LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 2002 >> C240 Automatic >> Repair and Diagnosis >> Collision >> General Collision Information >> Front End & Fire Wall >> Testing & Repair >> Replace complete wheelhouse - AR62.20-P-1200P

Replace complete wheelhouse - AR62.20-P-1200P

MODEL 203.0/ 2/ 7, 209 

Shown on model 203.0 

Fig 1: Identifying Complete Wheelhouse
G04735110
REMOVING Remove     
DANGER 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
DANGER 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
DANGER 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
NOTES Measures for preventing damage to vehicles or components when performing arc welding work All models AH00.00-N-0005-01A
NOTES General information on repairs to body All models AH60.00-N-0001-01A
NOTES Notes on paintwork repairs Model 124, 126, 129, 140, 163, 168, 169, 170, 171, 199, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 240, 414, 463, 639 AH98.00-P-9408-02A
1 Remove engine hood Model 203 AR88.40-P-3000P
    Model 209 AR88.40-P-3000Q
2 Remove front fender Model 203 AR88.10-P-1000P
    Model 209 AR88.10-P-1000Q
3 Remove front door Model 203 AR72.10-P-0500P
    Model 209 AR72.10-P-0500Q
4 Remove front seat Model 203 AR91.10-P-1000P
    Model 209 AR91.10-P-1000Q
5 Remove floor mats    
6.1 Remove instrument panel carrier Model 203
NOTES Secure heater or AC housing to prevent damage		 AR68.10-P-1111P
6.2 Remove crossmember under instrument panel Model 209.3 AR68.10-P-1120Q
    Model 209.4
NOTES Secure heater or AC housing to prevent damage		 AR68.10-P-1120QA
7 Remove parking brake pedal assembly   AR42.20-P-0510P
8 Remove or free up electrical lines and vacuum lines in area to be repaired.    
9 Remove front end assembly with reinforcement   AR62.30-P-1570P 
10 Remove exhaust system Engine 113.988 in model 203076/276
Engine 113 in model 209.376 as of 24.4.04		 AR49.10-P-7000AC
    Engine 112 in model 203
Engine 112 in model 209
Engine 113.968 in model 209.375/475
Engine 113.987 in model 209.376 up to 23.4.04
Engine 113.987 in model 209.476		 AR49.10-P-7000PV
    Engine 111.951 in model 203.035/235/735
Engine 111.955 in model 203.045/245/745
Engine 111.981 in model 203.747		 AR49.10-P-7000PR
    Engine 646 in model 203 AR49.10-P-7000PM
    Engine 271.940 in model 203.042/242/742
Engine 271.946 in model 203.046/246/746
Engine 271.948 in model 203.040/240/740
Engine 271.940 in model 209.342/442		 AR49.10-P-7000QK
    Engine 611.962 in model 203.004/006/204/206/706
Engine 612.962 in model 203.016/216
Engine 612.967 in model 209.316		 AR49.10-P-7000PP
    Engine 612.990 in model 203.018/218/718 AR49.10-P-7000PF
    Engine 271.942 in model 209.3, 203 AR49.10-P-7000QD
11 Remove engine    
    Engine 111.951 in model 203.035/235 /735 with transmission 716.6
Engine 111.955 in model 203.045/245 /745 with transmission 716.6		 AR01.10-P-2400PR
    Engine 111.951 in model 203.035/235 /735 with transmission 722.6
Engine 111.955 in model 203.045/245 /745 with transmission 722.6		 AR01.10-P-2400PK
    Engine 112.912 in model 203.061/261 with transmission 716.6, 722.6
Engine 112.961 in model 203.065/265 with transmission 722.6
Engine 112.946 in model 203.064/264/764
Engine 112.912 in model 209.361/461 with transmission 716.6, 722.6
Engine 112.955 in model 209.365/465 with transmission 722.6		 AR01.10-P-2400PV
    Engine 112 in model 203.081/084/281/284 AR01.10-P-2400PW
    Engine 113.968 in model 209.375/475 with transmission 722.633
Engine 113.987 in model 209.376/476 with transmission 722.636		 AR01.10-P-2400Q
    Engine 113.988 in model 203.076/276 with transmission 722.6 AR01.10-P-2400AC
    Engine 271.940 in model 203.042/242 /742 with transmission 716.6
Engine 271.946 in model 203.046/246 /746 with transmission 716.6
Engine 271.948 in model 203.040/740 with transmission 716.6
Engine 271.940 in model 209.342 with transmission 716.6		 AR01.10-P-2400QK
    Engine 611.962 in model 203.004/006/204/206/706 AR01.10-P-2400PP
    Engine 612.962 in model 203.016/216
Engine 612.967 in model 209.316		 AR01.10-P-2400PD
    Engine 612.990 in model 203.018/218/718 AR01.10-P-2400PF
    Engine 646 in model 203 AR01.10-P-2400PM
12 Remove front axle Model 209  
    Model 203 except model 203.081/084/281/284 AR33.10-P-0100P
    Model 081/084281/284203 AR33.10-P-0100PW
13 Remove jacket tube Model 203
Electrically adjustable jacket tube		  
    Model 203 with mechanically adjustable jacket tube, except 203.081/084/281/284 AR46.10-P-0400P
    Model 203.081/084/281/284 with mechanically adjustable jacket tube AR46.10-P-0400PA
    Model 209
Manually adjustable jacket tube		 AR46.10-P-0400Q
    Model 209
Electrically adjustable jacket tube		 AR46.10-P-0400QE
14 Remove detachable parts in area to be repaired    
15 Cover all detachable body components remaining in vehicle (area to be repaired) Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
16 Set up straightening bench with modular or crossmembers and straightening tools IMPORTANT Observe the setup plans enclosed!  
    Celette straightening bench M8S *WE58.40-Z-1001-01E 
    Celette straightening bench Sevenne *WE58.40-Z-1001-01E 
    Set of Celette module members 955.940 *WE58.40-Z-1007-01E 
