Completely Install A And B-Pillar With Longitudinal Member - Ar63.20-P-1120-03LF

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.

When using Celette straightening system, also use anchoring set 9212.013.

Install adjustable fastening brackets with following dimensions:

• front: x = 45 mm, y = 44 mm, z = 77 mm (on upper alignment hole), z = 62 mm (on lower alignment hole)
• rear: x = 100 mm, y = 44 mm, z = 77 mm (on upper alignment hole), z = 62 mm (on lower alignment hole)

1. Install A and B-pillar reinforcement (2), A-pillar inner panel (3.1), roof frame inner panel and B-pillar inner panel (3.3) with portal bracket, fit and fix in place.

   Use spacers.

2. Drill Ø 6.7 mm rivet holes in B-pillar inner panel (3.3).

   Shown on model 222.0 

   Courtesy of MERCEDES-BENZ USA

   Courtesy of MERCEDES-BENZ USA

   Shown on model 222.0 

3. Drill Ø 6.7 mm rivet holes in A and B-pillar reinforcement (2), A-pillar inner panel (3.1) and roof frame inner panel (3.2) (areas A₁ ).
4. Model 222.0/1

   except code Z07 (B7 armoring on special protection version)

   Drill Ø 6.7 mm rivet holes in A and B-pillar reinforcement (2) (area A₂ ).

5. Model 222.9

   except code Z07 (B7 armoring on special protection version)

   Prepare bonding surfaces (area A2).

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

   Connection is bonded.

6. Remove portal bracket, A and B-pillar reinforcement (2), A-pillar inner panel (3.1) and roof frame inner panel (3.2) and B-pillar inner panel (3.3).
7. Deburr rivet holes on A and B-pillar reinforcement (2), A-pillar inner panel (3.1) and roof frame inner panel (3.2) and B-pillar inner panel (3.3) and on body on both sides.
8. Cut out structural foam part in area of rivet holes until rivets can be inserted without problems (area A₂ ).
9. Remove drilling chips.
10. Coat insides of riveted joints on B-pillar inner panel (3.3) with zinc dust paint.

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

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

    Apply 2-component adhesive at bottom (area B).

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

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

12. Install A and B-pillar reinforcement (2), A-pillar inner panel (3.1), roof frame inner panel and B-pillar inner panel (3.3) with portal bracket and fit.

    Use spacers.

13. Fix A-pillar inner panel (3.1), roof frame inner panel and B-pillar inner panel (3.3) in place.
14. Remove portal bracket and A and B-pillar reinforcement (2).

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

15. Rivet B-pillar inner panel (3.3.) and A-pillar inner panel (3.1) with Ø 6.5x12.5 rivets (area C₁ ).
16. A-pillar inner panel (3.1) (areas C₂ ).

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

17. Rivet roof frame inner panel (3.2) from top with Ø 6.5x12.5 rivets (area D₂ ).

    Flow form rivets up to a clamping range "S1" of 3.5 can also be used, if riveter for punching and flow form rivets is used for installation.

18. B-pillar inner panel (3.3) and roof frame inner panel (3.2) (areas D₁ ).

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

19. Clean contact surfaces of foam parts on A and B-pillar reinforcement (2), apply sealant to A and B-pillar reinforcement (2) and insert foam parts (areas E).
20. Apply sealant to foam parts (areas E).
21. Clean contact surfaces on structural foam parts (8 and 10) on A and B-pillar reinforcement (2), apply 2-component adhesive for reinforcements to A and B-pillar reinforcements (2) and insert structural foam parts (8 and 10).

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

22. Apply 2-component adhesive for reinforcements to structural foam parts (8, 10 and 11).

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

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

23. Sand bonding surface on structured foam part with fine-grit sand paper and apply 2-component adhesive for reinforcement of structured foam part (area F1).

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

24. Apply 2-component adhesive to body in crosshatched areas (areas F₂ ).

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

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

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

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

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

26. Install A and B-pillar reinforcement (2) with portal bracket, fit and fix in place.
27. Rivet A and B-pillar reinforcement (2) with Ø 6.5X 12.5 rivets (area G₁ ).
28. A and B-pillar reinforcement (2) (areas G₂ ).
29. A and B-pillar reinforcement (2) (area G₃ ).

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

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

30. A and B-pillar reinforcement (2) (areas H₁ ).
31. A and B-pillar reinforcement (2) (area H₂ )

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

32. Model 222.0/1

    except code Z07 (B7 armoring on special protection version) Rivet A and B-pillar reinforcement (2) with Ø 6.4X 14 rivets (area I₁ ).

33. A and B-pillar reinforcement (2) (areas I₂ ).

    Shown on model 222.0 

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

34. A and B-pillar reinforcement (2) (area K).

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

35. Rivet A and B-pillar reinforcement (2) with Ø 6.5X 12.5 rivets (area L₁ ).
36. A and B-pillar reinforcement (2) (areas L2).
37. Remove portal bracket.
38. Clean weld joints which are no longer accessible after installing A-pillar reinforcement and front upper longitudinal member and coat with zinc dust paint.

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

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 inside through present holes in body.

42. Drill Ø 6.7 mm rivet holes in upper front longitudinal member (4) (area Q4).

    Countersink rivet hole to create level surface when riveting.

    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. Observe manufacturer's specifications for drying and processing time of adhesive.

