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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-1102-03LWO

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

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
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-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.

G15466752Courtesy of MERCEDES-BENZ USA
  1. Reinforcement (10) and inner A-pillar (11) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area A).
  2. Reinforcement (10) and inner A-pillar (11) SHIELDED GAS SEAM WELD (area B).
  3. Surface-grind inert gas weld on reinforcement (10) and inner A-pillar (11) (area B).
    G15466753Courtesy of MERCEDES-BENZ USA
  4. Install, fit and fix in place A-pillar reinforcement (6) using SPECIAL TOOL side portal frame and portal straightener.

    IMPORTANT Use spacers.

  5. Drill rivet holes in A-pillar reinforcement (6) with Ø 6.7 mm (area C).

    IMPORTANT Drill rivet holes from inside through existing holes in body (area C).

  6. Remove portal bracket and A-pillar reinforcement (6).
  7. Deburr rivet holes on A-pillar reinforcement (6) and body on both sides.
  8. Apply sealant in cross-hatched areas to A-pillar reinforcement (6).
    G15466754Courtesy of MERCEDES-BENZ USA
    G15466755Courtesy of MERCEDES-BENZ USA
  9. Apply 2-component adhesive in cross-hatched areas on body.

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

    G15466756Courtesy of MERCEDES-BENZ USA
  10. Install and fix in place A-pillar reinforcement (6).
  11. Rivet A-pillar reinforcement (6) with rivets Ø 6.5x12.5 (area H).

    IMPORTANT Clamping range is 5.80 mm.

  12. A-pillar reinforcement (6) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area F).
  13. A-pillar reinforcement (6) SHIELDED GAS SEAM WELD (areas D, E and G).

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

  14. Surface-grind inert gas welds on A-pillar reinforcement (6) (areas D and E).

    IMPORTANT Only surface-grind bead areas and contact surfaces of A-pillar paneling.

  15. Clean weld joints that can no longer be accessed after installation of upper front longitudinal member and A-pillar reinforcement, and coat with zinc dust paint.
  16. Install, fit and fix in place reinforcement (3).
  17. Drill rivet holes in reinforcement (3) with Ø 6.7 mm (area M).
  18. Remove reinforcement (3).
  19. Deburr rivet holes on reinforcement (3) and body on both sides.
  20. Remove chips from drilling.
    G15466757Courtesy of MERCEDES-BENZ USA
  21. Apply 2-component adhesive in cross-hatched areas on body.

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

    G15466758Courtesy of MERCEDES-BENZ USA
  22. Install and fix in place reinforcement (3).
  23. Rivet reinforcement (3) with rivets Ø 6.5x12.5 (area P2 ).

    IMPORTANT Clamping range is 4.00 mm.

  24. Rivet reinforcement (3) with rivets Ø 6.5x12.5 (area P4 ).

    IMPORTANT Clamping range is 2.50 to3.30 mm.

  25. Rivet reinforcement (3) with rivets Ø 6.5x14.5 (area P3 ).

    IMPORTANT Clamping range is 5.30 to5.50 mm.

  26. Reinforcement (3) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area Q).
    G15466759Courtesy of MERCEDES-BENZ USA
    G15466727Courtesy of MERCEDES-BENZ USA
  27. Install strut (2) and bracket (4), fit and fix in place.
  28. Drill rivet holes in strut (2) and bracket (4) with Ø 6.7 mm (area R and S).
  29. Remove strut (2) and bracket (4).
  30. Deburr rivet holes on strut (2), bracket (4) and body on both sides.
  31. Remove chips from drilling.
  32. 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.

  33. Apply 2-component adhesive in cross-hatched areas on body.

    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
  34. Install strut (2) and bracket (4) and fix in place.
  35. Rivet strut (2) with rivets Ø 6.5x12.5 (area T1 ).

    IMPORTANT Clamping range is 2.30 to3.52 mm.

  36. Drill strut (2) with rivets Ø 6.5x12.5 (area T3 ).

    IMPORTANT Clamping range is 3.69 to3.80 mm.

  37. Rivet strut (2) and bracket (4) with rivets Ø 6.4x12 (area T2 ).

    IMPORTANT Clamping range is 1.77 to1.90 mm.

    G15466763Courtesy of MERCEDES-BENZ USA
  38. Install, fit and fix in place A-pillar paneling (5).
  39. Drill rivet holes in A-pillar paneling (5) with Ø 6.7 mm (area V1 and V2 ).
  40. Remove A-pillar paneling (5).
  41. Deburr rivet holes on A-pillar paneling (5) and body on both sides.
  42. Remove chips from drilling.
  43. Coat insides of riveted joints with zinc dust paint..

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

    Otherwise adhesion problems can occur.

    G15466764Courtesy of MERCEDES-BENZ USA
  44. In the cross-hatched area, apply the 2-component adhesive on body.

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

    G15466765Courtesy of MERCEDES-BENZ USA
  45. Install and fix A-pillar paneling (5) in place.
  46. Rivet A-pillar paneling (5) with rivets Ø 6.5x12.5 (area W1 ).

    IMPORTANT Clamping range is 3.49 mm.

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

    IMPORTANT Clamping range is 4.45 to4.81 mm.

  48. Rivet A-pillar paneling (5) with rivets Ø 6.4 M6 (area W3 ).

    IMPORTANT Clamping range is 6.59 mm.

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

    IMPORTANT Clamping range is 3.90 to4.00 mm.

  50. Rivet A-pillar paneling (5) with rivets Ø 6.4x12 (area W5 ).

    IMPORTANT Clamping range is 2.45 mm.

  51. A-pillar paneling (5) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area X).
  52. A-pillar paneling (5) SHIELDED GAS SEAM WELD (area Y).

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

  53. Surface-grind inert gas welds (area Y).
  54. Solder surfaces on A-pillar paneling (5) with body solder and smoothen (area Y).
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