Remove/install D-pillar

AR63.20-P-2000ES

Remove/install D-pillar

09.03.2020

Model

212.2, 218.9

Shown on model 212.2

1

Outer D-pillar

2

Inner D-pillar

 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

 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

 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

 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

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

General information on MB materials

AH98.00-P-9409-03A



Remove

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
Welding 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 two-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 rear end assembly reinforcement

Type with reinforcements

AR64.20-P-1020-01ESA

 Remove only reinforcement on damaged vehicle side.

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

10

Separate D-pillar

Model 212.2

AR63.20-P-2000-01ES

Model 218.9

AR63.20-P-2000-01ELX

 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

11

Preparing D-pillar for installation

Model 212.2

AR63.20-P-2000-02ES

Model 218.9

AR63.20-P-2000-02ELX

 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



Install

12

Install D-pillar

Model 212.2

AR63.20-P-2000-03ES

General information on riveting

AH60.00-P-0003-01N

Model 218.9

AR63.20-P-2000-03ELX

 Commercially available devices/tools
Inert gas welder
Spot welder
Vise grip pliers
Rotary wire brush

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-1002-01U

Gap dimension MODEL 212.2Gap dimension

*BE60.00-P-1005-01U

Gap dimension MODEL 218.9Gap dimension

*BE60.00-P-1002-01O

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

13

Install fender

Model 212.2

AR63.50-P-1400ES

Model 218.9

AR63.50-P-1400ELX

14

Unfasten vehicle from straightening bench

15

Lift vehicle with two-post lifting platform



000 588 00 80 00 Vehicle lift

WS00.00-P-0040B

16

Remove straightening bench

17

Clean weld joints and sheet metal flanges with rotary wire brush

 Commercially available devices/tools
Rotary wire brush

18

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

19

Prime repair area using primer filler

Notes on paintwork repairs

AH98.00-P-9408-02A

 Paints to be used must be approved by Daimler AG.

http://portal.aftersales.i.daimler.com

20

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

21

Paint repair areas and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408-02A

 Paints to be used must be 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

22

Add cavity preserving agent

Model 212.2, 218.9

Notes on cavity preservation

AH97.20-P-0001-01B

Model 218.9

AR97.20-P-1500EL



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

23

Remove welding protection blankets

 On all covered parts remaining in vehicle.

24

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-1002-01O

Gap dimension

Fender to A-pillar

Dimension "D"

mm

3,5 (1)

Front door to fender

Dimension "E"

mm

4,0 (-0,5/+1)

Front door to rear door

Dimension "F"

mm

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

B-pillar cover to front window

Dimension "G"

mm

10 (1)

B-pillar cover to rear window

Dimension "H"

mm

10 (1)

Rear door to side piece, bottom

Dimension "I"

mm

4,5 (1)

Fixed window on rear door to fixed window on rear side window

Dimension "O"

mm

7,5 (1)

Picture

AR60.00-P-0700-01EL

Check values for gap dimensions

Number

Designation

Model 212.2

BE60.00-P-1002-01U

Gap dimension

Front door to fender

Dimension "G"

mm

4 (+1/-0,5)

Front door to rear door

Dimension "H"

mm

4,5 (+1/-0,5)

Front door to roof frame

Dimension "I"

mm

14 (1,5)

Rear door to roof frame

Dimension "J"

mm

13 (1,5)

Rear door to side piece, bottom

Dimension "K"

mm

4 (+1/-0,5)

Driver door cover to rear door cover

Dimension "W"

mm

4 (1)

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