Remove/install D-pillar

AR63.20-P-2000TA

Remove/install D-pillar

18.11.11



Removing

 Danger!

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

 Danger!

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

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

AS00.00-Z-0010-01A

 Danger!

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding splatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes.

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

AS00.00-Z-0007-01A

 Danger!

Risk of explosion as fuel vapors can ignite. Risk of poisoning from inhaling fuel vapors and exposed handling of fuel. Risk of injury if fuel splashes hit the eyes.

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A



General information on body repair

All models

AH60.00-N-0001-01A



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

All models

AH00.00-N-0005-01A



Guidelines for removing fuel tank when performing welding work on bodies

All models

AH60.00-P-3000-01Z



Notes on paintwork repairs

All models

AH98.00-P-9408-02A



General information on MB materials

All models

AH98.00-P-9409-03A

1

Remove detachable parts in area to be repaired

2

Cover all detachable body components remaining in vehicle (area to be repaired)

Tarp (fire-resistant)

3

Remove outer side wall

AR63.10-P-0805TA

4

Remove C and D-pillar connecting panel.

AR63.20-P-0500-04TA

5

Separate D-pillar

AR63.20-P-2000-01TA

 Spot weld milling cutter

*201589005100

Vario Drill WS 91 spot weld removing tool

Ball cutter, dia. 12 mm

Round wire brush, braided, dia. 70 mm

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

Drill
gotis://K_58.1_04.0

Straight grinder
gotis://K_58.0_03.0

Angle grinder
gotis://K_58.1_07.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Tarp (fire-resistant)

Two-post lifting platform 3.0-3.5 t, electromechanical
gotis://H_00.1_01.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

6

Preparing D-pillar for installation

AR63.20-P-2000-02TA

 Spot weld milling cutter

*201589005100

Ball cutter, dia. 12 mm

Vario Drill WS 91 spot weld removing tool

Round wire brush, braided, dia. 70 mm

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

Drill
gotis://K_58.1_04.0

Straight grinder
gotis://K_58.0_03.0

Angle grinder
gotis://K_58.1_07.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

7

Prepare C and D-pillar connecting panel

AR63.20-P-0500-05TA



Install

8

Fit D-pillar, rear fender, roof and trunk lid

9

Adjust gap dimensions on hoods, doors and lids

AR60.00-P-0700-01TA

Rear fender and taillamp

*BE60.00-P-1003-01F

Taillamp in rear-end door to taillamp

*BE60.00-P-1005-01F

Rear-end door to rear fender

*BE60.00-P-1005-01F

Rear window and D-pillar

*BE60.00-P-1005-01F

Fuel filler flap

*BE60.00-P-1004-01F

Rear door to side piece, bottom

*BE60.00-P-1002-01F

Feeler gauge

*129589032100

10

Install D-pillar

AR63.20-P-2000-03TA



General information on riveting

AH60.00-P-0003-01N

 Feeler gauge

*129589032100

Electrode miller

Clamping pliers

Manual temporary fastener, dia. 6.4 mm - clamping range 0 to 15 mm, identification color silver

Blind rivet/punch riveting method
gotis://K_68-80_06.0

Hand riveter

MIG MAG gas welder (steel, brazing, aluminum)
gotis://K_60-65_17.1

Inverter spot welder
gotis://K_60-65_16.0

Drill
gotis://K_58.1_04.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Tarp (fire-resistant)

Two-post lifting platform 3.0-3.5 t, electromechanical
gotis://H_00.1_01.0

Combination pressure spray gun (corrosion protection)
gotis://K_91-97_01.0

Polygrip flat round head rivet, 6.414

*BR00.45-Z-1001-13A

MB preservative

*BR00.45-Z-1003-05A

Sealant

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

11

Clean repair areas and prime using primer filler

12

Cavity preservation following repair work

AR97.20-P-1500T



Notes on cavity preservation

Model 211

AH97.20-P-0001-01B

13

Install C and D-pillar connecting panel

AR63.20-P-0500-06TA

14

Remove/install outer sidewall

AR63.10-P-0805TA

15

Install complete center roof paneling

AR65.10-P-1000TA

16

Install detachable parts in area to be repaired

Number

Designation

Model 211.2

BE60.00-P-1002-01F

Gap dimension

Front door to A-pillar

Dim. "D"

mm

4.5 (-0.5/+1)

Front door to fender

Dim. "E"

mm

4 (-0.5/+1)

Front door to rear door

Dim. "F"

mm

4 (-0.5/+1)

Front door to roof

Dim. "G"

mm

4.5 (-0.5/+1)

Rear door to top of side section

Dim. "H"

mm

-

Rear door to side piece, bottom

Dim. "I"

mm

3.5 (-0.5/+1)

See picture

AR60.00-P-0700-01TA

BE60.00-P-1003-01F

Gap dimension

Trunk lid to rear fender, top

Dim. "J"

mm

-

Trunk lid to rear lamp unit

Dim. "K"

mm

-

Trunk lid to bumper

Dim. "L"

mm

-

Rear fender to lamp unit

Dim. "M"

mm

2.5 (1)

Trunk lid license plate panel to rear lamp unit

Dim. "N"

mm

-

See picture

AR60.00-P-0700-01TA

BE60.00-P-1004-01F

Gap dimension

Fuel filler flap

Dim. "O"

mm

3.5 (0.5)

See picture

AR60.00-P-0700-01TA

BE60.00-P-1005-01F

Gap dimension

Liftgate spoiler/roof

Dim. "P"

mm

7 (-0.5/+1)

Rear-end door to rear fender

Dim. "Q"

mm

4.5 (1)

Taillamp in rear-end door to taillamp

Dim. "R"

mm

5 (1)

Rear-end door to bumper

Dim. "S"

mm

6 (1.5)

Rear window and D-pillar

Dim. "T"

mm

4.5 (1)

Front door to roof

Dim. "U"

mm

4.5 (-0.5/+1)

See picture

AR60.00-P-0700-01TA

Number

Designation

Order number

BR00.45-Z-1041-01A

Seam sealant, sprayable 310 ml

A 002 989 84 20

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1003-05A

Cavity sealant, solvent-free (1 l container)

A 000 986 72 70 05

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42

BR00.45-Z-1001-13A

Blind rivet 6.414

A 003 990 35 97