Remove/install D-pillar - AR63.20-P-2000TA: Notes
MODEL 211.2
| Remove | |||
|---|---|---|---|
| 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 and position the four support plates below the lifting platform support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of death caused by high voltage used for arc welding. Risk of explosion caused by welding in the area of highly inflammable materials. Injury hazard from welding spatter and UV-light while welding. Risk of poisoning caused by inhaling welding vapors. | Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor. | 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 body repair | All models | AH60.00-N-0001-01A | |
| Measures for preventing damage to vehicles or components when performing arc 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) | Tarpaulin (fire-resistant) | *WH58.30-Z-1001-40A |
| 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 | |
| Figure | |||
| *WH58.30-Z-1006-01A | |||
| *WH58.30-Z-1002-01A | |||
| *WH58.30-Z-1001-03A | |||
| *WH58.30-Z-1024-04A | |||
| Drill (electric/pneumatic) | *WE58.40-Z-1001-03A | ||
| Straight grinder (electric/pneumatic) | *WE58.40-Z-1002-03A | ||
| Angular grinder (electric/pneumatic) | *WE58.40-Z-1003-03A | ||
| Wet/dry vacuum cleaner | *WE58.40-Z-1005-03A | ||
| Tarpaulin (fire-resistant) | *WH58.30-Z-1001-40A | ||
| Two-post lift | *WE58.40-Z-1001-05A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 6 | Prepare D-pillar for installation | AR63.20-P-2000-02TA | |
| Figure | |||
| *WH58.30-Z-1002-01A | |||
| *WH58.30-Z-1006-01A | |||
| *WH58.30-Z-1001-03A | |||
| *WH58.30-Z-1024-04A | |||
| Drill (electric/pneumatic) | *WE58.40-Z-1001-03A | ||
| Straight grinder (electric/pneumatic) | *WE58.40-Z-1002-03A | ||
| Angular grinder (electric/pneumatic) | *WE58.40-Z-1003-03A | ||
| 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 and 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 | ||
| Figure | |||
| 10 | Install D-pillar | AR63.20-P-2000-03TA | |
| General information on riveting | AH60.00-P-0003-01N | ||
| Figure | |||
| *WH58.30-Z-1003-01A | |||
| *WH58.30-Z-1003-02A | |||
| *WH58.30-Z-1038-02A | |||
| *WE58.40-Z-1003-14A | |||
| *WH58.30-Z-1003-29A | |||
| Inert gas welder | *WE58.40-Z-1001-02A | ||
| Spot welder | *WE58.40-Z-1002-02A | ||
| Drill (electric/pneumatic) | *WE58.40-Z-1001-03A | ||
| Wet/dry vacuum cleaner | *WE58.40-Z-1005-03A | ||
| Tarpaulin (fire-resistant) | *WH58.30-Z-1001-40A | ||
| Two-post lift | *WE58.40-Z-1001-05A | ||
| Cavity preservation gun Sata HRS no. 11072 | *WE58.40-Z-1006-08A | ||
| 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 areas to be repaired and prime with priming 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 side wall | AR63.10-P-0805TA | |
| 15 | Install complete 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 | Rear door to side section, bottom | Dimension "I" | mm | 3.5 (-0.5/+1) |
| See picture in | AR60.00-P-0700-01TA | ||||
| BE60.00-P-1003-01F | Gap dimension | Rear fender to taillamp | Dimension "M" | mm | 2.5 (± 1) |
| See picture in | AR60.00-P-0700-01TA | ||||
| BE60.00-P-1004-01F | Gap dimension | Fuel filler flap | Dimension "O" | mm | 3.5 (± 0.5) |
| See picture in | AR60.00-P-0700-01TA | ||||
| BE60.00-P-1005-01F | Gap dimension | 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 window and D-pillar | Dimension "T" | mm | 4.5 (± 1) | ||
| See picture in | AR60.00-P-0700-01TA | ||||
COMMERCIALLY AVAILABLE TOOLS
| Number | Designation |
|---|---|
| WH58.30-Z-1002-01A | Ball cutter, dia. 12 mm |
| WH58.30-Z-1003-01A | Electrode miller |
| WH58.30-Z-1006-01A | Vario Drill WS 91 spot weld removing tool |
| WH58.30-Z-1003-02A | Clamping pliers |
| WH58.30-Z-1038-02A | Manual temporary fastener, dia.6.4 mm - clamping range 0 -15 mm, identification color silver Firm Hausmann GmbH D-34346 Hann. Munden, Germany |
| WH58.30-Z-1001-03A | Round wire brush, braided, dia. 70 mm |
| WH58.30-Z-1024-04A | Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm) |
| WH58.30-Z-1003-29A | Hand riveter |
| WH58.30-Z-1001-40A | Tap (fire-resistant) |
WORKSHOP EQUIPMENT
| WE58.40-Z-1001-02A | Inert gas welder |
| WE58.40-Z-1002-02A | Spot welder |
| WE58.40-Z-1001-03A | Drill (electric/pneumatic) |
| WE58.40-Z-1002-03A | Straight grinder (electric/pneumatic) |
| WE58.40-Z-1003-03A | Angle grinder (electric/pneumatic) |
| WE58.40-Z-1005-03A | Wet/dry vacuum cleaner |
| WE58.40-Z-1001-05A | Two-post lifting platform |
| WE58.40-Z-1006-08A | Cavity preservation gun |
| WE58.40-Z-1003-14A | Blind rivet tool |
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 | A 001 989 63 20 |
| BR00.45-Z-1003-05A | Preservation agent | 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 | Rivet | A 003 990 35 97 |