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Separating B-pillar - AR63.20-P-1350-05PB

Fig 1: Identifying Weld Spot Miller (201 589 00 51 00)
G04738859
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-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 B-Pillar Separation Area
G04738860
  1. Mark separation points and cut with body saw (areas A and B).

    IMPORTANT Completely separate B-pillar (area B).

  2. Expose spot welds and cut out with spot weld cutter (areas G and H).
    Fig 3: Identifying B-Pillar Spot Welds Area (1 Of 5)
    G04738861

    3. IMPORTANT The C-pillar can be repaired on the outside with partial replacement depending on the scope of damage.

    1. Expose spot welds and cut out with spot weld cutter (areas C, D, E and F).
      Fig 4: Identifying B-Pillar Spot Welds Area (2 Of 5)
      G04738862
    2. Expose spot welds and cut out with spot weld cutter (areas C and F).
  4. Separate C-pillar (area Y).

    IMPORTANT Only for sectional replacement.

  5. Remove B-pillar
    Fig 5: Identifying B-Pillar Spot Welds Area (3 Of 5)
    G04738863
    Fig 6: Identifying B-Pillar Spot Welds Area (4 Of 5)
    G04738864
  6. Expose spot welds and cut out with spot weld cutter (areas I, J, K and M).
  7. Remove bottom section of inner B-pillar.

    IMPORTANT Spot welds are not visible and must be felt from the inside of the spot welding flange (area M).

  8. Expose spot welds and cut out with spot weld cutter (areas N and O).
  9. Remove section of outer B-pillar reinforcement.
  10. Expose spot weld and cut out with spot weld cutter (area P).
  11. Remove section of upper reinforcement.
    Fig 7: Identifying B-Pillar Spot Welds Area (5 Of 5)
    G04738865
    Fig 8: Identifying Grinding Area
    G04738866
  12. Grind connection surfaces down to bare metal in shaded areas. Sand spot weld flanges to bare metal on both sides
  13. Remove grinding and drilling chips using wet/dry vacuum cleaner.
  14. Coat insides of spot weld flanges with zinc dust paint.
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