Replace complete B-pillar

AR63.20-P-1350QA

Replace complete B-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



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



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 left front door

2

Remove left front seat

3

Remove floor mats

4

Remove rear seat and rear seat backrest

5

Remove or detach electric lines and vacuum lines in areas to be repaired

6

Remove detachable parts in area to be repaired

7

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

Tarp (fire-resistant)

8

Equip straightening bench with modular or crossmembers and straightening tools

Observe set-up plans enclosed!

Passenger car straightening system (Celette)

gotis://K_60-65_02.0

Accessories for straightening systems (Celette)

gotis://K_60-65_04.1

Straightening systems for passenger cars (Car Bench)

gotis://K_60-65_03.0

Straightening system accessories (Car Bench)

gotis://K_60-65_04.2

9

Set vehicle onto straightening bench using two-post lift and fasten

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



General information on body repair

AH60.00-N-0001-01A

10

Set up side portal frame with inspection and welding device

Observe set-up plans enclosed!

 Side portal frame

*210589172300

 Inspection and welding device

*203589002300

 Inspection and welding device

*209589002300

11

Remove welding panel on side longitudinal member

Shown on model 209.3

AR63.30-P-1500Q

12

Remove rear fender

AR63.50-P-1400QA

13

Cut outer B-pillar with side longitudinal member

AR63.20-P-1370-01QA

 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)

Cutting disk, dia. 65 mm, 80m/s (max. 23,500 rpm)

Drill
gotis://K_58.1_04.0

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

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

Body jig saw
gotis://K_58.1_01.0

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

14

Cut off inner B-pillar

AR63.20-P-1350-01QA

 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)

Cutting disk, dia. 65 mm, 80m/s (max. 23,500 rpm)

Drill
gotis://K_58.1_04.0

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

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

Body jig saw
gotis://K_58.1_01.0

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

15

Prepare outer B-pillar with side longitudinal member

AR63.20-P-1370-04QA

Cutting disk, dia. 65 mm, 80m/s (max. 23,500 rpm)

Round wire brush, braided, dia. 70 mm

Abrasive disk, dia. 115 mm, 80m/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

Body jig saw
gotis://K_58.1_01.0

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

16

Prepare inner B-pillar for installation

AR63.20-P-1350-02QA

Beading pliers

Round wire brush, braided, dia. 70 mm

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

Cutting disk, dia. 65 mm, 80m/s (max. 23,500 rpm)

Drill
gotis://K_58.1_04.0

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

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

Body jig saw
gotis://K_58.1_01.0

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

17

Install inner B-pillar

AR63.20-P-1350-03QA



General information on riveting

AH60.00-P-0003-01N

 Side portal frame

*210589172300

 Inspection and welding device

*209589002300

 Inspection and welding device

*203589002300

Round wire brush, braided, dia. 70 mm

Electrode miller

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

Hand riveter

Clamping pliers

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

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

Polygrip flat/round head rivet, 6.4 x 14

*BR00.45-Z-1001-13A

Polygrip countersunk-head rivet, 6.414

*BR00.45-Z-1002-13A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

18

Install outer B-pillar with side longitudinal member

AR63.20-P-1370-05QA

 Side portal frame

*210589172300

 Inspection and welding device

*209589002300

 Inspection and welding device

*203589002300

Round wire brush, braided, dia. 70 mm

Electrode miller

Clamping pliers

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

Cutting disk, dia. 65 mm, 80m/s (max. 23,500 rpm)

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

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

19

Install rear fender

AR63.50-P-1400QA

20

Install welding on side longitudinal member

 Shown on model 209.3

AR63.30-P-1500Q

21

Release vehicle from straightening bench and lift with two-column lift, remove straightening bench

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

22

Clean weld joints and metal flanges with wire brush

23

Clean repair areas and prime using primer filler

24

Seam sealing following repair

Supplement standard sealant using MB preservative.

AR97.10-P-4000Q

Sealant

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

25

Paint repair areas and adjacent surfaces

26

Cavity preservation following repair work

AR97.20-P-1500Q

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



Notes on cavity preservation

AH97.20-P-0001-01B

27

Install electric lines and vacuum lines in repair area

28

Install left front seat

29

Remove rear seat and rear seat backrest

30

Install floor mats

31

Install left front door

32

Install all removed detachable parts

Number

Designation

Order number

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1041-01A

Seam sealant, sprayable 310 ml

A 002 989 84 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

BR00.45-Z-1002-13A

Polygrip countersunk-head rivet, 6.414

A 003 990 86 97 05