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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 >> 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-1150QA >> Separate A-pillar together with side longitudinal member - AR63.20-P-1150-01QA

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

Fig 1: Identifying Spot Weld Cutter (201 589 00 51 00)
G04959030Courtesy 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 Body Mark Area
G04959031Courtesy of MERCEDES-BENZ USA
  1. Mark separation line (area A), dimension a = approx. 10 mm dimension b = approx. 110 mm dimension ± = approx. 22 mm dimension d = approx. 30 mm and cut with body saw (area A).

    IMPORTANT Window solution. Do not damage plate located underneath when sawing.

  2. Remove window cutout.
    Fig 3: Identifying Body Mark Area
    G04959032Courtesy of MERCEDES-BENZ USA
  3. Mark separation line (area B), dimension e.= approx. 55 mm (from previous separating cut) and cut with body saw (area B).
  4. Expose spot welds and cut out with spot weld cutter (area C).
  5. Mill off welding spots through two plate thicknesses (area P).

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

    Fig 4: Identifying Cutting And Welding Area
    G04959033Courtesy of MERCEDES-BENZ USA
  6. Expose spot welds and cut out with spot weld cutter (areas D, G and H).
  7. Separate inert gas weld (area E).
  8. Mill off welding spots through two plate thicknesses (area F).
    Fig 5: Identifying Welding Area
    G04959034Courtesy of MERCEDES-BENZ USA
    Fig 6: Identifying Welding Spots Area
    G04959035Courtesy of MERCEDES-BENZ USA
  9. Expose welding spots and mill off using a spot weld cutter (areas I, J, K, L, M and N).
  10. Remove cover plate on front longitudinal member.
    Fig 7: Identifying Body Cutting Dimension Area
    G04959036Courtesy of MERCEDES-BENZ USA
  11. Mill off welding spots (area O).
  12. Remove A-pillar together with side longitudinal member.
  13. Mark separation point (area R), dimension f = approx. 55 mm and cut with body saw (area R).
  14. Mill off welding spots (area Q).
  15. Remove section of outer A-pillar.
    Fig 8: Identifying Shaded Areas
    G04959037Courtesy 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 using wet/dry vacuum cleaner.
  18. Coat spot welding flanges with zinc dust paint.
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