 6.4x12 rivets (areas W1 ).
  57. Rivet A-pillar paneling (5) with Ø 6.5x12 5 rivets (areas W2 ).
  58. Rivet A-pillar paneling (5) with Ø 6.5x12 5 rivet (area W3 ).
  59. A-pillar paneling (5) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area X).
  60. A-pillar paneling (5) SHIELDED GAS SEAM WELD (areas Y).

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

  61. Grind inert gas welds down flat (areas Y).
  62. Solder surfaces on A-pillar paneling (5) with body solder and smooth (areas YV).
  63. Remove solder residues and grinding dust.
G12824126Courtesy of MERCEDES-BENZ USA
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