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

Model 257, 290 

Fig 1: Side Portal Frame (210 589 17 23 00)

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Fig 2: Adapter Kit (213 589 00 23 00)

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Fig 3: Welding Device (253 589 00 23 00)

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The following operation steps are shown on the left side of the vehicle on model 257. In case of damage on the right side of the vehicle, these steps must be performed analogously.

Additional information can be found in the superordinate service document.

The safety information in the superordinate service document must be observed.

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1. Install, fit and fix in place A-pillar inner panel (7) and A-pillar reinforcement with side portal frame and portal straightener.

   Use spacers.

2. Drill rivet holes with a diameter of 6.7 mm in A-pillar inner panel (7) from the inside through the existing holes in the body (area A).
3. Remove portal bracket, A-pillar reinforcements and A-pillar inner panel (7).
4. Deburr rivet holes on A-pillar inner panel (7) and body on both sides.
5. Remove drilling chips.
6. Coat insides of riveted joints with zinc dust paint.
7. Apply 2-component adhesive to body in cross-hatched area.

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

   Courtesy of MERCEDES-BENZ USA

   Courtesy of MERCEDES-BENZ USA

8. Install A-pillar inner panel (7) and fix in place.
9. Rivet A-pillar inner panel (7) with rivets ø 6.5x12.5 (area B).
10. A-pillar inner panel (7) (area s F).
11. A-pillar inner panel (7) (areas C, E).

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

12. Surface-grind inert gas weld on A-pillar inner panel (7) (area E).
13. Clean welding areas which are no longer accessible after installing upper front longitudinal member and A-pillar reinforcement and coat with zinc dust paint.
14. Install, fit and fix in place outer connecting panel (8) and inner connecting panel (9).

    Ensure an overlap of the outer connecting panel (8) and inner connecting panel (9) with the body of approx. 60 mm.

15. Drill rivet holes in body and inner connecting panel (9) through holes predrilled in outer connecting panel (8) with ø 6.7 mm (areas G, H).

    During drilling, ensure that drill bit does not penetrate too far.

    Water drain hose in body will otherwise be damaged.

16. Countersink rivet holes in outer connecting panel (8) (area G).
17. Fix in place outer connecting panel (8) and inner connecting panel (9) with manual temporary fasteners.

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18. Install, fit and fix in place A-pillar reinforcement (6) with side portal frame and portal straightener.

    Use spacers.

    Position A-pillar reinforcement (6) between inner connecting panel and outer connecting panel (8). If necessary, slightly release manual temporary fasteners.

19. Drill rivet holes in A-pillar reinforcement (6) and inner connecting panel through the holes predrilled in outer connecting panel (8) with ø 6.7 mm (areas G₁ , H₁ ).

    During drilling, ensure that drill bit does not penetrate too far into A-pillar reinforcement (6).

    Water drain hose in A-pillar reinforcement (6) will otherwise be damaged.

20. Countersink rivet holes in outer connecting panel (8) (area G₁ ).

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21. Drill rivet holes in A-pillar reinforcement (6) with ø 6.7 mm (area K).
22. Remove portal straightener, A-pillar reinforcement (6) and connecting panels.
23. Deburr rivet holes on A-pillar reinforcement (6), connecting panels and body on both sides.
24. Remove drilling chips.

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

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26. Apply 2-component adhesive to A Pillar inner panel (7) 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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27. Apply 2-component adhesive to inner connecting panel (9) in cross-hatched area.

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

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28. Apply 2-component adhesive in cross-hatched area to outer connecting panel (8).

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

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29. Install, fit and fix in place inner connecting panel, outer connecting panel (8) and A-pillar reinforcement (6) with side portal frame and portal straightener.

    Position A-pillar reinforcement (6) between inner connecting panel and outer connecting panel (8).

    Use spacers.

30. Rivet outer connecting panel (8) with countersunk-head blind rivets ø 6.4x17.0 (area J₂ ).
31. Rivet outer connecting panel (8) with rivets ø 6.5x14.5 (area J₁ ).

