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

MODEL 217.3 

The following steps are shown on the left side of the vehicle and must be accomplished analogously on the right side in the event of damage.

1. Install A-pillar inner panel (4) and A-pillar reinforcement (3) with portal bracket, fit and fix in place.

   Use spacers.

2. Remove portal bracket, A-pillar reinforcements (3) and A-pillar inner panel (4).
3. Apply 2-component adhesive to body in crosshatched areas.

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

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   Courtesy of MERCEDES-BENZ USA

4. Install A-pillar inner panel (4) and fix in place.
5. A-pillar inner panel (4) (areas B₁ , B₂ , B ₃ and B₄ ).
6. A-pillar inner panel (4) (areas A₁ , A ₂ and A₃ ).
7. Clean weld joints no longer accessible after installing A-pillar reinforcement (3) and coat with zinc dust paint.

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8. Install duplicator (15), fit and fix in place.

   Center duplicator (15) above inert gas weld on offset reinforcement (14).

9. Drill Ø 6.7 mm rivet holes on duplicator (15) (areas X1).
10. Remove duplicator (15).
11. Deburr rivet holes on duplicator (15), offset reinforcement (14) and body on both sides.
12. Remove drilling chips.
13. Grind mating surface down to bare metal in cross-hatched area.
14. Remove grinding dust.
15. Apply 2-component adhesive to offest reinforcement (14) and 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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    Courtesy of MERCEDES-BENZ USA

16. Install duplicator (15) and fix in place.
17. Rivet duplicator (15) and offset reinforcement (14) with Ø 6.5x12.5 blind rivets (areas X₂ ).

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18. Install A-pillar reinforcement (3) with portal bracket, fit and fix in place.

    Use spacers.

19. Remove A-pillar reinforcement (3).
20. Apply sealant to A-pillar inner panel (4) and foam parts (area D).
21. Apply 2-component adhesive to body in crosshatched areas.

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

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22. Install A-pillar reinforcement (3), fit and fix in place.
23. Rivet A-pillar reinforcement (3) with Ø 6.5x12.5 blind rivets (areas G₁ and G₂ ).
24. A-pillar reinforcement (3) (areas E₁ , E₃ , E₄ , E₅ , E ₆ and E₇ ).
25. A-pillar reinforcement (3) (areas F₁ , F₂ and F₃ ).

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

26. Apply 2-component adhesive to body in crosshatched areas.

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

27. Grind inert gas weld on A-pillar reinforcement (3) down flat (area F₃ ).

    Grind down flat on contact surfaces on A-pillar paneling (1) and beaded area only.

28. Clean weld joints are no longer accessible after installing upper front longitudinal member and A-pillar paneling (1) and coat with zinc dust paint.
29. Install roof frame reinforcement (2), fit and fix in place.
30. Drill Ø 6.7 mm rivet holes in roof frame reinforcement (2) (area C).
31. Remove roof frame reinforcement (2).
32. Deburr rivet holes on roof frame reinforcement (2) and body on both sides.

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    Courtesy of MERCEDES-BENZ USA

33. Apply 2-component adhesive to body in crosshatched areas.

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

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34. Install roof frame reinforcement (2), fit and fix in place.
35. Rivet roof frame reinforcement (2) with Ø x 6.5x12.5 blind rivets (areas J₁ and J₂ ).
36. Roof frame reinforcement (2) (areas H₁ and H₂ ).
37. Clean weld joints no longer accessible after installing A-pillar paneling (1) and coat with zinc dust paint.

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38. Install upper front longitudinal member (6), fit and fix in place.
39. Drill Ø 6.7 mm rivet holes in upper front longitudinal member (6) (areas Q₁ , Q ₂ , Q₅ and Q₆ ).

    Transfer position of present holes in body to new part (area Q₁ ).

    Drill rivet holes from inside through present holes in body (areas Q₂ ).

40. Drill Ø 6.7 mm rivet holes in upper front longitudinal member (6) (areas Q₃ ).
41. Drill Ø 6.7 mm rivet holes in upper front longitudinal member (6) and countersink (area Q₄ ).

