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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-1100-10LWO

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

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 238.3 

Fig 1: Side Portal Frame (210 589 17 23 00)
G13669255Courtesy of MERCEDES-BENZ USA
Fig 2: Adapter Kit (213 589 00 23 00)
G12823988Courtesy of MERCEDES-BENZ USA
Fig 3: Welding Device (253 589 00 23 00)
G11269618Courtesy 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:

G15466707Courtesy of MERCEDES-BENZ USA
  1. Install, fit and fix in place A-pillar inner panel (7), roof frame inner panel (8) and A-pillar reinforcement using SPECIAL TOOL side portal frame and portal straightener.

    IMPORTANT Use spacers.

  2. Fix in place A-pillar inner panel (7) and roof frame inner panel (8).
  3. Remove portal straightener and A-pillar reinforcements.
  4. Drill rivet holes in A-pillar inner panel (7) and roof frame inner panel (8) with Ø 6.7 mm (area A1 , A 2 and A3 ).

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

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

  5. Remove A-pillar inner panel (7) and roof frame inner panel (8).
  6. Deburr rivet holes on A-pillar inner panel (7), roof frame inner panel (8) 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.

    G15466708Courtesy of MERCEDES-BENZ USA
    G15466709Courtesy of MERCEDES-BENZ USA
  10. Install and fix in place A-pillar inner panel (7) and roof frame inner panel (8).
  11. Rivet A-pillar inner panel (7) with Ø 6.5x14.5 rivets (area B1 ).

    IMPORTANT Clamping range is 4.50 mm.

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

    IMPORTANT Clamping range is 5.20 mm.

  13. Rivet A-pillar inner panel (7) with Ø 6.4 M6 rivets (area B3 ).

    IMPORTANT Clamping range is 6.25 to6.95 mm.

  14. Rivet A-pillar inner panel (7) and roof frame inner panel (8) with rivets Ø 6.5x12.5 (area B4 ).

    IMPORTANT Clamping range is 3.75 mm.

  15. A-pillar inner panel (7) and roof frame inner panel (8) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area C).
  16. A-pillar inner panel (7) and roof frame inner panel (8) SHIELDED GAS SEAM WELD (areas D1 , D2 and D3 ).

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

  17. Surface-grind inert gas weld on A-pillar inner panel (7) and roof frame inner panel (8) (areas D1 , D2 and D3 ).

    IMPORTANT Only surface-grind at bead areas and contact surfaces of A-pillar reinforcement (area D2 ).

  18. Clean weld joints that can no longer be accessed after installation of A-pillar reinforcement and coat with zinc dust paint.
    G15466710Courtesy of MERCEDES-BENZ USA
  19. Install, fit and fix in place duplicator (11).

    IMPORTANT Align duplicator (11) in center over inert gas weld on A-pillar inner panel (7).

  20. Mark positions for rivet holes on duplicator halves (11).

    IMPORTANTDimensions: 

    e1 = 10 mm

    e2 = 40 mm

    e3 = 15 mm

    e4 = 13 mm

    G15466711Courtesy of MERCEDES-BENZ USA
  21. Drill rivet holes in duplicator (11) with Ø 6.7 mm bit (area E).
  22. Remove duplicator (11).
  23. Deburr rivet holes on duplicator (11) and A-pillar inner panel (7) on both sides.
  24. Remove chips from drilling.
    G15466712Courtesy of MERCEDES-BENZ USA
  25. Grind mating surface on A-pillar inner panel (7) down to bare metal in cross-hatched area.
  26. Remove grinding dust.
  27. 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.

    G15466713Courtesy of MERCEDES-BENZ USA
  28. Install duplicator (11) and fix in place.

    IMPORTANT Clamping range is 3.50 mm.

  29. Rivet duplicator (11) with rivets Ø 6.5x12.5 (area F).
  30. Install, fit and fix in place A-pillar reinforcement (6) using SPECIAL TOOL side portal frame and portal straightener.

    IMPORTANT Use spacers.

