Outer Longitudinal Member Shell On Entrance Installation - Ar63.30-P-1102-03ME

Model 167 

The next steps are shown on the left side of vehicle on model 167.1 for the most extensive repair. In case of damage on the right side of the vehicle, these steps must be performed analogously.

The higher-level service document as well as the safety information in the service document must be observed.

Courtesy of MERCEDES-BENZ USA

1. Install longitudinal member outer shell (1), fit using straighteners and fix in place.
2. Drill rivet holes in longitudinal member outer shell (1) having a diameter of 6.7 mm (areas A, B).

   Drill rivet holes through existing holes in body (area B).

3. Remove outer longitudinal member shell (1).
4. Deburr rivet holes on the longitudinal member outer shell (1) and on the body on both sides.
5. Remove drill chips.
6. Coat with zinc dust paint insides of those riveted joints that will not be bonded.

   Courtesy of MERCEDES-BENZ USA

7. Apply sealant to foam part in cross-hatched area (area C).
8. Apply 2-component adhesive to body on cross-hatched areas (areas D).

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

   Courtesy of MERCEDES-BENZ USA

9. Apply sealant to the foam parts of the longitudinal member outer shell (1) in the cross-hatched areas (areas E).
10. Apply 2-component adhesive to the longitudinal member outer shell (1) in the cross-hatched areas (areas F).

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

    Courtesy of MERCEDES-BENZ USA

11. Install longitudinal member outer shell (1) using the straighteners and fix in place.
12. Rivet longitudinal member outer shell (1) using 6.5x12.5-diameter rivets (areas G).
13. Rivet longitudinal member outer shell (1) using 6.5x14.5-diameter rivets (areas H).
14. Longitudinal member outer shell (1) (areas J).

    Courtesy of MERCEDES-BENZ USA

15. Rivet longitudinal member outer shell (1) using 6.5x12.5-diameter rivets (area K).
16. Longitudinal member outer shell (1) (area L).
17. Longitudinal member outer shell (1) (area M).
18. Install A-pillar reinforcement (2), fit and fix in place.
19. Drill rivet holes in A-pillar reinforcement (2) having a diameter of 6.7 mm (area N).
20. Remove A-pillar reinforcement (2).
21. Deburr rivet holes in longitudinal member outer shell (1) and in A-pillar reinforcement (2) on both sides.
22. Remove drill chips.
23. Coater inner sides riveted joints with zinc dust paint (area N).
24. Longitudinal member outer shell (1) (area O).
25. Longitudinal member outer shell (1) (area P).

    Courtesy of MERCEDES-BENZ USA

26. Install A-pillar reinforcement (2) and fix in place.
27. Rivet A-pillar reinforcement (2) using 6.5x12.5-diameter rivets (area Q).
28. A-pillar reinforcement (2) (areas R).

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

29. Longitudinal member outer shell (1) and A-pillar reinforcement (2) depending on repair scope ((area S), (area T), (area U), (areas S, T), (areas S, U) or (areas T, U)).

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

30. Longitudinal member outer shell (1) (area V).

    Only when repairing the front area.

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

31. Surface grind inert gas welds on longitudinal member outer shell (1) and on A-pillar reinforcement (2) (areas S, T, U).

    Surface grind only on fold areas and contact surfaces of the longitudinal member paneling (areas S, T, U).

32. Clean weld joints no longer accessible after installing longitudinal member paneling and coat with zinc dust paint.