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

Model 222 

except code Z07 (B7 armoring on special protection version) 

IMPORTANT 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 reinforcement (2) with portal bracket, fit and fix in place.

    IMPORTANT Use spacers.

  2. Drill Ø 6.7 mm rivet holes in A-pillar reinforcement (2) (area A).
  3. Remove A-pillar reinforcement (2) and portal bracket.
  4. Deburr rivet holes on outer A-pillar reinforcement (2) and body on both sides.
    G15400028Courtesy of MERCEDES-BENZ USA
  5. Apply 2-component adhesive to body in crosshatched areas.

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

    G15400029Courtesy of MERCEDES-BENZ USA
  6. Apply 2-component adhesive for reinforcements on structured foam parts in A-pillar reinforcement (2) (area N).

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

    A-pillar reinforcement (2) inner side 

    G15400030Courtesy of MERCEDES-BENZ USA
    G15400031Courtesy of MERCEDES-BENZ USA
  7. Install A-pillar reinforcement (2), fit and fix in place.
  8. Rivet A-pillar reinforcement (2) with Ø 6.5x12.5 rivets (area B).
  9. A-pillar reinforcement (2) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas C).
  10. A-pillar reinforcement (2) SHIELDED GAS SEAM WELD (areas D and E).

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

  11. Grind inert gas welds on A-pillar reinforcement (2) down flat (areas D and E).

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

  12. Clean weld joints which are no longer accessible after installing A-pillar reinforcement and front upper longitudinal member and coat with zinc dust paint.
    G15400009Courtesy of MERCEDES-BENZ USA
  13. Install upper front longitudinal member (4), fit and fix in place.
  14. Drill Ø 6.7 mm rivet holes on upper front longitudinal member (4) (areas Q1, Q2 , Q5 and Q6 ).

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

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

  15. 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.

    IMPORTANT Drill rivet holes from inside through present holes in body.

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

    NOTES Countersink rivet hole to create level surface.

    Otherwise the fender cannot be adjusted.

    IMPORTANT Transfer position of present hole in body to new part.

  17. Remove upper front longitudinal member (4).
  18. Deburr drill holes on upper front longitudinal member (4) and body on both sides.
  19. Remove drilling chips.
  20. Coat insides of riveted joints with zinc dust paint (areas Q6).
  21. Apply 2-component adhesive to body in crosshatched areas.

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

    G15300248Courtesy of MERCEDES-BENZ USA
    G15400011Courtesy of MERCEDES-BENZ USA
  22. Install upper front longitudinal member (4) and fix in place.
  23. Rivet upper front longitudinal member (4) with Ø 6.5x14.5 rivets (areas R1).
  24. Rivet front upper longitudinal member (4) with Ø 6.5x12.5 rivets (areas R2 and R4).

    IMPORTANT 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).

  25. Rivet upper front longitudinal member (4) with Ø 6.4x14 countersunk head rivets (area R3).
  26. Front upper longitudinal member (4) SHIELDED GAS SEAM WELD (areas R5 ).
  27. Rivet upper front longitudinal member (4) with Ø 6.5x14.5 rivets (area S1 ).
  28. Rivet upper front longitudinal member (4) with Ø 6.5x12.5 rivets (area S2).

    IMPORTANT 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.

    G15400012Courtesy of MERCEDES-BENZ USA
  29. Install strut (5), fit and fix in place.
  30. 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.

    IMPORTANT Drill rivet holes from rear through present holes in body.

  31. Drill Ø 6.7 mm rivet holes in strut (5) (areas T2 ).
  32. Remove strut (5).
  33. Drill rivet holes in strut (5) and deburr on body on both sides.
  34. Remove drilling chips.
    G15300251Courtesy of MERCEDES-BENZ USA
  35. Apply 2-component adhesive to body in crosshatched areas.

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

    G15300094Courtesy of MERCEDES-BENZ USA
  36. Install strut (5) and fix in place.
  37. Rivet strut (5) with Ø 6.5x14.5 strut (areas T5 ).
  38. Rivet strut (5) with Ø 6.5x12.5 strut (areas T3 and T4 ).

    IMPORTANT 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).

    G15300253Courtesy of MERCEDES-BENZ USA
  39. Install longitudinal member paneling (1), fit and fix in place.
  40. Drill Ø 6.7 mm rivet holes in longitudinal member paneling (1) (areas F).
  41. Drill Ø 6.7 mm rivet holes in longitudinal member paneling (1) (areas G).
  42. Remove longitudinal member paneling (1).
  43. Drill rivet holes in crossmember (1) and deburr on body on both sides.
  44. Remove drilling chips.
  45. Coat insides of riveted joints with zinc dust paint.
    G15400039Courtesy of MERCEDES-BENZ USA
  46. Apply 2-component adhesive to body cross-hatched inner C-pillar side wall.

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

    G15400040Courtesy of MERCEDES-BENZ USA
  47. Install longitudinal member paneling (1), fit and fix in place.
  48. Rivet longitudinal member paneling (1) with Ø 6.4x12 rivets (area H).
  49. Rivet longitudinal member paneling (1) with Ø 6.4x14 countersunk rivets (areas I).
  50. Rivet longitudinal member paneling (1) with Ø 6.5x14.5 rivets (areas J).
  51. Longitudinal member paneling (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area K).

    NOTES The resistance spot welds must be positioned at exactly the same position as the previous resistance spot welds, because these areas were glued at the factory (area K).

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

  52. Longitudinal member paneling (1) SHIELDED GAS SEAM WELD (areas L and M).

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

  53. Grind inert gas welds down flat (areas L and M).
  54. Solder surfaces on longitudinal member paneling (1) with body solder and smooth (areas L and M).
  55. Remove solder residues and grinding dust.
G15400041Courtesy of MERCEDES-BENZ USA
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