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

Model 205.3 

A-PILLAR INSTALLATION REPAIR MATERIALS (Model 205.3)

Number Designation Order number
BR00.45-Z-1056-07A TK-zinc dust paint A 000 986 28 00
BR00.45-Z-1090-01A 2K-component filler foam A 000 989 35 73_
BR00.45-Z-1127-02A Adhesive sealant Sikaflex-252, black, cartridge 310 ml Sika Deutschland GmbH www.sika-industry.de
BR00.45-Z-1162-02A Parts kit for 2-component adhesive for body A 012 989 17 71

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

The superordinate customer service document and the safety information in the customer service document must be observed.

G14186729Courtesy 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 rivet holes on A-pillar inner panel (7) with Ø 6.7 mm bit (areas A and B).

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

    Drill rivet hole through existing hole in A-pillar inner panel (7) (area 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.
  7. Apply 2-component adhesive in cross-hatched areas on body.

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

    G14186730Courtesy of MERCEDES-BENZ USA
    G14186731Courtesy of MERCEDES-BENZ USA
  8. Install A-pillar inner panel (7) and fix in place.
  9. Rivet A-pillar inner panel (7) with Ø 6.5x12.5 (areas C).
  10. A-pillar inner panel (7) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas D).
  11. 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.

  12. A-pillar inner panel (7) SHIELDED GAS SEAM WELD (areas G).
  13. Grind inert gas weld on A-pillar inner panel (7) down flat (area F).

    IMPORTANT Face-grind only on beaded areas and contact surfaces of A-pillar reinforcement (6).

  14. Clean weld joints that are no longer accessible after installation of upper front longitudinal member and A-pillar reinforcement (6) and coat with zinc dust paint.
    G14186732Courtesy of MERCEDES-BENZ USA
  15. Install A-pillar inner panel (6) with portal bracket, fit and fix in place.

    IMPORTANT Use spacers.

  16. Drill rivet holes on A-pillar reinforcement (6) with Ø 6.7 mm (areas H and J).
  17. Remove portal bracket and A-pillar reinforcement (6).
  18. Deburr rivet holes on A-pillar reinforcement (6) and body on both sides, if accessible.
  19. In the cross-hatched area, apply sealant to foam part on A-pillar reinforcement (6).
    G14186733Courtesy of MERCEDES-BENZ USA
  20. Apply 2-component adhesive in cross-hatched areas on body.

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

    G14186734Courtesy of MERCEDES-BENZ USA
    G14186735Courtesy of MERCEDES-BENZ USA
  21. Rivet A-pillar reinforcement (6) with Ø 6.5x12.5 rivet (area K).
  22. Rivet A-pillar reinforcement (6) with Ø 6.4x15.5 countersunk head rivet (areas L).
  23. A-pillar reinforcement (6) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas M).
  24. A-pillar reinforcement (6) SHIELDED GAS SEAM WELD (area O).

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

  25. A-pillar reinforcement (6) SHIELDED GAS SEAM WELD (area N).
  26. Face-grind inert gas weld (area O) and MIG solder seam (area N) on A-pillar reinforcement (6).

    IMPORTANT Face-grind only on beaded areas and contact surfaces of A-pillar paneling (5).

  27. Clean weld joints that are no longer accessible after installation of upper front longitudinal member and A-pillar paneling (5) and coat with zinc dust paint.
  28. A-pillar reinforcement (6) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area P).
    G14186736Courtesy of MERCEDES-BENZ USA
    G14186737Courtesy of MERCEDES-BENZ USA
  29. Drill out connecting flange (9) on old A-pillar reinforcement part with 0 7 mm bit.

    If connecting flange (9) is damaged:

    ↓

    Fabricate connecting flange (9).

