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

Model 222 

except code Z07 (B7 armoring on special protection version) 

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

1. Install A-pillar inner panel (3) and A-pillar reinforcement with portal bracket, fit and fix in place.

   Use spacers.

2. Drill Ø 6.7 mm rivet holes in A-pillar inner panel (3) (area A).
3. Remove portal bracket, A-pillar reinforcements and A-pillar inner panel (3).
4. Deburr rivet holes on A-pillar inner panel (3) and body on both sides.
5. Remove drilling chips.
6. Coat insides of riveted joints with zinc dust paint.

   Courtesy of MERCEDES-BENZ USA

7. 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

8. Install A-pillar inner panel (3) and fix in place.
9. Rivet A-pillar inner panel (3) with Ø 6.5x12.5 rivets (area B)
10. A-pillar inner panel (3) (areas C).
11. A-pillar inner panel (3) (areas D, E and F).
12. Grind inert gas weld down flat on A-pillar inner panel (3) (area D).
13. Clean weld joints no longer accessible after installing A-pillar reinforcement and coat with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (area D)

    Otherwise adhesion problems may occur

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14. Install duplicator (8), fit and fix in place.

    Center duplicator (8) above inert gas weld on A-pillar inner panel (3).

15. Drill Ø 6.7 mm rivet holes on duplicator (8) (areas D1).
16. Remove duplicator (8).
17. Deburr rivet holes on duplicator (8), A-pillar inner panel (3) and body on both sides.
18. Remove drilling chips.
19. Grind mating surface down to bare metal in cross-hatched area.
20. Remove grinding dust.
21. Apply 2-component adhesive in crosshatched area on A-pillar inner panel (3) and body.

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

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22. Install duplicator (8) and fix in place.
23. Rivet duplicator (8) and A-pillar inner panel (3) with Ø 6.5x12.5 rivets (areas D₂ ).

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24. Install A-pillar reinforcement (2) with portal bracket, fit and fix in place.

    Use spacers.

25. Drill Ø 6.7 mm rivet holes in A-pillar reinforcement (2) (areas G and H).
26. Remove A-pillar reinforcement (2) and portal bracket.
27. Deburr rivet holes on A-pillar inner panel (2) and body on both sides.

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

28. 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.

29. Apply sealant to foam parts in A-pillar reinforcement (2) in crosshatched areas (areas I).
30. Apply 2-component adhesive for reinforcements on structured foam parts in A-pillar reinforcement (2) (area J).

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

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31. Install A-pillar reinforcement (2), fit and fix in place.
32. Rivet A-pillar reinforcement (2) with Ø 6.5x12.5 rivets (area K)
33. A-pillar reinforcement (2) (areas M₁ ).

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

34. Rivet A-pillar reinforcement (2) with Ø 6.5x12.5 rivets (area L).
35. A-pillar reinforcement (2) (areas M₂ ).
36. A-pillar reinforcement (2) (areas N and O₁ ).

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

37. Grind inert gas weld on A-pillar reinforcement (2) down flat (area N).

    Grind down flat on contact surfaces on A-pillar paneling and beaded area only.

38. Clean welding areas which are no longer accessible after installing front upper longitudinal member and A-pillar paneling and coat with zinc dust paint.

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39. Install upper front longitudinal member (4), fit and fix in place.
40. Drill Ø 6.7 mm rivet holes in upper front longitudinal member (4) (areas Q1, Q₂ , Q5 and Q₆ ).

    Transfer position of present holes in body to new part (area Q1).

    Drill rivet holes from inside through present holes in body (areas Q₂ ).

41. Drill Ø 6.7 mm rivet holes in upper front longitudinal member (4) (areas Q₃ ).

    Only if a riveter for punching and flow form rivets is not used for installation.

    Drill rivet holes from rear through present holes in body.

42. Drill Ø 6.7 mm rivet holes in upper front longitudinal member (4) and countersink (area Q₁ ).

    Countersink rivet hole to create level surface.