    Shown on model 222.0 

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

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 upper front longitudinal member (4) with Ø 6.5x12.5 rivets (areas R₂ and R₄ ).
51. Rivet upper front longitudinal member (4) with Ø 6.4x14 countersunk head rivet (area R3).
52. Upper front longitudinal member (4) (areas R₅ ).

    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).

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.

    Shown on model 222.0 

    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) (area T2).
58. Remove strut (5).
59. Drill rivet holes in strut (5) and deburr on body on both sides.
60. Remove drilling chips.

    Shown on model 222.0 

    Courtesy of MERCEDES-BENZ USA

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

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

    Shown on model 222.0 

    Courtesy of MERCEDES-BENZ USA

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

    Shown on model 222.0 

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

65. Install A and B-pillar paneling (1.1), roof frame paneling (1.2) and side longitudinal member paneling (1.3) with portal bracket, fit and fix in place.
66. Drill Ø 6.7 mm rivet holes on A and B-pillar paneling (1.1) and side longitudinal member paneling (1.3) (areas U1).
67. Model 222.0/1

    except code Z07 (B7 armoring on special protection version)

    Drill Ø 6.7 mm rivet holes on A and B-pillar paneling (1.1) and side longitudinal member paneling (1.3) (areas U4).

68. Drill Ø 6.7 mm rivet holes on A and B-pillar paneling (1.1) and countersink (area U₂ ).
69. Drill A and B-pillar paneling (1.1) with 0.7 mm bit to depth equal to thickness of one sheet metal panel (area U₃ ).
70. Remove portal bracket, A and B-pillar paneling (1.1), roof frame paneling (1.2) and side longitudinal member paneling (1.3).
71. Deburr rivet holes on A and B-pillar paneling (1.1) and side longitudinal member paneling (1.3) and body on both sides.
72. Remove drilling chips.
73. Coat insides of riveted joints with zinc dust paint.

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

74. Model 222.9

    except code Z07 (B7 armoring on special protection version)

    Drill Ø 6.7 mm rivet holes on A and B-pillar paneling (1.1) and side longitudinal member paneling (1.3) (areas U₅ )

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

75. Install rubber window spacers from glazing repair kit as spacers on outer rear wheel well at uniform intervals (area M₃ ).
76. Apply sealant to outer rear wheel well (area M3).
77. Clean contact surfaces of foam parts on A and B-pillar reinforcement (2), apply sealant to A and B-pillar reinforcement (2) and insert foam parts (areas M1).
78. Apply sealant to foam parts (areas M₁ ).
79. Clean contact surfaces on structural foam parts (6, 7 and 9) on A and B-pillar reinforcement (2), apply 2-component adhesive for reinforcements to A and B-pillar reinforcements (2) and insert structural foam parts (6, 7 and 9).

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

80. Apply 2-component adhesive for reinforcements to structural foam parts (6, 7 and 9).

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

81. Apply 2-component adhesive to body in crosshatched areas (areas M₂ ).

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

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

82. Install A and B-pillar paneling (1.1), roof frame paneling (1.2) and side longitudinal member paneling (1.3) with portal bracket, fit and fix in place.
83. Rivet A and B-pillar paneling (1.1) and side longitudinal member paneling (1.3) with Ø 6.4X12 rivets (areas W,).
84. Model 222.0/1

    except code Z07 (B7 armoring on special protection version)

    Rivet A and B-pillar paneling (1.1) and side longitudinal member paneling (1.3) with Ø 6.4X12 rivets (areas W5).

85. Rivet A and B-pillar paneling (1.1) with Ø 6.4x14 countersunk rivets (areas W2).
86. Rivet A and B-pillar paneling (1.1) with Ø 6.5X14.5 rivets (areas W₃ ).
87. A and B-pillar paneling (1.1) (area W₄ ).

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

88. Model 222.9

    except code Z07 (B7 armoring on special protection version)

    Rivet A and B-pillar paneling (1.1) and side longitudinal member paneling (1.3) with Ø 6.4X12 rivets (areas W6).

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

89. A and B-pillar paneling (1.1) and roof frame paneling (1.2) (area V₁ ).

    Courtesy of MERCEDES-BENZ USA

    Shown on model 222.0 

90. A and B-pillar paneling (1.1), roof frame paneling (1.2) and side longitudinal member paneling (1.3) (areas V₂ ).
91. A and B-pillar paneling (1.1), roof frame paneling (1.2) and side longitudinal member paneling (1.3) (areas X₁ ).

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

92. Grind inert gas welds down flat (areas X1).
93. Solder surfaces on A and B-pillar paneling (1.1), roof frame paneling (1.2) and side longitudinal member paneling (1.3) with body solder and smooth (areas X₁₎ )
94. Remove solder residues and grinding dust.

    Shown on model 222.0 

    Courtesy of MERCEDES-BENZ USA

95. Model 222.9

    except code Z07 (B7 armoring on special protection version) A and B-pillar paneling (1.1), roof frame paneling (1.2) and side longitudinal member paneling (1.3) (areas X3).

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

96. Model 222.9

    except code Z07 (B7 armoring on special protection version) Grind inert gas welds down flat (areas X3).

97. Model 222.9

    except code Z07 (B7 armoring on special protection version) Solder surfaces on A and B-pillar paneling (1.1), roof frame paneling (1.2) and side longitudinal member paneling (1.3) with body solder and smooth (areas X3))

98. Model 222.9

    except code Z07 (B7 armoring on special protection version) Remove solder residues and grinding dust.

    Shown on model 222.9 

Courtesy of MERCEDES-BENZ USA