LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 2008 >> S550 Base >> Repair and Diagnosis >> Collision >> General Collision Information >> Side Wall - GEN'L Info - S-Class (221) >> Testing & Repair >> Install and weld in B-pillar - AR63.20-P-1350-06SX

Install and weld in B-pillar - AR63.20-P-1350-06SX

Fig 1: Identifying Side Portal Frame (210 589 17 23 00)
G07583711Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Inspection And Welding Device (221 589 00 23 00)
G07583712Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1092-02A Adhesive kit, body, 2-component adhesive A 009 989 36 71
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
BR00.45-Z-1012-13A Blind rivet 6.5x12.5 A 004 990 16 97
BR00.45-Z-1016-13A Blind rivet, 6.5 x 14.5 A 004 990 17 97
BR00.45-Z-1002-13A Polygrip countersunk head rivet, 6.4 x14 A 003 990 86 97 05
  1. SPECIAL TOOL Set up side portal frame.
  2. Install doubler panel (4), outer longitudinal member (2) and B-pillar reinforcement (3), fit and fasten using SPECIAL TOOL inspection and welding device, bolts (6) and COMMERCIALLY AVAILABLE TOOLS clamping pliers.

    IMPORTANT Use spacer (5).

    Fig 3: Fitting Doubler Panel, Outer Longitudinal Member And B-Pillar Reinforcement
    G07583713Courtesy of MERCEDES-BENZ USA
  3. Mark holes for cavity preservation on B-pillar reinforcement (3) (area A).
  4. Drill holes for cavity preservation on B-pillar reinforcement (3) with BTR Usibor drill bit, dia. 8 mm (area A).
  5. Transfer holes for cavity preservation to inner roof frame (9) with dia. 8 mm drill bit and bore.

    Dimensions: 

    Fig 4: Identifying B-Pillar Reinforcement Dimensions
    G07583714Courtesy of MERCEDES-BENZ USA
  6. Align doubler panel (4) with center punch (7) on outer longitudinal member (2) and fasten using COMMERCIALLY AVAILABLE TOOLS clamping pliers.
    Fig 5: Aligning Doubler Panel With Center Punch On Outer Longitudinal Member
    G07583715Courtesy of MERCEDES-BENZ USA

    Dimensions: 

    Fig 6: Identifying Outer Longitudinal Member Dimensions
    G07583716Courtesy of MERCEDES-BENZ USA
  7. Scribe rivet holes at top on outer longitudinal member (2) (areas D1 and E1 ).
  8. Center punch rivet holes at top on outer longitudinal member (2) using COMMERCIALLY AVAILABLE TOOLS BTR Usibor center punch, dia. 8 x80 mm (areas D 1 and E1 ).
  9. Drill rivet holes at top on outer longitudinal member (2) with COMMERCIALLY AVAILABLE TOOLS BTR Usibor drill bit, dia. 6.7 mm (areas D 1 and E1 ).

    Dimensions: 

    Fig 7: Identifying Outer Longitudinal Member Dimensions
    G07583717Courtesy of MERCEDES-BENZ USA
  10. Scribe rivet holes at center on outer longitudinal member (2) (area F1 ).
  11. Center punch rivet holes at center on outer longitudinal member (2) using COMMERCIALLY AVAILABLE TOOLS BTR Usibor center punch, dia. 8 x80 mm (area F1 ).
  12. Drill rivet holes at center on outer longitudinal member (2) with COMMERCIALLY AVAILABLE TOOLS BTR Usibor drill bit, dia. 6.7 mm (area F 1 ).

    Dimensions: 

    Fig 8: Identifying Outer Longitudinal Member Dimensions
    G07583718Courtesy of MERCEDES-BENZ USA
  13. Scribe rivet holes at bottom on outer longitudinal member (2) (area G1 ).
  14. Center punch rivet holes at bottom on outer longitudinal member (2) using COMMERCIALLY AVAILABLE TOOLS BTR Usibor center punch, dia. 8 x80 mm (area G1 ).
  15. Drill rivet holes at bottom on outer longitudinal member (2) with COMMERCIALLY AVAILABLE TOOLS BTR Usibor drill bit, dia. 6.7 mm (area G 1 ).
  16. Remove outer longitudinal member (2) and doubler panel (4).
  17. Deburr rivet holes on outer longitudinal member (2) and doubler panel (4) on both sides.
  18. Coat insides of riveted joints with zinc dust paint.
  19. Drill rivet holes on outer longitudinal member (2) with COMMERCIALLY AVAILABLE TOOLS BTR Usibor drill bit, dia. 6.7 mm (areas I, J, K, L and N).

