Outer A-Pillar Section Installation - Ar63.20-P-1102-03S

	000 588 04 39 00 Rivet press tool		WS60.00-P-0440B
	000 588 03 39 00 Rivet die		WS60.00-P-0386K

Model 223.0/1 

Model 223.9 

16.03.2023

Sequence of operations modified.

Operation step 1 and operation step 2

Number	Designation			Model 223
BA63.10-P-1001-01A	Screw, lower A-pillar to bodyshell	M8	Nm	32
		M10	Nm	45

Courtesy of MERCEDES-BENZ USA

Countersunk-head rivet (Z) 

• Z₁ = countersunk-head rivet 6.4x14.0
• Z₂ = countersunk-head rivet 6.4x15.5
• Z₃ = countersunk-head rivet 6.4x17.0
• Z₄ = countersunk-head rivet 6.4x19.0
• Z₅ = countersunk-head rivet 6.4x21.0

Blind rivet (Y) 

• Y₁ = rivet 6.4x12
• Y₂ = rivet 6.5x12.5
• Y₃ = rivet 6.5x14.5
• Y₄ = Rivet 6.4M6
• Y₅ = Rivet 6.4
• Y₆ = rivet 6.5x13.5
• Y₇ = rivet 6.4x14
• Y₈ = rivet 6.4x17
• Y₉ = rivet 6.4x20

Flow-form rivet (W) 

• W₁ = Flow-form rivet structure up to 3.5 mm clamping range
• W₃ = Flow-form rivet structure 3.35 mm up to 4.1 mm clamping range
• W₄ = Flow-form rivet structure 4 mm up to 5.15 mm clamping range
• W₅ = Flow-form rivet structure 5.0 mm up to 6.1 mm clamping range
• W₆ = Flow-form rivet structure 6.0 mm up to 7.2 mm clamping range
• W₇ = Flow-form rivet structure 7.1 mm up to 8.3 mm clamping range

Blind rivet (V) 

• V₁ = rivet 3.2x4.5 (clamping range 1 mm to 1.8 mm)
• V₂ = rivet 3.2x6.5 (clamping range 1.5 mm to 3.5 mm)

Blind rivet (U) 

• U₁ = rivet 3.2x9.5

Flow-form rivet with countersunk head (T) 

• T₁ = blind rivet with countersunk head 3.0 mm to 5.0 mm clamping range
• T₂ = blind rivet with countersunk head 1.5 mm to 3.0 mm clamping range

Flow-form rivet with countersunk head (X) 

• X₁ = Flow-form rivet with countersunk head 1.3 mm to 2.5 mm clamping range
• X₂ = Flow-form rivet with countersunk head 2.3 mm to 3.5 mm clamping range
• X₃ = Flow-form rivet with countersunk head 3.35 mm to 4.1 mm clamping range
• X₄ = Flow-form rivet with countersunk head 4 mm to 5.15 mm clamping range
• X₅ = Flow-form rivet with countersunk head 5.0 mm to 6.1 mm clamping range
• X₆ = Flow-form rivet with countersunk head 6.0 mm to 7.2 mm clamping range
• X₇ = Flow-form rivet with countersunk head 7.1 mm to 8.3 mm clamping range

The following steps are shown on model 223.1 on the left side of the vehicle and must be similarly performed on the right side of the vehicle in the event of damage.

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

The graphics show the vehicle from the mechanic's perspective. At the same time, this perspective also specifies the direction in which the rivets must be placed.

Courtesy of MERCEDES-BENZ USA

1. Install, fit, and fix in place A-pillar reinforcement (1) using side portal frame and portal straightener.

   Use spacers.

2. Transfer existing holes in body to A-pillar reinforcement (1) using drill hole finder (areas B, F).
3. Install, fit and fix in place cover plate (2).
4. Drill rivet holes in A-pillar reinforcement (1) and striker plate (2) with Ø 6.7 mm bit (areas A, B, C, F).
5. Punch rivet holes in A-pillar reinforcement (1) with Ø 6.0 mm bit using a rivet press tool (areas G).
6. Countersink rivet holes in A-pillar reinforcement (1) and striker plate (2) (areas C).
7. Drill rivet holes in A-pillar reinforcement (1) with Ø 6.7 mm bit through existing holes in body (areas E, D).

   If upper A-pillar reinforcement was not removed.

8. Countersink rivet holes in A-pillar reinforcement (1) (area E).

   If upper A-pillar reinforcement was not removed.

9. Remove portal straightener, A-pillar reinforcement (1), and striker plate (2).
10. Deburr rivet holes in A-pillar reinforcement (1), striker plate (2), and body on both sides.
11. Remove drilling chips.
12. Insert structured foam parts (3, 7) with 2-component adhesive for reinforcements.

    The structured foam part (7) is part of the replacement parts scope for the A-pillar reinforcement.

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

13. Insert foam part (4) with sealant.

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

14. Apply sealant to foam part in cross-hatched area (area H).
15. Apply 2-component adhesive for reinforcements on structured foam parts in cross-hatched areas (areas J, K).

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

16. Apply 2-component adhesive to body in cross-hatched areas.

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

17. Apply 2-component adhesive in cross-hatched area on inside (area L).

    If upper A-pillar reinforcement was not removed.

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

    Courtesy of MERCEDES-BENZ USA

18. Install and fix in place A-pillar reinforcement (1) using side portal frame and portal straightener.

    Use spacers.

19. Install and fix in place cover plate (2).
20. Rivet A-pillar reinforcement (1) and striker plate (2) with Ø 6.5x12.5 rivets (area Y₂ ).
21. Rivet A-pillar reinforcement (1) with Ø 6.5x14.5 rivets (area Y₃ ).
22. Rivet A-pillar reinforcement (1) with Ø 6.4 rivet (area Y₅ ).
23. Rivet A-pillar reinforcement (1) with Ø 6.4x1 5.5 countersunk-head rivets (area Z₂ ).
24. Rivet A-pillar reinforcement (1) and striker plate (2) with Ø 6.4x17.0 countersunk-head rivets (areas Z₃ ).
25. Rivet A-pillar reinforcement (1) with flow-form rivet with countersunk head with 4.0 mm to 5.15 mm clamping range (areas X₄ ).
26. Screw in screws (5, 6) on A-pillar reinforcement (1).

    Courtesy of MERCEDES-BENZ USA