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Home >> Mercedes Benz >> 2004 >> CLK320 2D Convertible >> Repair and Diagnosis >> Collision >> General Collision Information >> Side Wall -- Testing & Repair -- 209 Chassis - 1 Of 3 >> Testing & Repair >> Replace complete A-pillar together with side longitudinal member - AR63.20-P-1150 >> Replace complete A-pillar together with side longitudinal member - AR63.20-P-1150Q >> Separate A-pillar with side longitudinal member - AR63.20-P-1150-01Q

Separate A-pillar with side longitudinal member - AR63.20-P-1150-01Q

Fig 1: Identifying Spot Weld Cutter (201 589 00 51 00)
G04959021Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1002-01A Ball cutter, dia. 12 mm
WH58.30-Z-1006-01A Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1001-03A Round wire brush, braided, dia. 70 mm
WH58.30-Z-1021-04A Cutting disk, dia. 65 mm, 80 m/s (max. 23, 500 RPM)
WH58.30-Z-1024-04A Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM)
WORKSHOP EQUIPMENT

WE58.40-Z-1001-03A Drill (electric/pneumatic)
WE58.40-Z-1002-03A Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A Body saw (electric/pneumatic)
WE58.40-Z-1005-03A Wet/dry vacuum cleaner
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
Fig 2: Identifying Cutting And Welding Area
G04959022Courtesy of MERCEDES-BENZ USA
  1. Expose spot welds and cut out with spot weld cutter (areas G and H).
  2. Expose spot welds and cut out with spot weld cutter (area P).

    IMPORTANT Only mill off weld spots which are welded to the inner A-pillar.

    Fig 3: Identifying Cutting And Welding Area
    G04959023Courtesy of MERCEDES-BENZ USA
    Fig 4: Identifying Cutting And Welding Area
    G04959024Courtesy of MERCEDES-BENZ USA
  3. Expose spot welds and cut out with spot weld cutter (areas A, B, J, K and Q).
  4. Remove cover plate from longitudinal member.
    Fig 5: Identifying Welding Spot Area
    G04959025Courtesy of MERCEDES-BENZ USA
  5. Expose spot welds and cut out with spot weld cutter (area R).
    Fig 6: Identifying Mark And Welding Area
    G04959026Courtesy of MERCEDES-BENZ USA
  6. Mark separation points (areas I, L and M).

    IMPORTANT Dimension a approx. 40 mm. Dimension b approx. 70 mm. Measure separation point I of new part.

  7. Separate paneling (areas L and M).
  8. Remove section of paneling.
  9. Expose spot welds and cut out with spot weld cutter (area O).
  10. Separate outer longitudinal member (area I).
  11. Remove outer A-pillar.
    Fig 7: Identifying Cutting And Welding Spot Area
    G04959027Courtesy of MERCEDES-BENZ USA
  12. Expose spot welds and cut out with spot weld cutter (areas C, D, E, S, U, V, W, X and Y).
  13. Remove bracket for paneling.
    Fig 8: Identifying Welding Spot Area
    G04959028Courtesy of MERCEDES-BENZ USA
  14. Expose spot welds and cut out with spot weld cutter (area T).
  15. Remove inner A-pillar.
    Fig 9: Identifying Grinding Area
    G04959029Courtesy of MERCEDES-BENZ USA
  16. Grind connection surfaces down to bare metal in shaded areas. Sand spot weld flanges to bare metal on both sides
  17. Remove grinding and drilling chips with wet/dry vacuum cleaner.
  18. Coat insides of spot welding flanges and riveted joint with zinc dust paint..
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