  30. Install connecting flange (9), fit, and fix in place.
  31. Connecting flange (9) SHIELDED GAS PLUG WELD (area K4 ).
    G14186738Courtesy of MERCEDES-BENZ USA
  32. Install upper front longitudinal member (1), fit with welding device and fix in place.
  33. Install reinforcement (3), fit and fix in place.
  34. Drill rivet holes in upper front longitudinal member (1) and reinforcement (3) with Ø 6.7 mm bit (areas M, N1 , and O1 ).

    IMPORTANT Drill rivet holes from inside through present hole in body (area N1).

  35. Remove upper front longitudinal member (1), reinforcement (3) and welding device.
  36. Deburr rivet holes on upper front longitudinal member (1), reinforcement (3) and body on both sides.
  37. Remove drilling chips.
  38. Coat inside of riveted joint with zinc dust paint (areas O1 ).
    G14186739Courtesy of MERCEDES-BENZ USA
  39. Apply 2-component adhesive in cross-hatched areas on body.

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

    G14186740Courtesy of MERCEDES-BENZ USA
  40. Install upper front longitudinal member (1), fit with welding device and fix in place.
  41. Install reinforcement (3) and fix in place.
  42. Rivet upper front longitudinal member (1) and reinforcement (3) with Ø 6.5x12.5 rivet (areas P1 , and P2 ).
  43. Rivet upper front longitudinal member (1) and reinforcement (3) with Ø 6.5x14.5 rivet (areas P3 ).
  44. Upper front longitudinal member (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas Q).
    G14186741Courtesy of MERCEDES-BENZ USA
  45. Install strut (2) and bracket (4), fit and fix in place.
  46. Drill rivet holes on strut (2) and bracket (4) with Ø 6.7 mm (areas R and S).
  47. Remove strut (2) and bracket (4).
  48. Deburr rivet holes on strut (2), bracket (4) and body on both sides.
  49. Remove drilling chips.
  50. Coat insides of riveted joints with zinc dust paint.

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

    Otherwise adhesion problems can occur.

  51. Apply 2-component adhesive in cross-hatched areas on body.

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

    G14186742Courtesy of MERCEDES-BENZ USA
    G14186743Courtesy of MERCEDES-BENZ USA
  52. Install strut (2) and bracket (4) and fix in place.
  53. Rivet strut (2) with Ø 6.5x12.5 rivet (areas T).
  54. Rivet strut (2) and bracket (4) with Ø 6.4x12 (areas U).
  55. Install A-pillar paneling (5), fit and fix in place.
  56. Drill rivet holes on A-pillar paneling (5) with Ø 6.7 mm bit (areas V1 , V2 , and V3 ).
  57. Remove A-pillar paneling (5).
  58. Deburr rivet holes on A-pillar inner panel (5) and body on both sides.
  59. Remove drilling chips.
  60. Coat insides of riveted joints with zinc dust paint.

    NOTES Do not coat bonding surface with zinc dust paint (area V,). Otherwise adhesion problems can occur.

    G14186744Courtesy of MERCEDES-BENZ USA
  61. In the cross-hatched area, apply sealant to foam part (area W).
  62. Apply 2-component adhesive in cross-hatched areas on A-pillar reinforcement (6) (area Y).

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

    G14186745Courtesy of MERCEDES-BENZ USA
    G14186746Courtesy of MERCEDES-BENZ USA
  63. Install A-pillar paneling (5) and fix in place.
  64. Rivet A-pillar paneling (5) with Ø 6.4x12 rivet (areas W1 ).
  65. Rivet A-pillar paneling (5) with Ø 6.5x12.5 (areas W2 ).
  66. A-pillar paneling (5) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas X).
  67. A-pillar paneling (5) SHIELDED GAS SEAM WELD (areas Z).

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

  68. Sand inert gas welds down flat (areas Z).
  69. Solder surfaces on A-pillar paneling (5) with body solder and smooth (areas Z).

    IMPORTANT Alternatively to restorage of the surfaces with body solder, it is also possible to use a body basic spatula.

  70. Foam cavity (cross-hatched area) through openings (arrows) with 2-component foam.
    G14186747Courtesy of MERCEDES-BENZ USA
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