Separate outer side wall - AR63.10-P-0805-01TA

WARNING: This page is about a different car, the 2009 Mercedes-Benz E550 and 2008 Mercedes-Benz E550. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Cutting Templates (211 589 05 23 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
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-1004-20A	Hot-air gun

WORKSHOP EQUIPMENT

WE58.40-Z-1001-03A	Drill (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 3: Identifying Outer Side Wall Cutting Line Areas

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Dimensions:

Mark cutting line (area B).
Mark cutting line (area T).
Mark marker line with cutting template (area A). Then mark cutting line approx. 3 mm (a) offset toward rear with cutting template (area T).

Secure cutting template with safety pin for marker line (area A)
Cut with body saw (areas B and T).
Do not damage C-pillar and or outside of longitudinal member below to prevent reduction of stability.

Fig 4: Identifying Outer Side Wall Spot Welding Areas (D, E, F And G)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Expose spot welds (areas D, E, F and G).
Cut out spot welds with spot weld milling cutter or Various Drill spot weld removing tool (areas D, E, F and G).

Fig 5: Identifying Outer Side Wall Spot Welding Areas (C, H, I, J, K, L And M)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Expose spot welds (areas C, H, I, J, K, L and M).
Cut out spot welds with spot weld milling cutter or Various Drill spot weld removing tool (areas C, H, I, J, K, L and M).

Fig 6: Identifying Outer Side Wall Spot Welding Areas (N, O, P, Q And R)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Expose spot welds (areas N, O, P, Q and R).
Cut out spot welds with spot weld milling cutter or Various Drill spot weld removing tool (areas N, O, P, Q and R).
Heat side wall in cross-hatched areas with hot air gun.
Cross-hatched areas are foam-protected and glued.
Remove side wall

Fig 7: Identifying Side Wall Cross-Hatched Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 8: Identifying Side Wall Mating Surfaces Cross-Hatched Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind mating surfaces in cross-hatched areas down to bare metal with round wire brush.
Grind spot weld flanges down to bare metal on both sides.
Remove grinding and drill shavings with wet/dry vacuum cleaner.
Coat insides of spot weld flanges with zinc dust paint.

Fig 9: Identifying Side Wall Mating Surfaces Grinding Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind mating surfaces in cross-hatched areas down to bare metal with round wire brush.
Grind spot weld flanges down to bare metal on both sides.
Remove grinding and drill shavings with wet/dry vacuum cleaner.
Coat insides of spot weld flanges with zinc dust paint.