Remove/install D-pillar - AR63.20-P-2000TA
MODEL 211.2
| Removing | |||
| 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. Deburr repair panels. |
AS00.00-Z-0017-01A | |
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding spatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. | Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. | AS00.00-Z-0007-01A | |
| Risk of explosion as fuel vapors can ignite. Risk of poisoning from inhaling fuel vapors and exposed handling of fuel. Risk of injury if fuel splashes hit the eyes. | No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel. |
AS47.00-Z-0001-01A | |
| General information on repairs to body | All models | AH60.00-N-0001-01A | |
| Measures for preventing damage to vehicles or components when performing electric welding work | All models | AH00.00-N-0005-01A | |
| Guidelines for removing fuel tank when performing welding work on bodies | All models | AH60.00-P-3000-01Z | |
| Notes on paintwork repairs | All models | AH98.00-P-9408-02A | |
| General information on MB materials | All models | AH98.00-P-9409-03A | |
| 1 | Remove detachable parts in area to be repaired | ||
| 2 | Cover all detachable body components remaining in vehicle (area to be repaired) | Tarp (fire-resistant) | |
| 3 | Remove outer side wall | AR63.10-P-0805TA | |
| 4 | Remove C and D-pillar connecting panel. | AR63.20-P-0500-04TA | |
| 5 | Separate D-pillar | AR63.20-P-2000-01TA | |
Vario Drill WS 91 spot weld removing tool Ball cutter, dia. 12 mm Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 RPM) Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Angle grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com Tarp (fire-resistant) Two-post lift http://gotis.aftersales.mercedes-benz.com |
*201589005100 | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 6 | Preparing D-pillar for installation | AR63.20-P-2000-02TA | |
Ball cutter, dia. 12 mm Vario Drill WS 91 spot weld removing tool Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 RPM) Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Angle grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com |
*201589005100 | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 7 | Prepare C and D-pillar connecting panel | AR63.20-P-0500-05TA | |
| Install | |||
| 8 | Fit D-pillar, rear fender, roof and trunk lid | ||
| 9 | Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01TA | |
| Rear fender and taillamp | *BE60.00-P-1003-01F | ||
| Taillamp in rear-end door to taillamp | *BE60.00-P-1005-01F | ||
| Rear-end door to rear fender | *BE60.00-P-1005-01F | ||
| Rear window and D-pillar | *BE60.00-P-1005-01F | ||
| Fuel filler flap | *BE60.00-P-1004-01F | ||
| Rear door to side section, bottom | *BE60.00-P-1002-01F | ||
| *129589032100 | |||
| 10 | Install D-pillar | AR63.20-P-2000-03TA | |
| General information on riveting | AH60.00-P-0003-01N | ||
Electrode miller Clamping pliers Manual temporary fastener, dia. 6.4 mm - clamping range 0 to 15 mm, identification color silver PowerBird blind rivet tool http://gotis.aftersales.mercedes-benz.com Hand riveter Inert gas welder http://gotis.aftersales.mercedes-benz.com Spot welder http://gotis.aftersales.mercedes-benz.com Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com Tarp (fire-resistant) Two-post lift http://gotis.aftersales.mercedes-benz.com Cavity preservation gun, Sata HRS no. 11072 http://gotis.aftersales.daimlerchrysler.com |
*129589032100 | ||
| Polygrip flat round head rivet, 6.4x14 | *BR00.45-Z-1001-13A | ||
| MB preservative | *BR00.45-Z-1003-05A | ||
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 11 | Clean repair areas and prime using primer filler | ||
| 12 | Cavity preservation following repair work | AR97.20-P-1500T | |
| Notes on cavity preservation | Model 211 | AH97.20-P-0001-01B | |
| 13 | Install C and D-pillar connecting panel | AR63.20-P-0500-06TA | |
| 14 | Remove/install outer sidewall | AR63.10-P-0805TA | |
| 15 | Completely install center roof paneling | AR65.10-P-1000TA | |
| 16 | Install detachable body components in area to be repaired |
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS
| Number | Designation | Model 211.2 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01F | Gap dimension | Front door to A-pillar | Dimension "D" | mm | 4.5 (-0.5/+1) |
| Front door to fender | Dimension "E" | mm | 4 (-0.5/+1) | ||
| Front door to rear door | Dimension "F" | mm | 4 (-0.5/+1) | ||
| Front door to roof | Dimension "G" | mm | 4.5 (-0.5/+1) | ||
| Rear door to top of side section | Dimension "H" | mm | - | ||
| Rear door to side section, bottom | Dimension "I" | mm | 3.5 (-0.5/+1) | ||
| See picture | AR60.00-P-0700-01T A | ||||
| BE60.00-P-1003-01F | Gap dimension | Trunk lid to rear fender, top | Dimension "J" | mm | - |
| Trunk lid to rear lamp unit | Dimension "K" | mm | - | ||
| Trunk lid to bumper | Dimension "L" | mm | - | ||
| Rear fender to rear lamp unit | Dimension "M" | mm | 2.5 (±1) | ||
| Trunk lid license plate panel to rear lamp unit | Dimension "N" | mm | - | ||
| See picture | AR60.00-P-0700-01T A | ||||
| BE60.00-P-1004-01F | Gap dimension | Fuel filler flap | Dimension "O" | mm | 3.5 (±0.5) |
| See picture | AR60.00-P-0700-01T A | ||||
| BE60.00-P-1005-01F | Gap dimension | Liftgate spoiler/roof | Dimension "P" | mm | 7 (-0.5/+1) |
| Rear-end door to rear fender | Dimension "Q" | mm | 4.5 (±1) | ||
| Taillamp in rear-end door to taillamp | Dimension "R" | mm | 5 (±1) | ||
| Rear-end door to bumper | Dimension "S" | mm | 6 (±1.5) | ||
| Rear window and D-pillar | Dimension "T" | mm | 4.5 (±1) | ||
| Front door to roof | Dimension "U" | mm | 4.5 (-0.5/+1) | ||
| See picture | AR60.00-P-0700-01T A | ||||
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, white, 310 ml, DB supply specification 6069.20 | A 001 989 63 20 |
| BR00.45-Z-1003-05A | Cavity preservation, solvent-free (1 l container) | A 000 986 72 70 05 |
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
| BR00.45-Z-1001-13A | Blind rivet 6.4 14 | A 003 990 35 97 |