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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 B-pillar - AR63.20-P-1350 >> Replace complete B-pillar - AR63.20-P-1350QA >> Notes

Replace complete B-pillar - AR63.20-P-1350QA: Notes

MODEL 209.4 

Fig 1: Identifying Inner B-Pillar, Outer B-Pillar And Longitudinal Member Reinforcement
G04959092Courtesy of MERCEDES-BENZ USA
REMOVING 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. AS00.00-Z-0017-01A
    Deburr repair panels.  
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 spatter 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
NOTES General information on repairs to body All models AH60.00-N-0001-01A
NOTES Measures for preventing damage to vehicles or components when performing electric welding work All models AH00.00-N-0005-01A
NOTES Notes on paintwork repairs All models AH98.00-P-9408-02A
IMPORTANT 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) *WH58.30-Z-1001-40A 
8 Equip straightening bench with modular or crossmembers and straightening tools IMPORTANT Observe the assembly plans provided.  
Celette straightening bench M8S *WE58.40-Z-1001-01E 
Celette straightening bench (MUF 5, MUF 7) *WE58.40-Z-1001-01E 
Celette straightening bench Sevenne *WE58.40-Z-1001-01E 
Set of Celette module members 955.940 *WE58.40-Z-1007-01E 
Celette additional member 955.908 *WE58.40-Z-1008-01E 
Celette straightening bench 7203.300 (for model 203) *WE58.40-Z-1029-01A 
Celette straightening set 7209.309 (for model A 209), as supplement to 7203.300 (model 203), as well as 7203.310 (model C 209) *WE58.40-Z-1042-01A 
Multi-Z straightening set system MZ 450.000 *WE58.40-Z-1006-01E 
Car-Bench straightening bench BT 17 *WE58.40-Z-1003-01E 
Car-Bench straightening bench BT 43/1 *WE58.40-Z-1003-01E 
Car-Bench universal crossmember set A296 *WE58.40-Z-1010-01E 
Car-bench straightening set 82434 (for model 203) *WE58.40-Z-1030-01A 
9 Set vehicle onto straightening bench using two-column lift and fasten   *WE58.40-Z-1001-05A 
IMPORTANT General information on body repair   AH60.00-N-0001-01A
10 Set up side portal frame with inspection and welding device IMPORTANT Observe the assembly plans provided.  
SPECIAL TOOL Side portal frame Figure
SPECIAL TOOL Inspection and welding device Figure
SPECIAL TOOL Inspection and welding device Figure
11 Remove welding panel from side longitudinal member. IMPORTANT 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 
SPECIAL TOOL Spot weld milling cutter Figure
COMMERCIALLY AVAILABLE TOOLS Ball cutter, dia. 12 mm *WH58.30-Z-1002-01A 
COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot weld removing tool *WH58.30-Z-1006-01A 
COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
COMMERCIALLY AVAILABLE TOOLS Cutting disk, 65 mm dia., 80m/s (max. 23, 500 RPM) *WH58.30-Z-1021-04A 
Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
Angle grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
14 Separate inner B-pillar   AR63.20-P-1350-01QA 
SPECIAL TOOL Spot weld milling cutter Figure
COMMERCIALLY AVAILABLE TOOLS Ball cutter, dia. 12 mm *WH58.30-Z-1002-01A 
COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot weld removing tool *WH58.30-Z-1006-01A 
COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
COMMERCIALLY AVAILABLE TOOLS Cutting disk, 65 mm dia., 80m/s (max. 23, 500 RPM) *WH58.30-Z-1021-04A 
Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
Angle grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
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 
COMMERCIALLY AVAILABLE TOOLS Cutting disk, 65 mm dia., 80m/s (max. 23, 500 RPM) *WH58.30-Z-1021-04A 
COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
Angle grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
16 Prepare inner B-pillar for installation   AR63.20-P-1350-02QA 
COMMERCIALLY AVAILABLE TOOLS Sheet metal crimping pliers *WH58.30-Z-1010-02A 
COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
COMMERCIALLY AVAILABLE TOOLS Cutting disk, 65 mm dia., 80m/s (max. 23, 500 RPM) *WH58.30-Z-1021-04A 
Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
Angle grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install     
17 Install inner B-pillar   AR63.20-P-1350-03QA 
IMPORTANT General information on riveting   AH60.00-P-0003-01N
    SPECIAL TOOL Side portal frame Figure
    SPECIAL TOOL Inspection and welding device Figure
    SPECIAL TOOL Inspection and welding device Figure
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Electrode miller *WH58.30-Z-1003-01A 
    COMMERCIALLY AVAILABLE TOOLS PowerBird blind rivet tool *WE58.40-Z-1003-14A 
    COMMERCIALLY AVAILABLE TOOLS Hand riveter *WH58.30-Z-1003-29A 
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    COMMERCIALLY AVAILABLE TOOLS Manual temporary fastener, dia. 6.4 mm clamping range 0 to 15 mm, identification color silver *WH58.30-Z-1038-02A 
    Inert gas welder *WE58.40-Z-1001-02A 
    Spot welder *WE58.40-Z-1002-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Polygrip flat/round head rivet, 6.4 x 14 *BR00.45-Z-1001-13A 
    Polygrip countersunk head rivet, 6.4X14 *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 
SPECIAL TOOL Side portal frame Figure
SPECIAL TOOL Inspection and welding device Figure
SPECIAL TOOL Inspection and welding device Figure
COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
COMMERCIALLY AVAILABLE TOOLS Electrode miller *WH58.30-Z-1003-01A 
COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
COMMERCIALLY AVAILABLE TOOLS Cutting disk, 65 mm dia., 80m/s (max. 23, 500 RPM) *WH58.30-Z-1021-04A 
Inert gas welder *WE58.40-Z-1001-02A 
Spot welder *WE58.40-Z-1002-02A 
Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
Angle grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
19 Install rear fender   AR63.50-P-1400QA 
20 Install welding panel on side longitudinal member. IMPORTANT Shown on model 209.3 AR63.30-P-1500Q 
21 Release vehicle from straightening bench and Two-post lift with two-column lift, remove straightening bench Two-post lift *WE58.40-Z-1001-05A 
22 Clean weld joints and metal flanges with wire brush    
23 Clean areas to be repaired and prime with primer filler    
24 Seam sealing following repair IMPORTANT Supplement standard seals with 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
    Cavity preservation gun Sata HRS no. 11072 *WE58.40-Z-1006-08A 
NOTES Notes on cavity preservation AH97.20-P-0001-01B   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 body components    
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G04959093Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Inspection And Welding Device (203 589 00 23 00)
G04959094Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Inspection And Welding Equipment (209 589 00 23 00)
G04959095Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Side Portal Frame (210 589 17 23 00)
G04959096Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS

