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

Model 205.4 

The following operation steps 1 to 63 are shown on the left side of the vehicle and must be performed in the same way on the right side of the vehicle in the event of damage.

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

   Use spacers.

2. Drill rivet holes on A-pillar inner panel (7) with Ø 6.7 mm bit (areas A).
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 to crosshatched area of body.

   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 (7) and fix in place.
9. Rivet A-pillar inner panel (7) with Ø 6.5x12.5 rivet (area B₁ ).

   Clamping range 4.6 mm

10. Rivet A-pillar inner panel (7) with Ø 6.5x14.5 rivet (area B₂ ).

    Clamping range 7.0 mm

11. Rivet A-pillar inner panel (7) with Ø 6.5x14.5 rivet (area B₃ ).

    Clamping range 6.3 mm

12. Rivet A-pillar inner panel (7) with Ø 6.4 M6 rivet (area B₄ ).
13. A-pillar inner panel (7) (areas C).
14. A-pillar inner panel (7) (areas D₁ and D₂ ).

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

    Clamping range 5.2 mm

15. Grind insert gas weld down flat on A-pillar inner panel (7) (area D₁ ).
16. 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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17. Install duplicator (11), fit and fix in place.

    Center duplicator (11) above inert gas weld on A-pillar inner panel (7).

18. Mark position of rivet holes on duplicator (11).

    Dimensions:

    f₁ =10 mm

    f₂ = 40 mm

    f₃ =15 mm

    f₄ =13 mm

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19. Drill rivet holes on duplicator (11) with Ø 6.7 mm bit (areas E).
20. Remove duplicator (11).
21. Deburr rivet holes on duplicator (11) and A-pillar inner panel (7) on both sides.
22. Remove drilling chips.
23. Grind mating surfaces on A-pillar inner panel (7) down to bare metal on crosshatched areas.
24. Remove grinding dust.
25. Apply 2-component adhesive to crosshatched area of body.

    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

26. Install duplicator (11) and fix in place.

    Clamping range 3.5 mm

27. Rivet duplicator (11) with Ø 6.5x12.5 rivet (areas G).
28. Install mounting console (9) and roof frame with portal bracket, fit and fix in place.
29. Mounting console (9) (area H).
30. Remove roof frame.

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    Courtesy of MERCEDES-BENZ USA

31. Install A-pillar inner panel (6) with portal bracket, fit and fix in place.

    Use spacers.

32. Drill rivet holes on A-pillar reinforcement (6) with Ø 6.7 mm bit (areas I₁ and I₂ ).

    Drill rivet hole from inside through present holes in body (area I2).

33. Remove portal bracket and A-pillar reinforcement (6).
34. Deburr rivet holes on A-pillar inner panel (6) and body on both sides.
35. Apply sealant to foam part on A-pillar reinforcement (6) in crosshatched area.

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36. 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

37. Install A-pillar reinforcement (6) and fix in place.
38. Rivet A-pillar reinforcement (6) with Ø 6.5x14.5 rivet (area J).

    Clamping range 5.8 mm

39. A-pillar reinforcement (6) (area K).

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40. Rivet A-pillar reinforcement (6) with Ø 6, 4x17 countersunk-head rivet (area L).

    Clamping range 5.0 mm

41. A-pillar reinforcement (6) (areas M).
42. A-pillar reinforcement (6) (areas N₁ and N₂ ).

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

43. Grind inert gas welds on A-pillar reinforcement (6) down flat (areas N₁ ).
44. 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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45. Install mounting rail (10), fit and fix in place.
46. Drill rivet holes on mounting rail (10) with Ø 6.7 mm bit (area O).
47. Remove mounting rail (10).
48. Deburr rivet holes on mounting rail (10) and A-pillar reinforcement (6) on both sides.
49. Remove drilling chips.

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50. Install mounting rail (10), fit and fix in place.
51. Rivet mounting rail (10) with Ø 6.5x12.5 rivet (area P).

    Clamping range 3.8 mm.

52. Mounting rail (10) (area Q₄ ).

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

53. Solder surface on mounting rail (10) with body solder and smooth (area Q₄ ).

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

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54. Install A-pillar paneling (5), fit and fix in place.
55. Drill rivet holes on A-pillar paneling (5) with Ø 6.7 mm bit (areas V).
56. Remove A-pillar paneling (5).
57. Deburr rivet holes on A-pillar inner panel (5) and body on both sides.
58. Remove drilling chips.
59. Coat insides of riveted joints with zinc dust paint.
60. Apply sealant to foam part in crosshatched area.

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

61. Install A-pillar paneling (5) and fix in place.
62. Rivet A-pillar paneling (5) with Ø 6.5x12.5 rivet (areas X₁ and X₂ ).

    Clamping range from 4.0 mm to 4.2 mm

63. A-pillar paneling (5) (areas W).

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64. Install roof frame (8) with portal bracket, fit and fix in place.
65. Roof frame (8) (areas Y).
66. Roof frame (8) (area Z₁ and Z₂ ).

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

67. Grind inert gas weld down flat on roof frame (8) (areas Z₁ ).
68. Remove portal bracket.