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

Model 205.0/1/2 

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.

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

   Use spacers.

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

   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.

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7. Install A-pillar inner panel (7) and fix in place.
8. Rivet A-pillar inner panel (7) with Ø 6.5x12.5 rivets (areas C).
9. A-pillar inner panel (7) (areas D).
10. A-pillar inner panel (7) (areas E, F and G).

    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 F).

    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.

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13. Install A-pillar reinforcement (6) with portal bracket, fit and fix in place.

    Hi Use spacers.

14. Drill Ø 6.7 mm rivet holes in A-pillar reinforcement (6) (areas H₁ and H₂ ).

    Drill rivet holes from inside through present hole in body (area H2).

15. Remove A-pillar reinforcement (6) and portal bracket.
16. Deburr rivet holes on A-pillar inner panel (6) and body on both sides.

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17. Apply sealant to foam parts on A-pillar reinforcement (6) in crosshatched areas.

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

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

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    Courtesy 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 (area I₂ ).
21. A-pillar reinforcement (6) (area J₂ ).

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22. Rivet A-pillar reinforcement (6) with 0 6, 5x12.5 rivet (area I1).
23. A-pillar reinforcement (6) (areas J1).
24. A-pillar reinforcement (6) (areas K₁ , K₂ and K₃ ).

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

25. Grind inert gas welds down flat on A-pillar reinforcement (6) K₁ and K₂ ).

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

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

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27. Drill out connecting flange (9) on old A-pillar reinforcement section with Ø 7 mm bit.

    If connecting flange (9) is damaged

    ↓

    Fabricate connecting flange (9).

28. Install connecting flange (9), fit and fix in place.
29. Connecting flange (9) (area K₄ ).

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30. Install connecting panel (8), fit and fix in place.

    Center connecting panel (8) above inert gas weld on A-pillar reinforcement.

31. Drill Ø 6.7 mm rivet holes in connecting panel (8) through present holes (area L₁ ).

    When drilling, ensure that the bit does not reach too far into the A-pillar reinforcement.

    Otherwise the water drain hose in the A-pillar reinforcement can be damaged.

32. Remove connecting panel (8).
33. Drill rivet holes on connecting panel (8) and body on both sides.
34. Apply 2-component adhesive to body cross-hatched inner C-pillar side wall.

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

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35. Install connecting panel (8) and fix in place.
36. Rivet connecting panel (8) with Ø 6.5x12.5 rivets (area L₂ ).

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37. Install upper front longitudinal member (1), fit with welding device and fix in place.
38. Install reinforcement (3), fit and fix in place.
39. Drill Ø 6.7 mm rivet holes in upper front longitudinal member (1) and reinforcement (3) (areas M, N and O).

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

40. Remove upper front longitudinal member (1), reinforcement (3) and welding device.
41. Deburr drill holes on upper front longitudinal member (1), reinforcement (3) and body on both sides.
42. Remove drilling chips.
43. Coat inside of riveted joint with zinc dust paint (areas O).

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

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

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45. Install upper front longitudinal member (1) with welding device and fix in place.
46. Install reinforcement (3) and fix in place.
47. Rivet upper front longitudinal member (1) and reinforcement (3) with Ø 6.5x12.5 rivets (areas P₁ and P₂ ).
48. Rivet upper front longitudinal member (1) and reinforcement (3) with Ø 6.5x14.5 rivets (areas P₃ ).
49. Upper front longitudinal member (1) (areas Q).

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50. Install strut (2) and bracket (4), fit and fix in place.
51. Drill Ø 6.7 mm rivet holes in strut (2) and bracket (4) (areas R and S).
52. Remove strut (2) and bracket (4).
53. Deburr rivet holes on strut (2), bracket (4) and body on both sides.
54. Remove drilling chips.
55. Coat insides of riveted joints with zinc dust paint.

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

    Otherwise adhesion problems may occur.

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

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

    Courtesy of MERCEDES-BENZ USA

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57. Install strut (2) and bracket (4) and fix in place.
58. Rivet strut (2) with Ø 6, 5x12.5 rivets (areas T).
59. Rivet strut (2) and bracket (4) with Ø 6.4x12 rivets (areas U).
60. Install A-pillar paneling (5), fit and fix in place.
61. Drill Ø 6.7 mm rivet holes on A-pillar paneling (5) (areas V₁ , V₂ and V₃ ).
62. Remove A-pillar paneling (5).
63. Deburr rivet holes on A-pillar inner panel (5) and body on both sides.
64. Remove drilling chips.
65. Coat insides of riveted joints with zinc dust paint.

    Do not apply zinc dust paint to bonding surfaces (areas V₂ ). Otherwise adhesion problems may occur.

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66. Apply sealant to foam part in crosshatched area (area J₃ ).
67. Apply 2-component adhesive to body in crosshatched areas J₄ ).

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

    Courtesy of MERCEDES-BENZ USA

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68. Install A-pillar paneling (5) and fix in place.
69. Rivet A-pillar paneling (5) with Ø 6.4x12 rivets (areas W₁ ).
70. Rivet A-pillar paneling (5) with Ø 6.5x12 5 rivets (areas W₂ ).
71. Rivet A-pillar paneling (5) with Ø 6.5x12 5 rivets (area W₃ ).
72. A-pillar paneling (5) (areas X).
73. A-pillar paneling (5) (areas Y).

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

74. Grind inert gas welds down flat (areas Y).
75. Solder surfaces on A-pillar paneling (5) with body solder and smooth (areas Y).
76. Remove solder residues and grinding dust.