Designation Number
WH58.30-Z-1002-01A Ball cutter, dia. 12 mm
WH58.30-Z-1003-01A Electrode miller
WH58.30-Z-1006-01A Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1003-02A Clamping pliers
WH58.30-Z-1010-02A Sheet metal crimping shears
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
WH58.30-Z-1001-40A Tarp (fire-resistant)
WORKSHOP EQUIPMENT

WE58.40-Z-1029-01A Celette straightening bracket set 7203.300 (model 203)
WE58.40-Z-1030-01A Car bench straightening bracket set 82434, (model 203)
WE58.40-Z-1031-01A Celette straightening bracket set 7203.309 (model 203), as supplement to 7203.300
WE58.40-Z-1042-01A Celette straightening bracket set 7209.309 (model A 209), as supplement to 7203.300 (model 203), as well as 7203.310 (model C209)
WE58.40-Z-1001-01E Celette straightening bench
WE58.40-Z-1003-01E Car-Bench straightening bench
WE58.40-Z-1006-01E Celette Multi-Z straightening set system
WE58.40-Z-1007-01E Celette module crossmember set 955.940
WE58.40-Z-1008-01E Celette additional member 955.908
WE58.40-Z-1010-01E Car-Bench universal cross member set A 296
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-1004-03A Body saw (electric/pneumatic)
WE58.40-Z-1005-03A Wet/dry vacuum cleaner
WE58.40-Z-1001-05A Two-post lifting platform
WE58.40-Z-1006-08A Cavity preservation gun
WE58.40-Z-1003-14A Blind rivet 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-1002-13A Polygrip countersunk head rivet, 6.4x14 A 003 990 86 97 05
BR00.45-Z-1001-13A Rivet A 003 990 35 97
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