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Replace Complete B-Pillar - Ar63.20-P-1350LWR

Model 205.4 

Fig 1: B-Pillar, Crossmember Reinforcement And Support Locations (Complete) (Model 205.4)
G13022084CAUTIONREMOVINGREFER TO SPECIAL TOOLSREFER TO SPECIAL TOOLSIMPORTANTIMPORTANTINSTALLINGREFER TO SPECIAL TOOLSREFER TO SPECIAL TOOLSREFER TO SPECIAL TOOLSIMPORTANTSPECIAL TOOLIMPORTANTIMPORTANTIMPORTANTIMPORTANTCourtesy of MERCEDES-BENZ USA
  Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. See AS00.00-Z-0010-01A .
CAUTION 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. See AS00.00-Z-0017-01A .
  General information on body repair   See AH60.00-N-0001-01A .
  Information on preventing damage to electronic components due to electrostatic discharge   See AH54.00-P-0001-01A .
  Pretreatment of bonding surfaces   See AH60.00-P-0008-01SX .
  General information on repair of vehicles with ultra-strength steels.   See AH60.00-P-0024-01N .
  Notes on acoustic foam and structural foam in the vehicle   See AH60.00-P-0039-01LW .
  General information on MB materials   See AH98.00-P-9409-03A .
REMOVING Remove     
1 Remove detachable parts in area to be repaired    
2 Cover all detachable parts remaining in vehicle with spark protection blanket    
3 Remove rear fender   See AR63.50-P-1401LWR .
4 Set up straightening bench with straightening bench crossmembers and straightening tool set    
REFER TO SPECIAL TOOLS 000 588 01 23 00 Body straightening system   See WS60.00-P-0023K .
5 Place vehicle on straightening bench and fasten    
6 Remove B-pillar (1), crossmember reinforcement (2) and support (3)   See AR63.20-P-1350-05LWR .
REFER TO SPECIAL TOOLS 000 588 00 84 00 Heat gun   See WS54.00-P-0049B .
    IMPORTANTCommercially available devices/tools 
Round wire brush
Body power jigsaw
Spot weld milling machine
Drill bits and milling cutters for high-strength steels
Wet/dry vacuum cleaner
Zinc dust paint suitable for spot welding		 See *BR00.45-Z-1001-07A .
7 Prepare B-pillar (1), crossmember reinforcement (2) and support (3)   See AR63.20-P-1350-07LWR .
    IMPORTANTCommercially available devices/tools 
Round wire brush
Body power jigsaw
Spot weld milling machine
Drill bits and milling cutters for high-strength steels
Zinc dust paint suitable for spot welding		 See *BR00.45-Z-1001-07A .
INSTALLING Install     
  The high voltage used for electric welding presents a lethal hazard. Risk of explosion  from welding in areas close to highly inflammable materials. Risk of injury  from weld splatter and UV-light when welding. Risk of poisoning  from inhaling welding gases Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system. See AS00.00-Z-0007-01A .
  Measures for preventing damage to components when performing electric welding and soldering work   See AH60.00-P-0001-02A
  General information on riveting   See AH60.00-P-0003-01N .
8 Install B-pillar (1), crossmember reinforcement (2) and support (3)   See AR63.20-P-1350-06LWR .
REFER TO SPECIAL TOOLS 000 588 01 84 00 Welder   See WS60.00-P-0021K .
REFER TO SPECIAL TOOLS 000 588 02 84 00 Welder   See WS60.00-P-0022K .
REFER TO SPECIAL TOOLS 000 588 01 23 00 Body straightening system   See WS60.00-P-0023K .
    IMPORTANTCommercially available devices/tools 
Round wire brush
Manual temporary fastener 6.35 mm
Drill bits and milling cutters for high-strength steels
Blind rivet gun (minimum pull-off force 19 kN)
Wet/dry vacuum cleaner
Zinc dust paint suitable for spot welding		 See *BR00.45-Z-1001-07A .
    White sealing compound, 310 ml, DBL 6069.20 See *BR00.45-Z-1003-01A .
    Parts kit for 2-component adhesive for body See *BR00.45-Z-1162-02A .
    Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) See *BR00.45-Z-1012-13A .
    SPECIAL TOOL Side portal frame
As an alternative to restoring surfaces with body solder.
↓
Apply basic body filler.		 See Fig 2.
      See AR60.00-P-0031-01LWG .
    Basic body filler See *BR00.45-Z-1057-07A .
    Parts kit for 2-component adhesive for body See *BR00.45-Z-1162-02A .
9 Release vehicle from straightening bench, lift vehicle and remove straightening bench    
10 Clean welds and sheet metal flanges IMPORTANTCommercially available devices/tools 
Round wire brush		  
11 Install rear fender   See AR63.50-P-1401LWR .
12 Remove spark protection blankets    
13 Clean repair area IMPORTANTCommercially available devices/tools 
Wet/dry vacuum cleaner		  
14 Prime repair area using primer filler
Notes on paintwork repairs		 IMPORTANT Use only primer filler approved by Daimler AG. See AH98.00-P-9408-02A .
15 Seal seam following repairs   See AR97.10-P-4000LW .
16 Paint repair areas and adjacent surfaces
Notes on paintwork repairs		 IMPORTANT Use only paints approved by Daimler AG. See AH98.00-P-9408-02A .
17 Add cavity preserving agent   AR97.20-P-1500LW
18 Install all detachable body components in area to be repaired    
Fig 2: Side Portal Frame (210 589 17 23 00)
G07321115Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20
BR00.45-Z-1012-13A Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) A 004 990 16 97
BR00.45-Z-1057-07A Basic body filler A 012 989 29 71
BR00.45-Z-1162-02A Parts kit for 2-component adhesive for body A 012 989 17 71
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