Remove/install D-pillar - AR63.20-P-2000ES
WARNING: This page does not describe the selected car, but rather 33 other vehicles, including the 2016 Mercedes-Benz E63 S AMG, 2016 Mercedes-Benz E400, 2016 Mercedes-Benz E350, 2016 Mercedes-Benz E300, and 2016 Mercedes-Benz E250. However, it is still accessible from the selected car via links, so may be relevant.
MODEL 212.2, 218.9
Shown on model 212.2
| 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 flammable materials from the hazard area. Use air extraction system. | AS00.00-Z-0007-01A | |
| 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. | AS00.00-Z-0010-01A | |
| Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes | Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only. | AS00.00-Z-0016-01A | |
| 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 | |
| General information on body repair | AH60.00-P-0001-01A | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| Remove | |||
| 1 | Prepare all workshop equipment and commercially available tools required for repair | ||
| 2 | Remove all detachable parts in repair area | ||
| 3 | Cover all detachable parts remaining in vehicle with welding protection blankets |
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| 4 | Equip straightening bench with module members, cross members and straightening tool set | Straightening systems for passenger cars (Celette) Straightening systems for passenger cars (Car Bench) Straightening systems for passenger cars (Car-O-Liner) |
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| 5 | Lift vehicle with two-post lifting platform | Two-column lift 2.5 - 3.5 t electrohydraulic | |
| 6 | Set vehicle onto straightening bench | ||
| 7 | Fasten vehicle to straightening bench | ||
| 8 | Remove rear fender | MODEL 212.2 | AR63.50-P-1400ES |
| MODEL 218.9 | AR63.50-P-1400ELX | ||
| 9 | Remove rear end assembly reinforcement | Type with reinforcements | AR64.20-P-1020-01ESA |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 10 | Separate D-pillar | MODEL 212.2 | AR63.20-P-2000-01ES |
MODEL 218.9
Body jig saw
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AR63.20-P-2000-01ELX | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 11 | Preparing D-pillar for installation | MODEL 212.2 | AR63.20-P-2000-02ES |
MODEL 218.9
Body jig saw
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AR63.20-P-2000-02ELX | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 12 | Install D-pillar | MODEL 212.2 | AR63.20-P-2000-03ES |
| General information on riveting | AH60.00-P-0003-01N | ||
| MODEL 218.9 | AR63.20-P-2000-03ELX | ||
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| Blind rivet 6.5 X 12.5 | *BR00.45-Z-1012-13A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Body adhesive kit, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| Gap dimension MODEL 212.2 | *BE60.00-P-1002-01U | ||
| Gap dimension MODEL 212.2 | *BE60.00-P-1005-01U | ||
| Gap dimension MODEL 218.9 | *BE60.00-P-1002-01O | ||
| Gap dimension MODEL 218.9 | *BE60.00-P-1005-01O | ||
| Figure | |||
| For measuring points of gap dimensions on body. Gap dimensions on hoods, doors and lids |
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| MODEL 212.2 | AR60.00-P-0700-01EW | ||
| MODEL 218.9 | AR60.00-P-0700-01EL | ||
| 13 | Install rear fender | MODEL 212.2 | AR63.50-P-1400ES |
| MODEL 218.9 | AR63.50-P-1400ELX | ||
| 14 | Unfasten vehicle from straightening bench | ||
| 15 | Lift vehicle with two-post lifting platform | Two-column lift 2.5 - 3.5 t electrohydraulic | |
| 16 | Remove straightening bench | ||
| 17 | Clean weld joints and sheet metal flanges with rotary wire brush |
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| 18 | Clean repair area |
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| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 19 | Prime repair area using primer filler | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 20 | Carry out seam sealing after repairs | MODEL 212.2 | AR97.10-P-4000EW |
