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

Model 167 

G13669308Courtesy of MERCEDES-BENZ USA

IMPORTANT The next steps are to be performed on model 167.1 on the left side of the vehicle and must be performed analogously on the right side. The higher-level service document as well as the safety information in the service document must be observed.

  1. Install and fit A-pillar inner panel (7).
  2. Install and fit longitudinal member outer shell using the straightener.
  3. Install and fit lower part of A-pillar reinforcement using the SPECIAL TOOL side portal frame and the portal straightener.

    IMPORTANT Use spacers.

  4. Install, fit and fix in place upper part of A-pillar reinforcement.
  5. Fix A-pillar inner panel (7) in place.
  6. Remove upper part of A-pillar reinforcement.
  7. Remove portal straightener and the lower part of the A-pillar reinforcement.
  8. Remove straightener and longitudinal member outer shell.
  9. Drill 6.7 mm-diameter rivet holes in the A-pillar inner panel (7) through the existing holes in the body (area A).
  10. Remove A-pillar inner panel (7).
  11. Deburr rivet holes on A-pillar inner panel (7) and body on both sides.
  12. Remove drill chips.
  13. Coat insides of riveted joints with zinc dust paint.
    G14791505Courtesy of MERCEDES-BENZ USA
  14. Install A-pillar inner panel (7) and fix in place.
  15. Rivet A-pillar inner panel (7) with rivets Ø 6.5x12.5 (area B).
  16. A-pillar inner panel (7) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas C).
  17. A-pillar inner panel (7) SHIELDED GAS SEAM WELD (areas D).

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

  18. Surface grind inert gas welds on the A-pillar inner panel (7) (areas D).
  19. Clean weld joints that will no longer be accessible after installing the lower part of the A-pillar reinforcement and the longitudinal member outer shell and coat with zinc dust paint.
    G14791506Courtesy of MERCEDES-BENZ USA
  20. Install reinforcement (6), fit and fix in place.
  21. Drill 6.7 mm-diameter rivet holes in reinforcement (6) (areas E).
  22. Remove reinforcement (6).
  23. Deburr rivet holes in reinforcement (6) and body on both sides.
  24. Remove drill chips.
  25. Coat insides of riveted joints with zinc dust paint.
    G14791507Courtesy of MERCEDES-BENZ USA
  26. Apply sealant in cross-hatched areas to foam part on reinforcement (6) on both sides.
    G14791508Courtesy of MERCEDES-BENZ USA
  27. Install reinforcement (6) and fix in place.
  28. Rivet reinforcement (6) using 6.5x12.5-diameter rivets (areas F1 ).
  29. Rivet reinforcement (6) using 6.5x14.5-diameter rivet (area F2 ).
  30. Reinforcement (6) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas G).
  31. Reinforcement (6)SHIELDED GAS SEAM WELD (area H).

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

  32. Clean weld joints that will no longer be accessible after installing the longitudinal member outer shell and coat with zinc dust paint.
    G14791509Courtesy of MERCEDES-BENZ USA
  33. Install, fit and fix in place connecting panel (8).

    IMPORTANTDimensions:  w = approx. 90 mm

  34. Drill 6.7 mm-diameter rivet holes in body through the pre-drilled holes in the connecting panel (8) (area W).
  35. Remove connecting panel (8).
  36. Deburr rivet holes in connecting panel (8) and body on both sides.
  37. Remove drill chips.
    G14791510Courtesy of MERCEDES-BENZ USA
  38. Apply 2-component adhesive to the inner side of the connecting panel (8).

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

  39. Install connecting panel (8) and fix in place.
  40. Rivet connecting panel (8) from the inside using 6.5x14.5 mm-diameter rivets (areas J).
    G14791511Courtesy of MERCEDES-BENZ USA
  41. Install connecting panel (5), fit and fix in place.

    IMPORTANT Be sure that the connecting panel (5) overlaps the body by approx. 60 mm.

  42. Mark rivet holes on body.

    IMPORTANTDimensions: 

    k1 = approx. 20 mm

    k2 = approx. 17 mm

    k3 = approx. 20 mm

    k4 = approx. 18 mm

  43. Drill 6.7 mm-diameter rivet holes in body and connecting panel (5) at the marked positions and countersink.

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

    Water drain hose in body will otherwise be damaged.

