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

Model 205.3 

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 reinforcement (6) with portal bracket, fit and fix in place.

   Use spacers.

2. Drill rivet holes with A-pillar reinforcement (6) with Ø 6.7 mm bit (area A).

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

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

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

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6. 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.

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7. Install A-pillar reinforcement (6) and fix in place.
8. Rivet A-pillar reinforcement (6) with Ø 6.5x12.5 rivets (area I).
9. A-pillar reinforcement (6) (areas J).
10. A-pillar reinforcement (6) (areas K and L).

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

11. Grind inert gas welds down flat on A-pillar reinforcement (6) (areas K and L).

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

12. 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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13. Install upper front longitudinal member (1), fit with welding device and fix in place.
14. Install reinforcement (3), fit and fix in place.
15. Drill rivet holes on upper front longitudinal member (1) and reinforcement with (3) with Ø 6.7 mm bit (areas M, N and O).

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

16. Remove upper front longitudinal member (1), reinforcement (3) and welding device.
17. Deburr rivet holes on upper front longitudinal member (1), reinforcement (3) and body on both sides.
18. Remove drilling chips.
19. Coat inside of riveted joint with zinc dust paint (areas O).

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20. 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.

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21. Install upper front longitudinal member (1) with welding device and fix in place.
22. Install reinforcement (3) and fix in place.
23. Rivet upper front longitudinal member (1) and reinforcement (3) with Ø 6.5x12.5 rivets (areas P₁ and P₂ ).
24. Rivet upper front longitudinal member (1) and reinforcement (3) with Ø 6.5x14.5 rivets (areas P₃ ).
25. Upper front longitudinal member (1) (areas Q).

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26. Install strut (2) and bracket (4), fit and fix in place.
27. Drill rivet holes with strut (2) and bracket (4) with Ø 6.7 mm bit (areas R and S).
28. Remove strut (2) and bracket (4).
29. Deburr rivet holes on strut (2), bracket (4) and body on both sides.
30. Remove drilling chips.
31. 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.

32. 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.

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33. Install strut (2) and bracket (4) and fix in place.
34. Rivet strut (2) with Ø 6.5x12.5 rivets (areas T).
35. Rivet strut (2) and bracket (4) with Ø 6.4x12 rivets (areas U).
36. Install A-pillar paneling (5), fit and fix in place.
37. Drill rivet holes with A-pillar paneling (5) with Ø 6.7 mm bit (areas V₁ and V₂ ).
38. Remove A-pillar paneling (5).
39. Deburr rivet holes on A-pillar inner panel (5) and body on both sides.
40. Remove drilling chips.
41. Coat insides of riveted joints with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (area V₂ ).

    Otherwise adhesion problems may occur.

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42. 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.

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43. Install A-pillar paneling (5) and fix in place.
44. Rivet A-pillar paneling (5) with Ø 6.4x12 rivets (areas W₁ ).
45. Rivet A-pillar paneling (5) with Ø 6.5x12.5 rivets (areas W₂ ).
46. A-pillar paneling (5) (area X).
47. A-pillar paneling (5) (areas Y).

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

48. Grind inert gas welds down flat (areas Y).
49. Solder surfaces on A-pillar paneling (5) with body solder and smooth (areas Y).

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

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