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    Courtesy of MERCEDES-BENZ USA

32. Rivet A-pillar reinforcement (6) with rivets ø 6.5x12.5 (area K₁ ).
33. A-pillar reinforcement (6) (area M).

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34. A-pillar reinforcement (6) (areas O₁ ).
35. A-pillar reinforcement (6) (areas N₁ , N₂ ).

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

36. Surface-grind inert gas welds on A-pillar reinforcement (6) (areas N₁ , N₂ ).

    Only surface-grind fold areas and contact surfaces of A Pillar paneling (area N₁ ).

37. 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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38. Drill off connecting flange (10) of A-pillar reinforcement old part with ø 7 mm.

    If connecting flange (10) can not be reused,

    ↓

    fabricate connecting flange (10) yourself.

39. Install connecting flange (10), fit and fix in place.
40. Connecting flange (10) (area K₄ ).

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41. Install upper front longitudinal member (1), fit and fix in place with welding fixture and adapter set.
42. Install reinforcement (3), fit and fix in place.
43. Drill rivet holes in upper front longitudinal member (1) and reinforcement (3) with ø 6.7 mm (areas M₁ , N₁ and O).

    Drill rivet holes from inside through present hole in body (area N₁ ).

44. Remove upper front longitudinal member (1), reinforcement (3), welding fixture and adapter set.
45. Deburr drill holes on upper front longitudinal member (1), reinforcement (3) and body on both sides.
46. Remove drilling chips.
47. Coat inside of riveted joint with zinc dust paint (areas O).

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48. 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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49. Install and fix in place upper front longitudinal member (1) with welding fixture and adapter set.
50. Install reinforcement (3) and fix in place.
51. Rivet upper front longitudinal member (1) and reinforcement (3) with rivets ø 6.5x12.5 (areas P₁ , P₂ ).
52. Rivet upper front longitudinal member (1) and reinforcement (3) with rivets ø 6.5x14.5 (areas P₃ ).
53. Upper front longitudinal member (1) (areas Q).

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54. Install strut (2) and bracket (4), fit and fix in place.
55. Drill rivet holes in strut (2) and bracket (4) with ø 6.7 mm (areas R, S).
56. Remove strut (2) and bracket (4).
57. Deburr rivet holes on strut (2), bracket (4) and body on both sides.
58. Remove drilling chips.
59. Coat insides of riveted joints in areas not bonded with zinc dust paint.

    Do not apply zinc dust paint to bonding surfaces.

    Otherwise adhesion problems may occur.

60. 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.

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

61. Install strut (2) and bracket (4) and fix in place.
62. Rivet strut (2) with rivets ø 6.5x12.5 (areas T).
63. Rivet strut (2) and bracket (4) with rivets ø 6.4x12 (areas U).
64. Install A-pillar paneling (5), fit and fix in place.
65. Drill rivet holes in A-pillar paneling (5) with ø 6.7 mm (areas V₁ , V₂ , V₃ ).
66. Remove A-pillar paneling (5).
67. Deburr rivet holes on A-pillar inner panel (5) and body on both sides.
68. Remove drilling chips.
69. Coat insides of riveted joints with zinc dust paint.

    Courtesy of MERCEDES-BENZ USA

70. Apply sealant to foam part in crosshatched area.

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    Courtesy of MERCEDES-BENZ USA

71. Install A-pillar paneling (5) and fix in place.
72. Rivet A-pillar paneling (5) with rivets ø 6.4x12 (areas W₁ ).
73. Rivet A-pillar paneling (5) with rivets ø 6.5x12.5 (areas W₂ ).
74. Rivet A-pillar paneling (5) with rivet ø 6.5x14.5 (area W₃ ).
75. A-pillar paneling (5) (areas X).
76. A-pillar paneling (5) (areas Y).

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

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

    As an alternative to restoring the surfaces with a body solder, it is also possible to use a basic body filler.