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

Model 217.4 

The following steps are shown on the left side of the vehicle and must be performed in the same way 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 cross-hatched areas.

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

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4. Install A-pillar inner panel (4) and fix in place.
5. A-pillar inner panel (4) (areas A₂ and A₃ ).
6. A-pillar inner panel (4) (areas B₁ , B₂ , B₃ and B₄ ).
7. Clean weld joints no longer accessible after installing A-pillar reinforcement (3) and coat with zinc dust paint.

   Shown on model 217.3 

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   Courtesy of MERCEDES-BENZ USA

8. A-pillar inner panel (4) (area B ₅ ).

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

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

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

17. Install duplicator (15) and fix in place.
18. Rivet duplicator (15) and offset reinforcement (14) with Ø 6.5x12.5 blind rivets (areas X₂ ).
19. Install A-pillar reinforcement (3) with portal bracket, fit and fix in place.

    Use spacers.

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

23. Install A-pillar reinforcement (3), fit and fix in place.
24. Rivet A-pillar reinforcement (3) with Ø 6.5x12.5 blind rivets (area G₁ ).
25. A-pillar reinforcement (3) (areas E₁ , E₂ , E₃ , E₄ and E₅ ).
26. 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.

27. Sand down inert gas weld on A-pillar reinforcement (3) until flat (area F₁ ).

    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.

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29. Install upper front longitudinal member (6), fit and fix in place.
30. Drill Ø 6.7 mm rivet holes in upper front longitudinal member (6) (areas Q₁ , Q₂ , 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 ).

31. Drill Ø 6.7 mm rivet holes in upper front longitudinal member (6) (areas Q₃ ).

    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.

32. 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.

33. Remove upper front longitudinal member (6).
34. Deburr rivet holes on upper front longitudinal member (6) and body on both sides.
35. Remove drilling chips.
36. Coat insides of riveted joints with zinc dust paint (areas Q₆ ).
37. Apply 2-component adhesive to body in cross-hatched 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

38. Install upper front longitudinal member (6) and fix in place.
39. Rivet upper front longitudinal member (6) with Ø 6.5x14.5 blind rivets (areas R₁ ).
40. 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 ).

41. Rivet upper front longitudinal member (6) with Ø 6, 4x14 countersunk head rivets (area R₃ ).
42. Upper front longitudinal member (6) (areas R₅ ).
43. Rivet upper front longitudinal member (6) with Ø 6.5x14.5 blind rivets (area S₁ ).
44. 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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45. Install strut (5), fit and fix in place.
46. 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.

47. Drill Ø 6.7 mm rivet holes in strut (5) (area T₂ ).
48. Remove strut (5).
49. Drill rivet holes in strut (5) and deburr on body on both sides.
50. Remove drilling chips.

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

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

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52. Install strut (5) and fix in place.
53. Rivet strut (5) with Ø 6.5x14.5 blind rivets (areas T₅ ).
54. 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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55. Install A-pillar paneling (1), fit and fix in place.
56. Drill Ø 6.7 mm rivet holes on A-pillar paneling (1) (areas U₁ ).
57. Drill Ø 6.7 mm rivet holes on A-pillar paneling (1) and countersink (area U₂ ).
58. Remove A-pillar paneling (1).
59. Deburr rivet holes on A-pillar panel (1) and body on both sides.
60. Remove drilling chips.
61. Coat insides of riveted joints with zinc dust paint.

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62. Apply sealant to foam part in crosshatched area (area I).
63. Apply 2-component adhesive to cross-hatched area of body.

    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

64. Install A-pillar paneling (1), fit and fix in place.
65. Rivet A-pillar paneling (1) with Ø 6.4x14 countersunk head rivet (area M).
66. 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 previously (areas X₁ ).

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

67. A-pillar panel (1) (areas N₁ and N₂ ).

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

68. Sand down inert gas welds until flat (areas N₁ and N₂ ).
69. Solder surfaces of A-pillar panel (1) with body solder, and smooth (area N₁ ).
70. Remove solder residues and grinding dust.

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71. Install mounting consoles (2) and fix in place.
72. Drill rivet holes Ø 6.7 mm in mounting consoles (2) using a drill bit for high-strength steels (areas Y₁ , Y₂ and Y₃ ).
73. Remove mounting console (2).
74. Deburr rivet holes on mounting console (2) on both sides.
75. Remove drilling chips.

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

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

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77. Install mounting console (2), fit and fix in place.
78. Rivet mounting console (2) with Ø 6.4 x 12 blind rivets (areas V₁ ).
79. Rivet mounting console (2) with Ø 6.5 x 12.5 blind rivets (areas V₂ , V₃ and V₄ ).

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80. Mounting consoles (2) (areas W₁ , W₂ , W₃ and W₄ ).
81. Arrest transitions at crimped edge for seals with vise grip pliers until the 2-component adhesive has cured.
82. Mounting consoles (2) (areas Z₁ , Z ₂ , Z₃ and Z₄ ).