Replace B-pillar with side longitudinal member

AR63.20-P-0550SC

Replace B-pillar with side longitudinal member

11.11.11



Removing

 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 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 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



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

AH00.00-N-0005-01A



General information on body repair

AH60.00-N-0001-01A



Pretreatment of bonding surfaces

AH60.00-P-0008-01SX



General information on repair of vehicles with ultra-strength steels.

Failure to observe instructions when straightening/repairing, separating, preparing adhesive points, joining/connecting, resistance spot welding, MIG welding, MIG brazing can lead to considerable damage to ultra-strength steels and their joints.

AH60.00-P-0024-01N



Notes on paintwork repairs

AH98.00-P-9408-02A



Notes on various body materials

AH60.00-P-0011-01SX



General information on body connection techniques

AH60.00-P-0015-01SX



General information on MB materials

AH98.00-P-9409-03A

1

Remove detachable parts in repair area and cover all remaining detachable parts remaining in the vehicle using a tarp (fire-resistant)

Tarp (fire-resistant)

Vehicle protection cover/workstation and sandblaster
gotis://K_91-97_03.0

2

Remove rear fender

AR63.50-P-1400SC

3

Set up straightening bench with straightening bracket set and attach vehicle

 Observe setup plans.

Setup plans

Passenger car straightening systems

gotis://K_60_65_02

4

Separate B-pillar with side longitudinal member

 For body repair use familiar tools approved by Daimler AG.

AR63.20-P-0550-01SC

Needle template
gotis://K_58.3_09.0

BTR Usibor milling cutter

Drill bit and milling cutter for high-strength steels (USIBOR) and rivets
gotis://K_58.3_13.0

5

Prepare B-pillar with side longitudinal member for installation

 For body repair use familiar tools approved by Daimler AG.

AR63.20-P-0550-04SC

Needle template
gotis://K_58.3_09.0



Install

6

Install side portal frame

 Observe setup plans.

 Side portal frame

*210589172300

 Welding device

*216589002300

 Inspection and welding device

*221589002300

Setup plans

Passenger car straightening systems

gotis://K_60_65_02

7

Install and weld in B-pillar with side longitudinal member

 For body repair use familiar tools approved by Daimler AG.
Observe setup plans.

AR63.20-P-0550-03SC

Setup plans

Passenger car straightening systems

gotis://K_60_65_02

Adjust gap dimensions on hoods, doors and lids

AR60.00-P-0700-01SC

Front door to rear fender

*BE60.00-P-1002-01T

Trunk lid to upper rear fender, trunk lid to taillamp, rear fender to taillamp

*BE60.00-P-1003-01T

Fuel filler flap

*BE60.00-P-1004-01T

Feeler gauge

*129589032100

 Inspection and welding device

*221589002300

Needle template
gotis://K_58.3_09.0

BTR Usibor drill bit, dia. 6.7 mm

Drill bit and milling cutter for high-strength steels (USIBOR) and rivets
gotis://K_58.3_13.0

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

Blind rivet tool 571110

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

Notes on brazing materials

Rivet

*BR00.45-Z-1001-13A

Adhesive

*BR00.45-Z-1092-02A

Rivet

*BR00.45-Z-1012-13A

Rivet

*BR00.45-Z-1016-13A



General information on riveting

AH60.00-P-0003-01N

8

Remove side portal frame with check and welding devices

 Side portal frame

*210589172300

 Welding device

*216589002300

 Inspection and welding device

*221589002300

9

Install rear fender

AR63.50-P-1400SC

10

Loosen vehicle and remove from straightening bench

11

Clean repair areas and prime using primer filler

12

Carry out seam sealing after repairs

 Supplement standard sealants with MB body sealant.

AR97.10-P-4000SX

13

Paint repair areas and adjacent surfaces

AR98.00-P-0150SX

14

Apply additional cavity preservation

AR97.20-P-1500SC

15

Remove tarp (fire-resistant) and install all detachable parts in the area of repair point

Number

Designation

Model
216 up to
model year 2011

Model
216 as of
model year 2011

BE60.00-P-1002-01T

Gap dimension

Front door to fender

Dim. "E"

mm

4.0 (0.5)

4.0 (0.5)

Front door to rear fender

Dim. "F"

mm

4.0 (0.5)

4.0 (0.5)

Front fender to A-pillar

Dim. "G"

mm

3.5 (0.5)

3.5 (0.5)

Front fender to headlamp

Dim. "H"

mm

3.5 (0.5)

3.5 (0.5)

See picture

AR60.00-P-0700-01SC

AR60.00-P-0700-01SC

BE60.00-P-1003-01T

Gap dimension

Trunk lid to rear fender, top

Dim. "J"

mm

3.5 (0.8)

3.5 (0.8)

Trunk lid to rear lamp unit

Dim. "K"

mm

3.5 (0.8)

3.5 (0.8)

Trunk lid to bumper

Dim. "L"

mm

5.5 (1.5)

5.5 (1.5)

Rear fender to lamp unit

Dim. "M"

mm

2.5 (0.5)

2.5 (0.5)

See picture

AR60.00-P-0700-01SC

AR60.00-P-0700-01SC

BE60.00-P-1004-01T

Gap dimension

Fuel filler flap

Dim. "O"

mm

3.0 (0.5)

3.0 (0.5)

See picture

AR60.00-P-0700-01SC

AR60.00-P-0700-01SC

Number

Designation

Order number

BR00.45-Z-1001-13A

Blind rivet 6.414

A 003 990 35 97

BR00.45-Z-1092-02A

Adhesive kit, body, 2-component adhesive

A 009 989 36 71

BR00.45-Z-1012-13A

Blind rivet 6.512.5

A 004 990 16 97

BR00.45-Z-1016-13A

Blind rivet, 6.5 x 14.5

A 004 990 17 97