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Home >> Mercedes Benz >> 2021 >> E53 AMG 2D Convertible >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Collision - Side Wall (238 Chassis) >> Side Wall Body Repair >> Install And Weld In Complete A-Pillar - Ar63.20-P-1100-10LWA

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

DANGER The high voltage used for electric welding presents a lethal hazard. Risk of explosion  from welding in areas close to highly inflammable materials. Risk of injury  from weld splatter and UV-light when welding. Risk of poisoning  from inhaling welding gases Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system. AS00.00-Z-0007-01A
WARNING Risk of injury  . Skin or eye injuries may result when handling hot or glowing objects. Wear protective gloves, protective clothing and safety glasses, if necessary. AS00.00-Z-0002-01A
CAUTION Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.		 AS00.00-Z-0017-01A
Notice General information on body repair   AH60.00-P-0001-01KOA
Notice Information on preventing damage to electronic components due to electrostatic discharge   AH54.00-P-0001-01A
Notice Measures for preventing damage to components when performing electric welding and soldering work   AH60.00-P-0001-02A
Notice Pretreatment of bonding surfaces   AH60.00-P-0008-01SX
  General information on riveting   AH60.00-P-0003-01N
  General information on repair of vehicles with ultra-strength steels.   AH60.00-P-0024-01N
  Notes on acoustic foam and structural foam in the vehicle   AH60.00-P-0039-01LWO

Model 238.4 

Fig 1: Side Portal Frame (210 589 17 23 00)
G13669255Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20
BR00.45-Z-1012-13A Blind rivet Y2 6.5 x 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) A 004 990 16 97
BR00.45-Z-1016-13A Blind rivet Y3 6.5 x 14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) A 004 990 17 97
BR00.45-Z-1032-13A Blind rivet Y4 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN) A 003 990 81 97
BR00.45-Z-1035-13A Blind rivet Y1 6.4 x 12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) A 000 991 76 32
BR00.45-Z-1043-13A Countersunk-head blind rivet Z1 6.4 x 14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) A 000 991 82 32
BR00.45-Z-1044-13A Countersunk-head blind rivet Z2 6.4 x 15.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) A 000 991 83 32
BR00.45-Z-1056-07A 1K-zinc dust paint A 000 986 28 00
BR00.45-Z-1162-02A Parts kit for 2-component adhesive for body A 012 989 17 71

IMPORTANT The next steps are shown on the left side of the vehicle. This must be similarly performed for damage to the right side of the vehicle.

IMPORTANT Use following repair materials:

G15466691Courtesy of MERCEDES-BENZ USA
  1. Install, fit and fix in place A-pillar inner panel (5) and A-pillar outer panel with installed A-pillar reinforcement using SPECIAL TOOL side portal frame and portal straightener.

    IMPORTANT Use spacers.

  2. Fix in place A-pillar inner panel (5).
  3. Remove portal straightener and A-pillar outer panel with installed A-pillar reinforcement.
  4. Drill rivet holes in A-pillar inner panel (5) with Ø 6.7 mm bit (area A1 , A2 , A3 and A4 ).

    IMPORTANT Drill rivet hole through existing hole in body (area A2 ).

    IMPORTANT Drill rivet holes through existing holes in new part (areas A3 ).

    IMPORTANT Drill rivet holes through existing holes in new part and in mounting support (9) (areas A4 ).

  5. Remove A-pillar inner panel (5).
  6. Deburr rivet holes on A-pillar inner panel (5) and body on both sides.
  7. Remove chips from drilling.
  8. Coat insides of riveted joints with zinc dust paint.
  9. Apply 2-component adhesive to body in cross-hatched area.

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

    G15466692Courtesy of MERCEDES-BENZ USA
    G15466693Courtesy of MERCEDES-BENZ USA
  10. Install A-pillar inner panel (5) and fix in place.
  11. Rivet A-pillar inner panel (5) with Ø 6.5x14.5 rivets (area B1 ).

    IMPORTANT Clamping range is 4.50 mm.

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

    IMPORTANT Clamping range is 5.20 mm.

  13. Rivet A-pillar inner panel (5) with rivets Ø 6.4 M6 (area B3 ).

    IMPORTANT Clamping range is 6.25 to6.95 mm.

  14. Rivet A-pillar inner panel (5) with Ø 6.5x12.5 rivets (area B4 ).

    IMPORTANT Clamping range is 3.75 mm.