    NOTES It is necessary to maintain the intervals of the rivet holes to the edge of the flange to prevent the BTR steel from tearing.

    Dimensions: 

    Fig 9: Identifying Rivet Holes Dimensions
    G07583719Courtesy of MERCEDES-BENZ USA

    Dimensions: 

    Fig 10: Identifying Longitudinal Member Dimensions
    G07583720Courtesy of MERCEDES-BENZ USA
  20. Remove multi-Z element (10) from SPECIAL TOOL side portal frame.
  21. Scribe rivet holes on outer longitudinal member (2) and B-pillar reinforcement (3) (areas O, P, Q and R).
  22. Center punch rivet holes on outer longitudinal member (2) and B-pillar reinforcement (3) using COMMERCIALLY AVAILABLE TOOLS BTR Usibor center punch, dia. 8x80 mm (areas O, P, Q and R).
  23. Drill rivet holes at bottom on outer longitudinal member (2) and B-pillar reinforcement (3) with COMMERCIALLY AVAILABLE TOOLS BTR Usibor drill bit, dia. 6.7 mm (areas P, Q and R).
  24. Drill rivet holes on B-pillar reinforcement (3) with COMMERCIALLY AVAILABLE TOOLS BTR Usibor drill bit, dia. 6.7 mm (area B).
  25. Drill rivet holes on outer longitudinal member (2) from inside with COMMERCIALLY AVAILABLE TOOLS BTR Usibor drill bit, dia. 6.7 mm (area H).
  26. Drill rivet holes on outer longitudinal member (2) with COMMERCIALLY AVAILABLE TOOLS BTR Usibor drill bit, dia. 6.7 mm (areas O and H 1 ).
  27. COMMERCIALLY AVAILABLE TOOLS Remove inspection and welding device from B-pillar.
  28. Remove outer longitudinal member (2) and B-pillar reinforcement (3).
  29. Deburr rivet holes on outer longitudinal member (2) and B-pillar reinforcement (3) on both sides.
    Fig 11: Identifying Outer Longitudinal Member And B-Pillar Reinforcement Riveting Areas
    G07583721Courtesy of MERCEDES-BENZ USA
    Fig 12: Identifying Side Portal Frame Adhesive Areas
    G07583722Courtesy of MERCEDES-BENZ USA
  30. Install multi-Z element (10) on SPECIAL TOOL side portal frame.
  31. Apply 2-component adhesive material in cross-hatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces.

    IMPORTANT Refer to manufacturer specifications for adhesive curing and application times.

  32. Apply MB body sealant to foam rubber element (8).

    IMPORTANT Damaged foam parts must be removed and replaced.

    Fig 13: Identifying B-Pillar Reinforcement Spot Welding & Rivet Areas
    G07583723Courtesy of MERCEDES-BENZ USA
  33. Install B-pillar reinforcement (3) with SPECIAL TOOL inspection and welding device for B-pillar, fit and fasten using COMMERCIALLY AVAILABLE TOOLS clamping pliers and COMMERCIALLY AVAILABLE TOOLS manual temporary fasteners.

    IMPORTANT Use spacer (5).

  34. Weld in B-pillar reinforcement (3) with POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas S, T, U, U1 and V).
  35. Rivet B-pillar reinforcement (3) using blind rivet, steel/steel, dia. 6.5x12.5 (area B).
  36. Level resistance spot welds (areas S, T, U, U 1 and V).

    NOTES To ensure the required minimum strength of the weld, place new spot welds at precisely the same position as the factory spot welds because these areas were glued previously (areas S, T, U, U1 and V)

  37. Remove multi-Z element (10) from SPECIAL TOOL side portal frame.
  38. Install outer longitudinal member (2), fit and fasten using COMMERCIALLY AVAILABLE TOOLS clamping pliers and COMMERCIALLY AVAILABLE TOOLS manual temporary fasteners.
  39. Drill rivet holes on outer longitudinal member (2) with COMMERCIALLY AVAILABLE TOOLS BTR Usibor drill bit dia. 6.7 mm (area W).

    IMPORTANT Position rivet holes so that the outer longitudinal member (2) can be drilled with the B-pillar reinforcement (3) (arrows).

    Fig 14: Identifying Outer Longitudinal Member Drilling Area
    G07583724Courtesy of MERCEDES-BENZ USA
  40. Install multi-Z element (10) on SPECIAL TOOL side portal frame.
  41. Apply 2-component adhesive material in cross-hatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces.

    IMPORTANT Refer to manufacturer specifications for adhesive curing and application times.

