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Home >> Mercedes Benz >> 2007 >> S600 >> Repair and Diagnosis >> Collision >> General Collision Information >> Side Wall - GEN'L Info - S-Class (221) >> Testing & Repair >> Remove inner C-pillar side wall. - AR63.10-P-0700-01SX

Remove inner C-pillar side wall. - AR63.10-P-0700-01SX

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G07668636Courtesy 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)
WH58.30-Z-1004-20A Hot-air gun
WH58.30-Z-1001-35A Aluminum workshop vehicle
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 Outer C-Pillar Spot Welding Areas
G07668637Courtesy of MERCEDES-BENZ USA
  1. Remove insulating foam rubber (4) from outer C-pillar (1).
  2. Expose spot welds on outer C-pillar (1) (areas A, B, C, D and E).
  3. Cut out spot welds on outer C-pillar (1) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas A, B, C, D and E).
    Fig 3: Identifying Inner C-Pillar Spot Welding Areas
    G07668638Courtesy of MERCEDES-BENZ USA
  4. Expose spot weld on inner C-pillar (2) (area F).
  5. Cut out spot weld on inner C-pillar (2) with COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (area F).
  6. Heat outer C-pillar (1) in cross-hatched areas with COMMERCIALLY AVAILABLE TOOLS hot air gun.

    IMPORTANT Cross-hatched areas are bonded.

  7. Remove damaged outer C-pillar (1).
    Fig 4: Identifying Outer C-Pillar Spot Welding Areas & Separation Point
    G07668639Courtesy of MERCEDES-BENZ USA
  8. Detach water drain hose (5) from retaining clips (6).
  9. Remove water drain hose (5) and retaining clips (6).
  10. Cut inner C-pillar (2) on coarse separation point with body saw (area G).
  11. Expose spot welds on outer rear wheelhouse (3) and rear roof frame (7) (areas H, K, K 1 and U).
  12. Cut out spot welds on outer rear wheelhouse (3) with SPECIAL TOOL spot weld milling cutter (area K).

    IMPORTANT Drill dia. 6.5 mm spot weld on outer rear wheelhouse (3) (area K1 ).

  13. Drill dia. 6.5 mm spot welds in rear roof frame (7) (area H).
  14. Cut out spot welds on rear roof frame (7) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (area U).
    Fig 5: Identifying Spot Welding Areas
    G07668640Courtesy of MERCEDES-BENZ USA
  15. Expose spot welds on inner C-pillar (2) and outer rear wheelhouse (3) (areas H 1 , L, M, N, N1 , O, P and Q).
  16. Drill dia. 6.5 mm spot welds in inner C-pillar (2) and outer rear wheelhouse (3) (areas L and P).
  17. Cut out spot welds on inner C-pillar (2) and outer rear wheelhouse (3) with SPECIAL TOOL spot weld milling cutter (areas H 1 , M, N, N1 , O and Q).

    IMPORTANT Cut out spot welds on inner C-pillar (2) through two sheet metal thicknesses (area M).

  18. Expose spot welds on outer rear wheelhouse (3) (areas R, R 1 and S).
  19. Cut out spot welds on outer rear wheelhouse (3) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas R and R 1 ).

    IMPORTANT Cut out spot welds on outer rear wheelhouse (3) through two sheet metal thicknesses (area R 1 ).

  20. Cut out spot welds on outer rear wheelhouse (3) with COMMERCIALLY AVAILABLE TOOLS ball cutter (area S).
    Fig 6: Identifying Inner C-Pillar And Outer Rear Wheel House Spot Welding Areas
    G07668641Courtesy of MERCEDES-BENZ USA
    Fig 7: Identifying Inner C-Pillar And Outer Rear Wheelhouse Areas To Be Heated
    G07668642Courtesy of MERCEDES-BENZ USA
  21. Heat inner C-pillar (2) and outer rear wheelhouse (3) in cross-hatched areas with COMMERCIALLY AVAILABLE TOOLS hot air gun.

    IMPORTANT Cross-hatched areas are bonded.

  22. Remove damaged inner C-pillar (2) and outer rear wheelhouse (3).
    Fig 8: Identifying Connection Surfaces
    G07668643Courtesy of MERCEDES-BENZ USA
  23. Grind connection surface down to bare metal in cross-hatched areas with COMMERCIALLY AVAILABLE TOOLS stainless steel round wire brush blank (areas T and W).
  24. Grind connection surfaces down to bare metal in cross-hatched areas with COMMERCIALLY AVAILABLE TOOLS round wire brush (areas U, V, X, Y and Z).

    IMPORTANT Grind spot weld flanges down to bare metal on both sides.

  25. Remove grinding and drill shavings using wet/dry vacuum cleaner.
  26. Coat insides of spot weld flanges with zinc dust paint.

    NOTES Do not coat bonding surfaces with zinc dust paint to prevent adhesion problems (areas T, V, W, X, Y and Z).

    IMPORTANT Observe pretreatment of bonding surfaces.

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