    Otherwise the fender cannot be adjusted.

    Transfer position of present hole in body to new part.

43. Remove upper front longitudinal member (4).
44. Deburr drill holes on upper front longitudinal member (4) and body on both sides.
45. Remove drilling chips.
46. Coat insides of riveted joints with zinc dust paint (areas Q₆ ).
47. 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

48. Install upper front longitudinal member (4) and fix in place.
49. Rivet upper front longitudinal member (4) with Ø 6.5x14.5 rivets (areas R1).
50. Rivet front upper longitudinal member (4) with Ø 6.5x12.5 rivets (areas R2 and R₄ ).

    Flow form rivets with a clamping range of 3.35 mm to 4.1 "S2" can be used if a riveter for punching and flow form rivets is used for installation (area R4).

51. Rivet upper front longitudinal member (4) with Ø 6.4x14 countersunk head rivets (area R3).
52. Upper front longitudinal member (4) (areas R₅ ).
53. Rivet upper front longitudinal member (4) with Ø 6.5x14.5 rivets (area S₁ ).
54. Rivet upper front longitudinal member (4) with Ø 6.5x12.5 rivets (area S2).

    Flow form rivets with a clamping range of 3.35 mm to 4.1 "S2" can be used if a riveter for punching and flow form rivets is used for installation.

    Courtesy of MERCEDES-BENZ USA

55. Install strut (5), fit and fix in place.
56. Drill Ø 6.7 mm rivet holes in strut (5) (area T₁ ).

    Only if a riveter for punching and flow form rivets is not used for installation.

    Drill rivet holes from rear through present holes in body.

57. Drill Ø 6.7 mm rivet holes in strut (5) (areas T₂ ).
58. Remove strut (5).
59. Drill rivet holes in strut (5) and deburr on body on both sides.
60. Remove drilling chips.

    Courtesy of MERCEDES-BENZ USA

61. 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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62. Install strut (5) and fix in place.
63. Rivet strut (5) with Ø 6.5x14.5 strut (areas T₅ ).
64. Rivet strut (5) with Ø 6.5x12.5 strut (areas T₃ and T₄ ).

    Flow form rivets with a clamping range of 3.35 mm to 4.1 "S2" can be used, if a riveter for punching and flow form rivets is used for installation (area T4).

    Courtesy of MERCEDES-BENZ USA

65. Install A-pillar paneling (1) fit and fix in place.
66. Drill Ø 6.7 mm rivet holes on A-pillar paneling (1) (areas U1).
67. Drill Ø 6.7 mm rivet holes on A-pillar paneling (1) and countersink (area U₂ ).
68. Drill A-pillar paneling (1) with Ø 7 mm bit to depth equal to thickness of one sheet metal panel (area U₃ ).
69. Remove A-pillar paneling (1).
70. Deburr rivet holes on A-pillar inner panel (1) and body on both sides.
71. Remove drilling chips.
72. Coat insides of riveted joints with zinc dust paint.

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

73. Apply sealant to foam parts in crosshatched areas (areas V).
74. 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

75. Install A-pillar paneling (1), fit and fix in place.
76. Rivet A-pillar paneling (1) with Ø 6.4x12 rivets (areas W₁ ).
77. Rivet A-pillar paneling (1) with Ø 6.4x14 countersunk head rivets (areas W₂ ).
78. Rivet A-pillar paneling (1) with Ø 6, 5x14.5 rivets (areas W3).
79. A-pillar paneling (1) (areas X1).

    The resistance spot welds must be positioned at exactly the same position as the previous resistance spot welds, because these areas were glued previously (areas X₁ ).

    Otherwise the required minimum strength of the weld joint is not ensured.

80. A-pillar paneling (1) (area X₂ ).
81. A-pillar paneling (1) (areas Y).

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

82. Grind inert gas welds down flat (areas Y).
83. Solder surfaces on A-pillar paneling (1) with body solder and smooth (areas YV).
84. Remove solder residues and grinding dust.