    Countersink rivet hole to create level surface.

    Otherwise the fender cannot be adjusted.

    Transfer position of present hole in body to new part.

42. Remove upper front longitudinal member (6).
43. Deburr drill holes on upper front longitudinal member (6) and body on both sides.

    Only if a riveter for punching and flow form rivets is not used for installation.

    Drill rivet holes from rear through present holes in body.

44. Remove drilling chips.
45. Coat insides of riveted joints with zinc dust paint (areas Q₆ ).
46. Apply 2-component adhesive to body in crosshatched areas.

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

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

47. Install upper front longitudinal member (6) and fix in place.
48. Rivet upper front longitudinal member (6) with Ø 6.5x14.5 blind rivets (areas R₁ ).
49. Rivet front upper longitudinal member (6) with Ø 6.5x12.5 blind rivets (areas R2 and R₄ ).

    Flow form rivets with a clamping range of 3.35 mm to 4.1 "S2" can be used, if a riveter for punching and flow form rivets is used for installation (area R₄ ).

50. Rivet upper front longitudinal member (6) with Ø 6, 4x14 countersunk head rivets (area R₃ ).
51. Upper front longitudinal member (6) (areas R₅ ).
52. Rivet upper front longitudinal member (6) with Ø 6.5x14.5 blind rivets (area S₁ ).
53. Rivet upper front longitudinal member (6) with Ø 6, 5x12.5 blind rivets (area S2).

    Flow form rivets with a clamping range of 3.35 mm to 4.1 "S2" can be used, if a riveter for punching and flow form rivets is used for installation.

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54. Install strut (5), fit and fix in place.
55. Drill Ø 6.7 mm rivet holes in strut (5) (area T₁ ).

    Only if a riveter for punching and flow form rivets is not used for installation.

    Drill rivet holes from rear through present holes in body.

56. Drill Ø 6.7 mm rivet holes in strut (5) (areas T₂ ).
57. Remove strut (5).
58. Drill rivet holes in strut (5) and deburr on body on both sides.
59. Remove drilling chips.

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60. Apply 2-component adhesive to body in crosshatched areas.

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

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61. Install strut (5) and fix in place.
62. Rivet strut (5) with Ø 6.5x14.5 blind rivets (areas T₅ ).
63. Rivet strut (5) with Ø 6.5x12.5 blind rivets (areas T₃ and T₄ ).

    Flow form rivets with a clamping range of 3.35 mm to 4.1 "S2" can be used, if a riveter for punching and flow form rivets is used for installation (area T4).

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64. Install A-pillar paneling (1), fit and fix in place.
65. Drill Ø 6.7 mm rivet holes on A-pillar paneling (1) (areas U₁ ).
66. Drill Ø 6.7 mm rivet holes on A-pillar paneling (1) and countersink (area U₂ ).
67. Remove A-pillar paneling (1).
68. Deburr rivet holes on A-pillar inner panel (1) and body on both sides.
69. Remove drilling chips.
70. Coat insides of riveted joints with zinc dust paint.

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71. Apply sealant to foam part in crosshatched area (area I).
72. Apply 2-component adhesive to body cross-hatched inner C-pillar side wall.

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

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    Courtesy of MERCEDES-BENZ USA

73. Install A-pillar paneling (1), fit and fix in place.
74. Rivet A-pillar paneling (1) with Ø 6.4x14 countersunk head rivet (area M).
75. A-pillar paneling (1) (areas K and L).

    The resistance spot welds must be positioned at exactly the same position as the previous resistance spot welds, because these areas were glued previous (areas X₁ ).

    Otherwise the required minimum strength of the weld joint is not ensured.

76. A-pillar paneling (1) (areas N₁ , N₂ and N₃ ).

    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 N₁ , N₂ and N₃ ).
78. Solder surfaces on A-pillar paneling (1) with body solder and smooth (areas N₁ and N₂ ).
79. Remove solder residues and grinding dust.