    Fig 15: Identifying Portal Frame Adhesive Application Area
    G07583725Courtesy of MERCEDES-BENZ USA
    Fig 16: Identifying Outer Longitudinal Member Spot Welding Areas
    G07583726Courtesy of MERCEDES-BENZ USA
  42. Install outer longitudinal member (2), fit and fasten using COMMERCIALLY AVAILABLE TOOLS clamping pliers and COMMERCIALLY AVAILABLE TOOLS manual temporary fasteners.
  43. Weld in outer longitudinal member (2) with POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas M, AH and AI).
  44. Rivet outer longitudinal member (2) using blind rivet, steel/steel, dia. 6.5 x 12.5 (areas I, J, K, L and N).
    Fig 17: Identifying Outer Longitudinal Member Riveting Areas
    G07583727Courtesy of MERCEDES-BENZ USA
  45. Rivet outer longitudinal member (2) using blind rivet, steel/steel, dia. 6.5 x 12.5 (areas C, D, E, F and G).
    Fig 18: Identifying Outer Longitudinal Member Riveting Areas (1 Of 2)
    G07583728Courtesy of MERCEDES-BENZ USA
    Fig 19: Identifying Outer Longitudinal Member Riveting Areas (2 Of 2)
    G07583729Courtesy of MERCEDES-BENZ USA
  46. Rivet outer longitudinal member (2) using blind rivet, steel/ steel, dia. 6.5x14.5 (areas O, P and Q).
  47. Remove multi-Z element (10) from SPECIAL TOOL side portal frame.
  48. Rivet outer longitudinal member (2) using blind rivet, steel/ steel, dia. 6.5x14.5 (areas H, R and W).
    Fig 20: Identifying B-Pillar Outer Paneling Drilling Areas
    G07583730Courtesy of MERCEDES-BENZ USA
  49. Install multi-Z element (10) on SPECIAL TOOL side portal frame.
  50. Install B-pillar outer paneling (1) with SPECIAL TOOL inspection and welding device for B-pillar and fasten bolts (6) and COMMERCIALLY AVAILABLE TOOLS clamping pliers.
  51. Drill rivet holes on B-pillar outer paneling (1) with COMMERCIALLY AVAILABLE TOOLS BTR Usibor drill bit, dia. 6.7 mm (area X).

    IMPORTANT To drill rivet holes in B-pillar outer paneling (1) transfer every second spot welds from old B-pillar outer paneling to new part.

  52. Countersink rivet holes on B-pillar outer paneling (1) (area X).
  53. Remove B-pillar outer paneling (1)
  54. Deburr rivet holes on B-pillar outer paneling (1) on both sides.
  55. Coat insides of riveted joints with zinc dust paint.
  56. Apply 2-component adhesive in cross-hatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces.

    IMPORTANT Refer to manufacturer specifications for adhesive curing and application times.

    Fig 21: Identifying B-Pillar Outer Paneling Adhesive Areas
    G07583731Courtesy of MERCEDES-BENZ USA
    Fig 22: Identifying B-Pillar Outer Paneling Spot Welding Areas
    G07583732Courtesy of MERCEDES-BENZ USA
  57. Install B-pillar outer paneling (1) with SPECIAL TOOL inspection and welding device for B-pillar and fasten using bolts (6), COMMERCIALLY AVAILABLE TOOLS manual temporary fasteners and COMMERCIALLY AVAILABLE TOOLS clamping pliers.
  58. Weld in B-pillar outer paneling (1) with POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas Y, Z, AA, AB, AC and AD).

    NOTES To ensure the required minimum strength of the weld, place new spot welds at precisely the same position as the factory spot welds because these areas were glued previously (areas Y, Z, AA, AB, AC and AD).

    Fig 23: Identifying B-Pillar Outer Paneling Gas Seam Welding Areas
    G07583733Courtesy of MERCEDES-BENZ USA
  59. Weld in B-pillar outer paneling (1) with SHIELDED GAS SEAM WELD (areas AE, AF and AG).

    IMPORTANT Weld in intervals, allow to cool down in between to minimize heat distortion (area AE).

    Fig 24: Identifying B-Pillar Outer Paneling Riveting Areas
    G07583734Courtesy of MERCEDES-BENZ USA
  60. Rivet B-pillar outer paneling (1) with Polygrip countersunk head rivet, dia. 6.4x14 (area X).
  61. Grind B-pillar outer paneling (1) down flat in cross-hatched areas using COMMERCIALLY AVAILABLE TOOLS abrasive disk.
  62. Remove grinding and drill shavings using wet/dry vacuum cleaner.
  63. Complete surface on B-pillar outer paneling (1), fill and smooth.
Fig 25: Identifying B-Pillar Outer Paneling Grinding Areas
G07583735Courtesy of MERCEDES-BENZ USA
scientia non olet · About LEMON Manuals