  15. Rivet A-pillar inner panel (5) with Ø 6.5x12.5 rivets (area B5 ).

    IMPORTANT Clamping range is 3 mm.

  16. A-pillar inner panel (5) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area C).
  17. A-pillar inner panel (5) SHIELDED GAS SEAM WELD (areas D1 and D2 ).

    IMPORTANT Perform inert gas welding at intervals and allow welding area to cool down in between. Heat distortion can thus be reduced.

  18. Surface-grind inert gas weld on A-pillar inner panel (5) (areas D1 and D2 ).

    IMPORTANT Only surface-grind contact surfaces of duplicator (area D2 ).

  19. Clean weld joints that can no longer be accessed after installation of A-pillar outer panel with installed A-pillar reinforcement and coat with zinc dust paint.
    G15466694Courtesy of MERCEDES-BENZ USA
  20. Install, fit and fix in place duplicator (10).

    IMPORTANT Align duplicator (10) in center over inert gas weld on A-pillar inner panel (5).

  21. Mark positions for rivet holes on duplicator halves (10).

    IMPORTANTDimensions: 

    e1 = 10 mm

    e2 = 40 mm

    e3 = 15 mm

    e4 = 13 mm

    G15466695Courtesy of MERCEDES-BENZ USA
  22. Drill rivet holes in duplicator (10) with Ø 6.7 mm bit (area E).
  23. Remove duplicator (10).
  24. Deburr rivet holes on duplicator (10) and A-pillar inner panel (5) on both sides.
  25. Remove chips from drilling.
    G15466696Courtesy of MERCEDES-BENZ USA
  26. Grind mating surface on A-pillar inner panel (5) down to bare metal in the cross-hatched area.
  27. Remove grinding dust.
  28. Apply 2-component adhesive to body in cross-hatched area.

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

    G15466697Courtesy of MERCEDES-BENZ USA
  29. Install duplicator (10) and fix in place.

    IMPORTANT Clamping range is 3.50 mm.

  30. Rivet duplicator (10) with rivets Ø 6.5x12.5 (area F).
  31. Install, fit and fix in place A-pillar outer panel (7) with installed A-pillar reinforcement using SPECIAL TOOL side portal frame and portal straightener.

    IMPORTANT Use spacers.

  32. Mark positions for rivet holes on A-pillar outer panel (7) with installed A-pillar reinforcement.

    IMPORTANTDimensions: 

    g1 = 15 mm

    g2 = 10 mm

    g3 = 35 mm

    G15466698Courtesy of MERCEDES-BENZ USA
  33. Drill rivet holes in A-pillar outer panel (7) with installed A-pillar reinforcement with Ø 6.7 mm (area H).
  34. Remove portal straightener and A-pillar outer panel (7) with installed A-pillar reinforcement.
  35. Deburr rivet holes on A-pillar outer panel (7) with installed A-pillar reinforcement and on body on both sides.
    G15466699Courtesy of MERCEDES-BENZ USA
  36. In the cross-hatched areas, apply sealant to A-pillar outer panel (7) with installed A-pillar reinforcement.
    G15466700Courtesy of MERCEDES-BENZ USA
  37. Apply 2-component adhesive to body in cross-hatched areas.

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

    G15466701Courtesy of MERCEDES-BENZ USA
    G15466702Courtesy of MERCEDES-BENZ USA
  38. Install and fix in place A-pillar outer panel (7) with installed A-pillar reinforcement.
  39. Rivet A-pillar outer panel (7) with installed A-pillar reinforcement with rivets Ø 6.5x12.5 (area I).

    IMPORTANT Clamping range is 4.25 mm.

  40. A-pillar outer panel (7) with installed A-pillar reinforcement POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area J1 ).
    G15466703Courtesy of MERCEDES-BENZ USA
  41. A-pillar outer panel (7) with installed A-pillar reinforcement POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area J2 ).
  42. A-pillar outer panel (7) with installed A-pillar reinforcement SHIELDED GAS SEAM WELD (areas J3 , J 4 and J5 ).

    IMPORTANT Perform inert gas welding at intervals and allow welding area to cool down in between. Heat distortion can thus be reduced.

  43. Surface-grind inert gas welds on A-pillar outer panel (7) (areas J4 and J5 ).

    IMPORTANT Only surface-grind at bead areas and contact surfaces of A-pillar paneling (area J4 ).

  44. Clean weld joints that can no longer be accessed after installation of A-pillar paneling and coat with zinc dust paint.
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