| MODEL 218.9 | AR97.10-P-4000EL | ||
| White sealing compound, 310 ml, DBL 6069.20 | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 21 | Paint repair areas and adjacent surfaces | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents | Never spray corrosion protection on flames or hot, glowing objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection. | AS97.00-Z-0001-01A | |
| 22 | Apply additional cavity preservation | MODEL 212.2, 218.9 | |
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| MODEL 218.9 | AR97.20-P-1500EL | ||
| Cavity preservation, solvent-free (1 l container) Combination spray gun (corrosion protection) |
*BR00.45-Z-1003-05A | ||
| 23 | Remove welding protection blankets | ||
| 24 | Install all detachable body components in area to be repaired |
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS
| Number | Designation | MODEL 218.9 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01O | Gap dimension | Fender to A-pillar | Dimension "D" | mm | 3, 5 (±1) |
| Front door to fender | Dimension "E" | mm | 4, 0 (-0, 5/+1) | ||
| Front door to rear door | Dimension "F" | mm | 5, 0 (-0, 5/+1) | ||
| B-pillar cover to front window | Dimension "G" | mm | 10 (±1) | ||
| B-pillar cover to rear window | Dimension "H" | mm | 10 (±1) | ||
| Rear door to side piece, bottom | Dimension "I" | mm | 4, 5 (±1) | ||
| Fixed window on rear door to fixed window on rear side window | Dimension "O" | mm | 7, 5 (±1) | ||
| Picture | AR60.00-P-0700-01EL | ||||
CHECK VALUES FOR GAP DIMENSIONS
| Number | Designation | MODEL 212.2 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01U | Gap dimension | Front door to fender | Dimension "G" | mm | 4 (+1/-0, 5) |
| Front door to rear door | Dimension "H" | mm | 4, 5 (+1/-0, 5) | ||
| Front door to roof frame | Dimension "I" | mm | 14 (±1, 5) | ||
| Rear door to roof frame | Dimension "J" | mm | 13 (±1, 5) | ||
| Rear door to side piece, bottom | Dimension "K" | mm | 4 (+1/-0, 5) | ||
| Driver door cover to rear door cover | Dimension "W" | mm | 4 (±1) | ||
| Picture | AR60.00-P-0700-01EW | ||||
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS
| Number | Designation | MODEL 218.9 | |||
|---|---|---|---|---|---|
| BE60.00-P-1005-01O | Gap dimensions | Liftgate to roof (spoiler removed) | Dimension "R1" | mm | 10 (±1, 5) |
| Spoiler to roof | Dimension "R2" | mm | 5, 0 (±1, 5) | ||
| Liftgate to rear fender | Dimension "P" | mm | 4, 5 (±1) | ||
| Liftgate to taillamp | Dimension "V" | mm | 5, 0 (±1) | ||
| Liftgate to bumper | Dimension "W" | mm | 6, 0 (±1, 5) | ||
| Rear window and D-pillar | Dimension "X" | mm | 4, 5 (±1, 5) | ||
| Rear window to liftgate, bottom | Dimension "Y" | mm | 3, 0 (±0, 5) | ||
CHECK VALUES FOR GAP DIMENSIONS
| Number | Designation | MODEL 212.2 | |||
|---|---|---|---|---|---|
| BE60.00-P-1005-01U | Gap dimension | Liftgate to roof | Dimension "R" | mm | - |
| Liftgate to roof (spoiler removed) | Dimension "R1" | mm | 9, 5 (±1, 5) | ||
| Spoiler to roof | Dimension "R2" | mm | 5 (±1, 5) | ||
| Liftgate to rear fender | Dimension "S" | mm | 4 (+1, 5/-1) | ||
| Liftgate to taillamp | Dimension "T" | mm | - | ||
| Liftgate to bumper | Dimension "U" | mm | 6 (±1, 5) | ||
| Liftgate to D-pillar | Dimension "V" | mm | - | ||
| Rear window and D-pillar | Dimension "X" | mm | - | ||
| Top sliding roof to roof | Dimension "Y" | mm | 5 (±1, 5) | ||
| Rear window to liftgate, bottom | Dimension "Z" | mm | 3 (±1, 5) | ||
| - | |||||
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-1003-05A | Cavity preservation, solvent-free (1 l container) | A 000 986 72 70 05 |
| BR00.45-Z-1012-13A | Blind rivet 6.5 X 12.5 | A 004 990 16 97 |
| BR00.45-Z-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 20 |
| BR00.45-Z-1092-02A | Body adhesive kit, 2-component adhesive | A 009 989 36 71 |