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Home >> Mercedes Benz >> 2008 >> S550 Base >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Side Wall - GEN'L Info - S-Class (221) >> Testing & Repair >> Separate B-pillar - AR63.20-P-1350-05SX

Separate B-pillar - AR63.20-P-1350-05SX

Fig 1: Identifying Set Of Cutting Templates (221 589 03 23 00)
G07583700Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G07583701Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1006-01A Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1008-01A BTR Usibor milling cutter, dia. 8 mm
WH58.30-Z-1009-01A BTR Usibor milling cutter, dia. 8 x44 mm
WH58.30-Z-1010-01A BTR Usibor center punch Ø 8 x80 mm
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
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

Dimensions: 

Fig 3: Identifying B-Pillar Outer Paneling Separation Line Dimensions
G07583702Courtesy of MERCEDES-BENZ USA
  1. Scribe separation lines on B-pillar outer paneling (1) with SPECIAL TOOL cutting template (areas A and B).

    IMPORTANTSPECIAL TOOL Position cutting template on Y-marking. Expose Y-marking if applicable (arrows).

  2. Transfer separation line on B-pillar outer paneling (1) from new part.
  3. Mark cutting on B-pillar outer paneling (1) (area C).
  4. Cut separation lines on B-pillar outer paneling (1) with body saw and COMMERCIALLY AVAILABLE TOOLS cutting disk (areas A, B and C).

    IMPORTANT Do not damage side longitudinal member below.

  5. Expose spot welds on B-pillar outer paneling (1) (areas D, E and F).
    Fig 4: Identifying B-Pillar Outer Paneling Spot Welding Areas
    G07583703Courtesy of MERCEDES-BENZ USA
  6. Cut out spot welds on B-pillar outer paneling (1) using SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas D, E and F).
    Fig 5: Identifying B-Pillar Outer Paneling Heating Areas
    G07583704Courtesy of MERCEDES-BENZ USA
  7. Heat B-pillar outer paneling (1) in cross-hatched areas using COMMERCIALLY AVAILABLE TOOLS hot air gun.

    IMPORTANT Cross-hatched areas are bonded.

  8. Remove damaged B-pillar outer paneling (1).

    Dimensions: 

    Fig 6: Identifying Outer Longitudinal Member Spot Welding Areas & Separation Line
    G07583705Courtesy of MERCEDES-BENZ USA
  9. Scribe separation line on outer longitudinal member (2) (area G).
  10. Cut separation point on outer longitudinal member (2) with COMMERCIALLY AVAILABLE TOOLS cutting disk (area G).
  11. Expose spot welds on outer longitudinal member (2) (areas H, I and J).
  12. Cut out spot welds on outer longitudinal member (2) using COMMERCIALLY AVAILABLE TOOLS BTR Usibor milling cutter, dia. 8 x44 mm or COMMERCIALLY AVAILABLE TOOLS BTR Usibor milling cutter, dia. 8 mm (areas H, I and J).
    Fig 7: Identifying Outer Longitudinal Member Spot Welding Areas
    G07583706Courtesy of MERCEDES-BENZ USA
  13. Expose spot welds on outer longitudinal member (2) (areas K, L, M, N and O).
  14. Cut out spot welds on outer longitudinal member (2) using COMMERCIALLY AVAILABLE TOOLS BTR Usibor milling cutter, dia. 8 x44 mm or his COMMERCIALLY AVAILABLE TOOLS BTR Usibor milling cutter, dia. 8 mm (areas K, L, M and N).
  15. Grind out spot welds on outer longitudinal member (2) with COMMERCIALLY AVAILABLE TOOLS cutting disk (area O).
    Fig 8: Identifying Outer Longitudinal Member Heating Areas
    G07583707Courtesy of MERCEDES-BENZ USA
  16. Heat outer longitudinal member (2) in cross-hatched areas using COMMERCIALLY AVAILABLE TOOLS hot air gun.
  17. Remove damaged outer longitudinal member (2).

    IMPORTANT Cross-hatched areas are foamed and bonded

  18. Expose spot welds on B-pillar reinforcement (3) (areas P, Q, R, S and T).
  19. Cut out spot welds on B-pillar reinforcement (3) with COMMERCIALLY AVAILABLE TOOLS BTR Usibor milling cutter, dia. 8x44 mm or COMMERCIALLY AVAILABLE TOOLS BTR Usibor milling cutter, dia. 8 mm (areas P, Q, R, S and T).
    Fig 9: Identifying B-Pillar Reinforcement Spot Welding Areas
    G07583708Courtesy of MERCEDES-BENZ USA
  20. Heat B-pillar reinforcement (3) in cross-hatched areas using COMMERCIALLY AVAILABLE TOOLS hot air gun.

    IMPORTANT Cross-hatched areas are foamed or bonded.

    Fig 10: Identifying B-Pillar Reinforcement Heating Areas
    G07583709Courtesy of MERCEDES-BENZ USA
    Fig 11: Identifying B-Pillar Reinforcement Mating Surfaces
    G07583710Courtesy of MERCEDES-BENZ USA
  21. Grind mating surfaces down to bare metal in cross-hatched areas using COMMERCIALLY AVAILABLE TOOLS round wire brush or COMMERCIALLY AVAILABLE TOOLS abrasive disk

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

  22. Remove grinding and drill shavings using wet/dry vacuum cleaner.
  23. Coat mating surface with zinc dust paint (area U).

    NOTES To prevent adhesion problems, do not coat bonding surfaces with zinc dust paint.

    IMPORTANT Observe pretreatment of bonding surfaces.

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