  44. Remove connecting panel (5).
  45. Deburr rivet holes in connecting panel (5) and body on both sides.
  46. Remove drill chips.
    G14791512Courtesy of MERCEDES-BENZ USA
  47. Apply 2-component adhesive to half of the outer side of the connecting panel (5).

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

  48. Fix connecting panel (5) in place using manual temporary fasteners.
  49. Rivet connecting panel (5) using 6.4x15.5 mm-diameter countersunk-head blind rivet (areas L).
    G14791513Courtesy of MERCEDES-BENZ USA
    G14791514Courtesy of MERCEDES-BENZ USA
  50. Install outer longitudinal member shell (2) using the straightener and fix in place.
  51. Install lower part of A-pillar reinforcement (3) using the SPECIAL TOOL side portal frame and the portal straightener, fit and fix in place.

    IMPORTANT Use spacers.

  52. Install upper part of A-pillar reinforcement (4), fit and fix in place.
  53. Mark rivet holes on upper part of A-pillar reinforcement (4).

    IMPORTANTDimensions: 

    m1 = approx. 20 mm

    m2 = approx. 17 mm

    m3 = approx. 20 mm

    m4 = approx. 18 mm

  54. Drill 6.7 mm-diameter rivet holes in the upper part of the A-pillar reinforcement (4) at the marked positions and countersink.

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

    Water drain hose in body will otherwise be damaged.

  55. Drill 6.7 mm-diameter rivet holes in the upper part of A-pillar reinforcement (4) and lower part of A-pillar reinforcement (3) (areas N).
  56. Remove upper part of A-pillar reinforcement (4).
  57. Remove portal straightener and lower part of A-pillar reinforcement (3).
  58. Remove straightener and longitudinal member outer shell (2).
  59. Deburr rivet holes on upper part of A-pillar reinforcement (4), lower part of A-pillar reinforcement (3), longitudinal member outer shell (2), connecting panel and body on both sides.
  60. Remove drill chips.
  61. Apply sealant to foam parts on longitudinal member outer shell (2) in cross-hatched areas.
    G14791515Courtesy of MERCEDES-BENZ USA
  62. Install foam piece duct using sealing compound (area O1 ).
  63. Apply sealing compound to the outside of the foam piece duct (area O2 ).
  64. Apply sealant to foam part in cross-hatched area (area O3 ).
  65. Apply 2-component adhesive to the body in the cross-hatched areas (areas O1 )

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

    G14791516Courtesy of MERCEDES-BENZ USA
  66. Install outer longitudinal member shell (2) using the straightener and fix in place.
  67. Install lower part of A-pillar reinforcement (3) and fix in place.
  68. Apply 2-component adhesive on upper part of A-pillar reinforcement (4) in cross-hatched area.
  69. Install upper part of A-pillar reinforcement (4) and fix in place.

    IMPORTANT Use spacers.

    G14791517Courtesy of MERCEDES-BENZ USA
    G14791518Courtesy of MERCEDES-BENZ USA
  70. Rivet upper part of A-pillar reinforcement (4) using 6.4x15.5-diameter countersunk-head blind rivets (areas P2 ).
  71. Rivet lower part of A-pillar reinforcement (3) using 6.5x12.5-diameter rivets (areas P3 ).
  72. Rivet lower part of A-pillar reinforcement (3) using 6.5x14.5-diameter rivets (areas P1 ).
  73. Longitudinal member outer shell (2), lower part of A-pillar reinforcement (3) and upper part of A-pillar reinforcement (4) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas Q).
  74. Lower part of A-pillar reinforcement (3) and longitudinal member outer shell (2) SHIELDED GAS SEAM WELD (areas R1 , R2 ).

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

  75. Surface grind inert gas welds an lower part of A-pillar reinforcement (3) and longitudinal member outer shell (2) (areas R1 , R2 ).

    IMPORTANT Surface-grind only fold areas and contact surfaces of A-pillar paneling (area R2 ).

    G14791519Courtesy of MERCEDES-BENZ USA
  76. Rivet longitudinal member outer shell (2) using 6.5x12.5-diameter rivets (area T).
  77. Longitudinal member outer shell (2)POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area U).
  78. Longitudinal member outer shell (2)SHIELDED GAS SEAM WELD (area V).

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

  79. Longitudinal member outer shell (2)SHIELDED GAS PLUG WELD (area S).
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