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Side portal frame
The next steps are shown on the left side of the vehicle in model 177.0. In case of damage on the right side of the vehicle, these steps must be performed analogously.
The superordinate service document as well as the safety information in the service document must be observed.
1 | Install and fit A-pillar inner section. |
2 | Install and fit A-pillar reinforcement using the side portal frame and the portal straightener. |
Use spacers. |
3 | Remove the portal straightener and A-pillar reinforcement. |
4 | Remove A-pillar inner section. |
5 | Apply 2-component adhesive to the body in the cross-hatched areas (areas A, B). |
Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive. |
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6 | Install and fix in place A-pillar inner section (2). |
7 | A-pillar inner section (2) (areas C1, C2, C3, C4, C5). |
8 | A-pillar inner section (2) (areas D1, D2). |
Perform inert gas welding at intervals and allow to cool down in between. This reduces heat distortion. |
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9 | Install, fit and fix in place half of connecting panel (3) in roof frame reinforcement (4). |
Dimensions: |
10 | Drill rivet holes in roof frame reinforcement (4) and connecting panel (3) with Ø 6.7 mm (areas E, F). |
During drilling, ensure that drill bit does not bore too far into connecting panel (3). |
Dimensions: |
11 | Install A-pillar reinforcement (1) with portal straightener, fit and fix in place. |
Use spacers. |
12 | Drill rivet holes in A-pillar reinforcement (1) and connecting panel (3) with Ø 6.7 mm (areas G, H). |
During drilling, ensure that drill bit does not bore too far into connecting panel (3). |
Dimensions: |
13 | Remove A-pillar reinforcement (1) with the portal straightener. |
14 | Remove connecting panel (3). |
15 | Deburr rivet holes in A-pillar reinforcement (1), connecting panel (3) and in roof frame reinforcement (4) on both sides. |
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16 | Apply 2-component adhesive to connecting panel (3) in cross-hatched area. |
Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive. |
17 | Install, fit and fix in place half of connecting panel (3) in roof frame reinforcement (4). |
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18 | Clean contact surfaces of foam part on A-pillar inner section (2) and apply sealant in the cross-hatched area (area J). |
19 | Apply 2-component adhesive to the body in the cross-hatched areas (areas I1, I2, I3). |
Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive. |
20 | Install A-pillar reinforcement (1) with the portal straightener and fix in place. |
Use spacers. |
21 | Rivet connecting panel, A-pillar reinforcement (1) and roof frame reinforcement with rivet Ø 6.5x12.5 (areas K). |
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22 | A-pillar reinforcement (1) (area L). |
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23 | A-pillar reinforcement (1) (areas M1, M2). |
24 | A-pillar reinforcement (1) (areas N1, N2, N3). |
25 | A-pillar reinforcement (1) (area O1). |
Perform inert gas welding at intervals and allow to cool down in between. Reduces heat distortion. |
26 | Grind inert gas welds on A-pillar reinforcement (1) flat (area O1). |
Only grind flat on beaded areas and contact surfaces of A-pillar reinforcement (1) (area O1). |
27 | Clean welding areas which are no longer accessible after installing upper front longitudinal member and A-pillar paneling and coat with zinc dust paint. |
28 | Remove portal straightener and side portal frame. |
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