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Home >> Mercedes Benz >> 2021 >> E53 AMG 2D Convertible >> Repair and Diagnosis >> Collision >> Body Panels >> Collision - Side Wall (238 Chassis) >> Side Wall Body Repair >> Install A-Pillar Outer Section - Ar63.20-P-1102-03LWA

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

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 

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-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.

G15466747Courtesy of MERCEDES-BENZ USA
  1. Install, fit and fix in place A-pillar paneling (1).
  2. Drill rivet holes in A-pillar paneling (1) with a diameter of 6.7 mm (areas J1 , J2 , J 3 , J4 ).
  3. Remove A-pillar paneling (1).
  4. Deburr rivet holes on A-pillar paneling (1) and body on both sides.
  5. Remove chips from drilling.
  6. Coat insides of riveted joints with zinc dust paint..

    NOTES Do not coat bonding surfaces with zinc dust paint (area J4).

    Otherwise adhesion problems can occur.

    G15466748Courtesy of MERCEDES-BENZ USA
  7. Apply 2-component adhesive in cross-hatched areas to the body (area K, L).

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

  8. Apply sealant in cross-hatched area (area M).
    G15466749Courtesy of MERCEDES-BENZ USA
  9. Install and fix A-pillar paneling in place (1).
  10. Rivet A-pillar paneling (1) with Ø 6.4x12 rivets (area N1 ).

    IMPORTANT Clamping range is 1.0 mm to 3.5 mm.

  11. Rivet A-pillar paneling (1) with Ø 6.4x14 countersunk-head blind rivets (area N2 ).

    IMPORTANT Clamping range is 1.5 mm to 3.0 mm.

  12. Rivet A-pillar paneling (1) with Ø 6.4x15.5 countersunk-head blind rivets (area N3 ).

    IMPORTANT Clamping range is 3.0 mm to 5.0 mm.

  13. Rivet A-pillar paneling (1) with Ø 6.5x12.5 rivets (area N4 ).

    IMPORTANT Clamping range is 2.0 mm to 5.0 mm.

  14. A-pillar paneling (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area O).
    G15466750Courtesy of MERCEDES-BENZ USA
  15. Bend down lugs (areas P1 , P 2 ) to initial state.
  16. A-pillar paneling (1) and roof frame (2) SHIELDED GAS SEAM WELD (areas P1 , P2 ).

    IMPORTANT Perform inert gas welding at intervals and allow welding area to cool down in between. This reduces the heat distortion.

  17. A-pillar paneling (1) SHIELDED GAS SEAM WELD (area Q).

    IMPORTANT Perform inert gas welding at intervals and allow welding area to cool down in between. This reduces the heat distortion.

  18. Surface-grind inert gas welds on A-pillar paneling (1) and roof frame (2) (areas P1 , P2 , Q).
  19. Solder surfaces on A-pillar paneling (1) with body solder and smoothen (area Q).
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