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Home >> Mercedes Benz >> 2005 >> CLK55 2D Convertible >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Side Wall -- Testing & Repair -- 209 Chassis - 1 Of 3 >> Testing & Repair >> Replace outer B-pillar with side longitudinal member - AR63.20-P-1370Q >> Notes

Replace outer B-pillar with side longitudinal member - AR63.20-P-1370Q: Notes

MODEL 209.3 

Fig 1: Identifying Outer B-Pillar With Side Longitudinal Member
G04959128Courtesy of MERCEDES-BENZ USA
REMOVING Remove    
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 and position the four support plates below 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 arc welding. Risk of explosion  caused by welding in the area of highly inflammable materials. Injury hazard  from welding spatter and UV-light while welding. Risk of poisoning  caused by inhaling welding vapors. Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor. 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 arc 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   AR72.10-P-0500Q
2 Remove left front seat   AR91.10-P-1000Q
3 Remove foot mats    
4 Remove fold-down rear backrest Model 209.342, 209.361, 209.365, 209.375 AR91.12-P-1720Q
5 Remove rear seat cushion Model 209.342, 209.361, 209.365, 209.375 AR91.12-P-1020P
6 Remove or detach electric lines and vacuum lines in area to be repaired    
7 Remove detachable parts in area to be repaired    
8 Cover all detachable body components remaining in vehicle (area to be repaired) Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
9 Equip straightening bench with modular or crossmembers and straightening tools IMPORTANT Observe setup plans enclosed!  
Celette straightening bench (MUF 5, MUF 7) *WE58.40-Z-1001-01E 
Celette straightening bench M8S *WE58.40-Z-1001-01E 
Celette straightening bench Sevenne *WE58.40-Z-1001-01E 
Set of Celette modular 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 
Car-Bench straightening bench BT 17 *WE58.40-Z-1003-01E 
Car-Bench straightening bench BT 43/1 *WE58.40-Z-1003-01E 
Celette straightening bracket set 7203.309 (for model 203), as supplement to 7203.300 *WE58.40-Z-1031-01A 
Celette straightening set 7203.310 (for model 203), only for new orders, includes supplement 7203.309 *WE58.40-Z-1032-01A 
Car-Bench universal crossmember set A 296 *WE58.40-Z-1010-01E 
Car-bench straightening set 82434 (for model 203) *WE58.40-Z-1030-01A 
Multi-Z straightening set system MZ 450.000 *WE58.40-Z-1006-01E 
10 Set vehicle onto straightening bench using two-column lift and fasten   *WE58.40-Z-1001-05A 
IMPORTANT General information on body repairs   AH60.00-N-0001-01A
11 Set up side portal frame with check and welding device IMPORTANT Observe setup plans enclosed!  
SPECIAL TOOL Side portal frame Figure
SPECIAL TOOL Test and welding device Figure
SPECIAL TOOL Test and welding device Figure
12 Check installation position of B-pillar    
13 Straighten B-pillar IMPORTANT If the deformation depth is so large that the inner B-pillar can no longer be straightened, then the Replacing complete B-pillar repair specification is to be used.
Completely replace B-pillar		 AR63.20-P-1350Q 
14 Remove rear fender   AR63.50-P-1400Q 
15 Remove weld panel on side longitudinal member   AR63.30-P-1500Q 
16 Cut outer B-pillar with side longitudinal member   AR63.20-P-1370-01Q 
SPECIAL TOOL Spot weld milling cutter Figure
COMMERCIALLY AVAILABLE TOOLS Spherical milling 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, ø 70 mm *WH58.30-Z-1001-03A 
COMMERCIALLY AVAILABLE TOOLS Abrasive disk, ø 115 mm, 80 m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
COMMERCIALLY AVAILABLE TOOLS Cutting disk, ø 65 mm, 80 m/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 
Angular 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 
17 Prepare outer B-pillar with side longitudinal member   AR63.20-P-1370-04Q 
COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, ø 70 mm *WH58.30-Z-1001-03A 
COMMERCIALLY AVAILABLE TOOLS Abrasive disk, ø 115 mm, 80 m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install    
18 Install outer B-pillar with side longitudinal member   AR63.20-P-1370-05Q 
SPECIAL TOOL Side portal frame Figure
SPECIAL TOOL Test and welding device Figure
SPECIAL TOOL Test and welding device Figure
COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, ø 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, ø 115 mm, 80 m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
COMMERCIALLY AVAILABLE TOOLS Cutting disk, ø 65 mm, 80 m/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 
Angular 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-1400Q 
20 Install weld panel on side longitudinal member   AR63.30-P-1500Q 
21 Release vehicle from straightening bench and 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 priming 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
NOTES		 Cavity preservation following repair work
Notes on cavity preservation		 Model 209 AH97.20-P-0001-01B
27 Install electric lines and vacuum lines in repair area    
28 Remove fold-down rear backrest Model 209.3 AR91.12-P-1720Q
29 Remove rear seat cushion Model 209.3 AR91.12-P-1020P
30 Install left front seat   AR91.10-P-1000Q
31 Install foot mats    
32 Install left front door   AR72.10-P-0500Q
33 Install all removed detachable body components    
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G04959129Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Inspection And Welding Device (203 589 00 23 00)
G04959130Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Inspection And Welding Equipment (209 589 00 23 00)
G04959131Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Side Portal Frame (210 589 17 23 00)
G04959132Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1002-01A Ball cutter, dia. 12 mm
WH58.30-Z-1003-01A Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1006-01A Electrode miller
WH58.30-Z-1003-02A Clamping pliers
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-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-1032-01A Celette straightening bracket set 7203.310 (model 203), only with new ordering contains addition 7203.309
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
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1041-01A Seam sealant, sprayable 310 ml A 002 989 84 20
BR00.45-Z-1003-01A Sealant A 001 989 63 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
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