  31. Mark positions for rivet holes on A-pillar reinforcement (6).

    IMPORTANTDimensions: 

    g1 = 15 mm

    g2 = 10 mm

    g3 = 35 mm

    g4 = 9 mm

    g5 = 8 mm

    g6 = 12 mm

    G15466714Courtesy of MERCEDES-BENZ USA
  32. Drill rivet holes in A-pillar reinforcement (6) with Ø 6.7 mm bit (area H1 and H2 ).
  33. Countersink rivet holes in A-pillar reinforcement (6) (area H2 ).
  34. Remove portal bracket and A-pillar reinforcement (6).
  35. Deburr rivet holes on A-pillar reinforcement (6) and body on both sides.
    G15466715Courtesy of MERCEDES-BENZ USA
  36. Apply sealant on A-pillar reinforcement (6) in cross-hatched areas.
    G15466716Courtesy of MERCEDES-BENZ USA
    G15466717Courtesy 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.

    G15466718Courtesy of MERCEDES-BENZ USA
  38. Install and fix in place A-pillar reinforcement (6).
  39. Rivet A-pillar reinforcement (6) with Ø 6.5x12.5 rivets (area I1 ).

    IMPORTANT Clamping range is 4.25 mm.

  40. Rivet A-pillar reinforcement (6) with Ø 6.4x15.5 countersunk-head blind rivets (area I2 ).
  41. A-pillar reinforcement (6) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area J1 ).
    G15466719Courtesy of MERCEDES-BENZ USA
  42. A-pillar reinforcement (6) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area J2 ).
  43. A-pillar reinforcement (6) SHIELDED GAS SEAM WELD (areas J3 , J4 and J5 ).

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

  44. Surface-grind inert gas welds on A-pillar reinforcement (6) (areas J4 and J5 ).

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

  45. Clean weld joints that can no longer be accessed after installation of upper front longitudinal member and A-pillar paneling and coat with zinc dust paint.
  46. Install, fit and fix in place roof frame reinforcement (9).
  47. Drill rivet holes in roof frame reinforcement (9) with Ø 6.7 mm bit through the existing holes (area K1 , K 2 and K3 ).

    NOTES When drilling, ensure that the bit does not reach too far into the A-pillar reinforcement. Water drain hose in A-pillar reinforcement will otherwise be damaged.

  48. Remove roof frame reinforcement (9).
  49. Deburr rivet holes on roof frame reinforcement (9) and body.
    G15466720Courtesy of MERCEDES-BENZ USA
  50. Apply 2-component adhesive to body in cross-hatched area.

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

    G15466721Courtesy of MERCEDES-BENZ USA
  51. Install and fix in place roof frame reinforcement (9).
  52. Rivet roof frame reinforcement (9) with Ø 6.5x12.5 rivets (area L1 ).

    IMPORTANT Clamping range is 3.07 mm.

  53. Rivet roof frame reinforcement (9) with Ø 6.5x14.5 rivet (area L2 ).

    IMPORTANT Clamping range is 4.82 mm.

  54. Rivet roof frame reinforcement (9) with Ø 6.4x15.5 countersunk-head blind rivets (area L3 ).
  55. Rivet roof frame reinforcement (9) with Ø 6.4x14.0 countersunk-head blind rivets (area L4 ).
  56. Roof frame reinforcement (9) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area L5 ).
    G15466722Courtesy of MERCEDES-BENZ USA
    G13773979Courtesy of MERCEDES-BENZ USA
  57. Drill off connecting flange (10) from A-pillar reinforcement old part with Ø 7 mm.
  58. Install, fit and fix in place connecting flange (10).
  59. Connecting flange (10) SHIELDED GAS PLUG WELD (area K4 ).
    G13773980Courtesy of MERCEDES-BENZ USA
  60. Install upper front longitudinal member (1), fit and fix in place with SPECIAL TOOL welding fixture and SPECIAL TOOL adapter.
  61. Install, fit and fix in place reinforcement (3).
  62. Drill rivet holes in upper front longitudinal member (1) and reinforcement (3) with Ø 6.7 mm bit (area M1 , N1 and O).

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

  63. Remove upper front longitudinal member (1), reinforcement (3), SPECIAL TOOL welding fixture and SPECIAL TOOL adapter.
  64. Deburr rivet holes on upper front longitudinal member (1), reinforcement (3) and body on both sides.
  65. Remove chips from drilling.
  66. Coat inside of riveted joint with zinc dust paint (area O).
    G12823981Courtesy of MERCEDES-BENZ USA
  67. 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.

    G15466726Courtesy of MERCEDES-BENZ USA
  68. Install and fix in place upper front longitudinal member (1) with SPECIAL TOOL welding fixture and SPECIAL TOOL adapter.
  69. Install and fix in place reinforcement (3).
  70. Rivet upper front longitudinal member (1) and reinforcement (3) with rivets Ø 6.5x12.5 (area P1 ).

