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Home >> Mercedes Benz >> 2004 >> CLK500 2D Convertible >> Repair and Diagnosis >> Collision >> General Collision Information >> Side Wall -- Testing & Repair -- 209 Chassis - 1 Of 3 >> Testing & Repair >> Install and weld in complete A-pillar - AR63.20-P-1100 >> Install and weld in complete A-pillar - AR63.20-P-1100-10Q

Install and weld in complete A-pillar - AR63.20-P-1100-10Q

Fig 1: Identifying Inspection And Welding Device (203 589 00 23 00)
G04958974Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Inspection And Welding Equipment (209 589 00 23 00)
G04958975Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Welding Device (209 589 09 23 00)
G04958976Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Welding Device (209 589 08 23 00)
G04958977Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Side Portal Frame (210 589 17 23 00)
G04958978Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1003-01A Electrode miller
WH58.30-Z-1003-02A Clamping pliers
WH58.30-Z-1038-02A Manual temporary fastener, dia.6.4 mm - clamping range 0 -15 mm, identification color silver Firma Hausmann GmbH D-34346 Hann. Munden, Germany
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)
WH58.30-Z-1003-29A Hand riveter
WORKSHOP EQUIPMENT

WE58.40-Z-1001-02A Inert gas welder
WE58.40-Z-1002-02A Spot welder
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-1005-03A Wet/dry vacuum cleaner
WE58.40-Z-1003-14A Blind rivet tool
WE58.40-Z-1006-14A Blind rivet nut hand tool
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1003-01A Sealant 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 Preservation agent 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 Rivet A 003 990 35 97
BR00.45-Z-1002-13A Polygrip countersunk head rivet, 6.4 x 14 A 003 990 86 97 05
Fig 6: Identifying Rivet Holes Area
G04958979Courtesy of MERCEDES-BENZ USA
  1. Install inner and outer A-pillar with side portal frame, inspection and welding gauges and clamping pliers, fit and fasten.
  2. Drill dia. 6.5 mm rivet holes (areas Q and Y).
  3. Fasten inner A-pillar with manual temporary fasteners and clamping pliers.
  4. Remove side portal frame with inspection and welding gauges.
  5. Install welding panel with longitudinal member paneling, fit and fasten.
  6. Install A-pillar paneling analog to undamaged side of vehicle, fit and fasten.
  7. Drill dia. 6.5 mm rivet holes (areas G, H and AA).
  8. Remove A-pillar paneling. Countersink rivet holes from outside and deburr.
  9. Remove welding panel and outer A- pillar and deburr rivet holes on both sides.
    Fig 7: Identifying Rivet Holes Area
    G04958980Courtesy of MERCEDES-BENZ USA
    Fig 8: Identifying Rivet Holes Area
    G04958981Courtesy of MERCEDES-BENZ USA
  10. Drill dia. 6.5 mm rivet holes (areas T, U, V and Z).
  11. Drill dia. 7 mm holes (area V).
  12. Fasten inner A-pillar with manual temporary fasteners (areas W and Z).
  13. Remove inspection and welding gauge for crossmember mount (instrument panel).
  14. Install bracket for paneling with welding gauge and fasten.
  15. Drill dia. 6.5 mm rivet holes (area S).
  16. Remove inspection and welding gauge, inner A-pillar and bracket for paneling and deburr rivet holes on both sides.
    Fig 9: Identifying Polygrip Flat Head Rivets Area
    G04958982Courtesy of MERCEDES-BENZ USA
  17. Install inner A-pillar with inspection and welding gauge (instrument panel), fit and fasten with clamping pliers and manual temporary fasteners.
  18. Inner A-pillar POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area C).
  19. Inner A-pillar SHIELDED GAS PLUG WELD (area V).
  20. Rivet inner A-pillar with Polygrip flat head rivets, dia. 6.4 x 14 mm (areas U, W and Z).
    Fig 10: Identifying Windshield Area
    G04958983Courtesy of MERCEDES-BENZ USA
  21. Inner A-pillar and crossmember below windshield SHIELDED GAS PLUG WELD (area X).
  22. Inner A-pillar POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas D, E and T).
  23. Install bracket for paneling and fasten with manual temporary fasteners.
  24. Inner A-pillar and mount for paneling POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area S).
  25. Inner A-pillar POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas P and K).
  26. Rivet inner A-pillar and mount paneling with Polygrip flat head rivets, 6.4 x 14 mm dia. (area S).
  27. Clean inner welding areas with wire brush and coat with zinc dust paint.
    Fig 11: Identifying Polygrip Flat Head Rivets Area
    G04958984Courtesy of MERCEDES-BENZ USA
  28. Outer and inner A-pillar POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area R).
  29. End panel on longitudinal member POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area B).
    Fig 12: Identifying Outer And Inner A-Pillar
    G04958985Courtesy of MERCEDES-BENZ USA
    Fig 13: Identifying Polygrip Flat Head Rivets Area
    G04958986Courtesy of MERCEDES-BENZ USA
  30. Install outer A-pillar with inspection and welding gauge, clamping pliers and manual temporary fasteners and fasten.
  31. Rivet outer and inner A-pillar with Polygrip flat head rivets, 6.4 x 14 mm dia. (area J).
  32. Outer A-pillar SHIELDED GAS SEAM WELD (area Z1).
  33. Outer A-pillar SHIELDED GAS PLUG WELD (areas N and O).

    IMPORTANT Face grind inert gas weld spots on the connection surfaces (areas N and O).

  34. Remove inspection and welding gauge for A-pillar mount.
  35. Outer and inner A-pillar POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas J and K).
  36. Clean inner welding area with wire brush and coat with zinc dust paint.
    Fig 14: Identifying Rivets Area
    G04958987Courtesy of MERCEDES-BENZ USA
  37. Install A-pillar paneling and fasten with clamping pliers and manual temporary fasteners.
  38. A-pillar paneling and A-pillar POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas K and P).
  39. Rivet A-pillar paneling and A-pillar with Polygrip countersunk rivets, 6.4 x 14 mm dia. (area AA).

    IMPORTANT Countersink rivet holes beforehand.

    Fig 15: Identifying Welding Area
    G04958988Courtesy of MERCEDES-BENZ USA
  40. A-pillar paneling SHIELDED GAS STITCH WELD (area L).
  41. Outer A-pillar SHIELDED GAS STITCH WELD (area A).
  42. Grind inert gas welds down flat (areas A and L).
    Fig 16: Identifying Polygrip Flat Head Rivets Area
    G04958989Courtesy of MERCEDES-BENZ USA
  43. Install welding panel and fasten with manual temporary fasteners.
  44. Rivet welding panel and side longitudinal member with Polygrip flat head rivets, 6.4 x 14 mm dia. (areas G and H).
  45. Fill A-pillar paneling with body solder in cross-hatched areas and smooth.
Fig 17: Identifying Body Solder Hatched Areas
G04958990Courtesy of MERCEDES-BENZ USA
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