Remove/install C-pillar

AR63.20-P-0500ES

Remove/install C-pillar

09.03.2020

Model

212.2, 218.9

1

Outer C-pillar

2

Inner C-pillar



Remove

 Danger

The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases

Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system.

AS00.00-Z-0007-01A

 Warning

Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes

Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only.

AS00.00-Z-0016-01A

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

General information on body repair

AH60.00-N-0001-01A

Topical note

Measures for preventing damage to vehicles or components when performing electric welding work

AH00.00-N-0005-01A

Topical note

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

General information on MB materials

AH98.00-P-9409-03A

1

Prepare all workshop equipment and commercially available tools required for repair

2

Remove all detachable parts in repair area

3

Cover all detachable parts remaining in vehicle with welding protection blankets

 Commercially available devices/tools
Weld protection blanket

4

Equip straightening bench with module members, cross members and straightening tool set



000 588 01 23 00 Body straightening system

WS60.00-P-0023K

 Observe set-up plans provided.

5

Lift vehicle with 2-post lifting platform



000 588 00 80 00 Vehicle lift

WS00.00-P-0040B

6

Set vehicle onto straightening bench

7

Fasten vehicle to straightening bench

8

Remove fender

Model 212.2

AR63.50-P-1400ES

Model 218.9

AR63.50-P-1400ELX

9

Remove C-pillar

Model 212.2

AR63.20-P-0500-01ES

Model 218.9

AR63.20-P-0500-01ELX

 Commercially available devices/tools
Spot weld milling machine
Body jig saw
Rotary wire brush
Heat gun
Wet and dry vacuum cleaner

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

 Spot weld milling cutter

*201589005100

10

Prepare C-pillar for installation

Model 212.2

AR63.20-P-0500-02ES

Model 218.9

AR63.20-P-0500-02ELX

 Commercially available devices/tools
Spot weld milling machine
Body jig saw
Rotary wire brush

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

 Spot weld milling cutter

*201589005100



Install

11

Install C-pillar

Model 212.2

AR63.20-P-0500-03ES

Topical note

General information on riveting

AH60.00-P-0003-01N

Model 218.9

AR63.20-P-0500-03ELX

 Commercially available devices/tools
Blind rivet tool
Locking pliers
Rotary wire brush
Multifunction unit (spot welding)

Blind rivet 6.512.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)

*BR00.45-Z-1012-13A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

Gap dimension MODEL 212.2Gap dimension

*BE60.00-P-1004-01U

Gap dimension MODEL 212.2Gap dimension

*BE60.00-P-1005-01U

Gap dimension MODEL 218.9Gap dimension

*BE60.00-P-1004-01O

Gap dimension MODEL 218.9Gap dimensions

*BE60.00-P-1005-01O

 Feeler gauge

*129589032100

For measuring points of gap dimensions on body see:



Gap dimensions on hoods, doors and lids

Model 212.2

AR60.00-P-0700-01EW

Model 218.9

AR60.00-P-0700-01EL

12

Install fender

Model 212.2

AR63.50-P-1400ES

Model 218.9

AR63.50-P-1400ELX

13

Unfasten vehicle from straightening bench

14

Lift vehicle with 2-post lifting platform



000 588 00 80 00 Vehicle lift

WS00.00-P-0040B

15

Remove straightening bench

16

Clean weld joints and sheet metal flanges with rotary wire brush

 Commercially available devices/tools
Rotary wire brush

17

Clean repair area

 Commercially available devices/tools
Wet and dry vacuum cleaner

 Danger

Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.

No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

18

Prime repair area using primer filler

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

 Use only primer filler approved by Daimler AG.

http://portal.aftersales.i.daimler.com

19

Seal seam following repairs

Model 212.2

AR97.10-P-4000EW

Model 218.9

AR97.10-P-4000EL

 Supplement standard sealant with sealant.

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

 Danger

Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.

No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

20

Paint repair areas and adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

 Use only paints approved by Daimler AG.

http://portal.aftersales.i.daimler.com

 Danger

Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents

Never spray corrosion protection on flames or hot, glowing objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection.

AS97.00-Z-0001-01A

21

Add cavity preserving agent

Topical note

Notes on cavity preservation

AH97.20-P-0001-01B



000 588 00 72 00 Sealing and corrosion protection gun

WS97.00-P-0001B

Cavity preservation (free of solvents), 1 liter

*BR00.45-Z-1003-05A

22

Remove welding protection blankets

 On all covered parts remaining in vehicle.

23

Install all detachable parts in area to be repaired

Test values for gap dimensions on hoods, doors and lids

Number

Designation

Model 218.9

BE60.00-P-1004-01O

Gap dimension

Fuel filler flap

Dimension "N"

mm

3,0 (-0,5/+1)

Picture

AR60.00-P-0700-01EL

Check values for gap dimensions

Number

Designation

Model 212.2

BE60.00-P-1004-01U

Gap dimension

Fuel filler flap (circumference)

Dimension "Q"

mm

3 (+1/-0,5)

Picture

AR60.00-P-0700-01EW

Test values for gap dimensions on hoods, doors and lids

Number

Designation

Model 218.9

BE60.00-P-1005-01O

Gap dimensions

Liftgate to roof (spoiler removed)

Dimension "R1"

mm

10 (1,5)

Spoiler to roof

Dimension "R2"

mm

5,0 (1,5)

Liftgate to rear fender

Dimension "P"

mm

4,5 (1)

Liftgate to taillamp

Dimension "V"

mm

5,0 (1)

Liftgate to bumper

Dimension "W"

mm

6,0 (1,5)

Rear window and D-pillar

Dimension "X"

mm

4,5 (1,5)

Rear window to liftgate, bottom

Dimension "Y"

mm

3,0 (0,5)

Check values for gap dimensions

Number

Designation

Model 212.2

BE60.00-P-1005-01U

Gap dimension

Liftgate to roof

Dimension "R"

mm

–

Liftgate to roof (spoiler removed)

Dimension "R1"

mm

9,5 (1,5)

Spoiler to roof

Dimension "R2"

mm

5 (1,5)

Liftgate to rear fender

Dimension "S"

mm

4 (+1,5/-1)

Liftgate to taillamp

Dimension "T"

mm

–

Liftgate to bumper

Dimension "U"

mm

6 (1,5)

Liftgate to D-pillar

Dimension "V"

mm

–

Rear window and D-pillar

Dimension "X"

mm

–

Top sliding roof to roof

Dimension "Y"

mm

5 (1,5)

Rear window to liftgate, bottom

Dimension "Z"

mm

3 (1,5)

Picture

-

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1003-05A

Cavity preservation (free of solvents), 1 liter

A 000 986 72 70 10

BR00.45-Z-1012-13A

Blind rivet 6.512.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)

A 004 990 16 97

BR00.45-Z-1041-01A

Seam sealant, sprayable 310 ml

A 002 989 84 20

BR00.45-Z-1092-02A

Adhesive kit, body, 2-component adhesive

A 012 989 17 71