    IMPORTANT Clamping range is 3.74 to4.97 mm.

  71. Rivet upper front longitudinal member (1) and reinforcement (3) with rivets Ø 6.5x12.5 (area P2 ).

    IMPORTANT Clamping range is 2.47 to3.52 mm.

  72. Rivet upper front longitudinal member (1) and reinforcement (3) with rivets Ø 6.5x14.5 (area P3 ).

    IMPORTANT Clamping range is 5.47 mm.

  73. Remove SPECIAL TOOL welding fixture and SPECIAL TOOL adapter.
  74. Upper front longitudinal member (1) and reinforcement (3) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area Q).
    G15466727Courtesy of MERCEDES-BENZ USA
  75. Install strut (2) and bracket (4), fit and fix in place.
  76. Drill rivet holes in strut (2) and the bracket (4) with Ø 6.7 mm bit (area R and S).
  77. Remove strut (2) and bracket (4).
  78. Deburr rivet holes in strut (2), bracket (4) and body on both sides.
  79. Remove chips from drilling.
  80. Coat insides of riveted joints with zinc dust paint.

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

    Otherwise adhesion problems can occur.

  81. 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.

    G12823986Courtesy of MERCEDES-BENZ USA
    G15466729Courtesy of MERCEDES-BENZ USA
  82. Install strut (2) and bracket (4) and fix in place.
  83. Rivet strut (2) and bracket (4) with rivets Ø 6.5x12.5 (area T1 ).

    IMPORTANT Clamping range is 2.30 to3.52 mm.

  84. Rivet strut (2) with Ø 6.5x12.5 rivets (area T3 ).

    IMPORTANT Clamping range is 3.69 to3.80 mm.

  85. Rivet strut (2) with rivets Ø 6.4x12 (area T2 ).

    IMPORTANT Clamping range is 1.77 to1.90 mm.

    G15466730Courtesy of MERCEDES-BENZ USA
  86. Install, fit and fix in place A-pillar paneling (5.1) and roof frame paneling (5.2).
  87. Drill rivet holes in A-pillar paneling (5.1) with Ø 6.7 mm bit (area V1 , V2 and V3 ).
  88. Remove A-pillar paneling (5.1).
  89. Deburr rivet holes on A-pillar paneling (5.1) and body on both sides.
  90. Remove chips from drilling.
  91. Coat insides of riveted joints with zinc dust paint.

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

    Otherwise adhesion problems can occur.

  92. Apply 2-component adhesive to body in cross-hatched area (area Z1 ).

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

  93. Apply sealant on foam part in cross-hatched area (area Z2 ).
    G15466731Courtesy of MERCEDES-BENZ USA
    G15466732Courtesy of MERCEDES-BENZ USA
  94. Install and fix in place A-pillar paneling (5.1).
  95. Rivet A-pillar paneling (5.1) with Ø 6.5x12.5 rivets (area W1 ).

    IMPORTANT Clamping range is 3.49 mm.

  96. Rivet A-pillar paneling (5.1) with Ø 6.5x14.5 rivets (area W2 ).

    IMPORTANT Clamping range is 4.45 mm to4.81 mm.

  97. Rivet A-pillar paneling (5.1) with rivets Ø 6.4 M6 (area W3 ).

    IMPORTANT Clamping range is 6.59 mm.

  98. Rivet A-pillar paneling (5.1) with Ø 6.5x12.5 rivets (area W4 ).

    IMPORTANT Clamping range is 3.92 mm to4.17 mm.

  99. Rivet A-pillar paneling (5.1) with rivets Ø 6.4x12 (area W5 ).

    IMPORTANT Clamping range is 2.45 mm.

  100. Rivet A-pillar paneling (5.1) with rivets Ø 6.4x12 (area W6 ).

    IMPORTANT Clamping range is 2.22 mm to2.29 mm.

  101. Rivet A-pillar paneling (5.1) with Ø 6.5x14.5 rivets (area W7 ).

    IMPORTANT Clamping range is 5.21 mm.

  102. A-pillar paneling (5.1) and roof frame paneling (5.2) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area X).
  103. A-pillar paneling (5.1) and roof frame paneling (5.2) SHIELDED GAS SEAM WELD (area Y).

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

  104. Surface-grind inert gas welds (area Y).
  105. Solder surfaces on A-pillar paneling (5.1) and roof frame paneling (5.2) with body solder and smoothen (area Y).
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