    Celette additional member 955.908 *WE58.40-Z-1008-01E 
    Celette straightening bench 7203.300 (for model 203) *WE58.40-Z-1029-01A 
    Car-Bench straightening bench BT 17 *WE58.40-Z-1003-01E 
    Car-Bench straightening bench BT 43/1 *WE58.40-Z-1003-01E 
    Celette straightening bracket set 7203.309 (for model 203) as supplement to 7203.300 *WE58.40-Z-1031-01A 
    Celette straightening bracket set 7203.310 (for model 203), only for new orders, includes supplement 7203.309 *WE58.40-Z-1032-01A 
    Celette straightening bracket set 7209.309 (for model A 209) as supplement to 7203.300 (model 203) as well as 7203.310 (model C 209) *WE58.40-Z-1042-01A 
    Celette 7203.308 supplementary straightening bracket set for Celette straightening bracket set 7203.310 (for model 203 4MATIC) *WE58.40-Z-1047-01A 
    Car-Bench universal crossmember set A296 *WE58.40-Z-1010-01E 
    Car-bench straightening bracket set 82434 (for model 203) *WE58.40-Z-1030-01A 
    Car-Bench 82445 supplementary straightening set for Car-Bench straightening bracket set 82434 (for model 203 4MATIC) *WE58.40-Z-1048-01A 
    Multi-Z straightening set system MZ 450.000 *WE58.40-Z-1006-01E 
17 Place vehicle on straightening bench using two-post lift Two-post lift *WE58.40-Z-1001-05A 
18 Attach vehicle to straightening bench    
19 Cut out wheelhouse on passenger compartment side   AR62.20-P-1200-11P 
    SPECIAL TOOL Spot weld milling cutter Figure
    COMMERCIALLY AVAILABLE TOOLS Spherical milling cutter, dia. 12 mm *WH58.30-Z-1002-01A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
20 Separate wheelhouse on fender side   AR62.20-P-1200-12P 
    SPECIAL TOOL Spot weld milling cutter Figure
    COMMERCIALLY AVAILABLE TOOLS Spherical milling cutter, dia. 12 mm *WH58.30-Z-1002-01A 
    COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot weld removing tool *WH58.30-Z-1006-01A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
21 Cut out wheelhouse on engine compartment side   AR62.20-P-1200-03P 
    SPECIAL TOOL Spot weld milling cutter Figure
    COMMERCIALLY AVAILABLE TOOLS Spherical milling cutter, dia. 12 mm *WH58.30-Z-1002-01A 
    COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot weld removing tool *WH58.30-Z-1006-01A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
    Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
22 Prepare body for welding in wheelhouse   AR62.20-P-1200-13P 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm) *WH58.30-Z-1024-04A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
23 Prepare wheelhouse for welding   AR62.20-P-1200-14P 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Hole punching pliers, dia. 7 mm *WH58.30-Z-1002-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install     
24 Install wheelhouse and weld in   AR62.20-P-1200-17P 
    COMMERCIALLY AVAILABLE TOOLS Electrode miller *WH58.30-Z-1003-01A 
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    Inert gas welder *WE58.40-Z-1001-02A 
    Spot welder *WE58.40-Z-1002-02A 
    Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Cavity preservation gun Sata HRS no. 11072 *WE58.40-Z-1006-08A 
    Sealant *BR00.45-Z-1003-01A 
    Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
    MB cavity wax preservation, 1 l *BR00.45-Z-1003-05A 
25 Unfasten vehicle from straightening bench    
26 Lift vehicle with two-post lift Two-post lift *WE58.40-Z-1001-05A 
27 Remove straightening bench.    
28 Clean repair areas IMPORTANT Observe notes on paintwork repairs  
29 Prime area to be repaired with priming filler    
30 Carry out seam sealing after repairs Model 203 AR97.10-P-4000P
    Model 209
IMPORTANT Supplement standard seals with MB body sealant.		 AR97.10-P-4000Q
    Sealant *BR00.45-Z-1003-01A 
31 Paint wheelhouse and adjacent surfaces    
32 Perform cavity preservation after repair work Model 203.0 AR97.20-P-1500P
    Model 203.2 AR97.20-P-1500PA
    Model 203.7 AR97.20-P-1500PB
    Model 209.3 AR97.20-P-1500Q
    Model 209.4 AR97.20-P-1500QA
NOTES Notes on cavity preservation Model 124, 126, 129, 140, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 240, 463, 639, 671, 690.6, 901, 902, 903, 904, 905
Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7		 AH97.20-P-0001-01B
33 Install parking brake pedal assembly   AR42.20-P-0510P
34 Install jacket tube Model 203
Electrically adjustable jacket tube		  
    Model 203 with mechanically adjustable jacket tube, except 203.081/084/281/284 AR46.10-P-0400P
    Model 203.081/084/281/284 with mechanically adjustable jacket tube AR46.10-P-0400PA
    Model 209
Manually adjustable jacket tube		 AR46.10-P-0400Q
    Model 209
Electrically adjustable jacket tube		 AR46.10-P-0400QE
35 Install front axle Model 209  
    Model 203 except model 203.081/084/281/284 AR33.10-P-0100P
    Model 081/084281/284203 AR33.10-P-0100PW
36 Install engine    
    Engine 111.951 in model 203.035/235 /735 with transmission 716.6
Engine 111.955 in model 203.045/245 /745 with transmission 716.6		 AR01.10-P-2400PR
    Engine 111.951 in model 203.035/235 /735 with transmission 722.6
Engine 111.955 in model 203.045/245 /745 with transmission 722.6		 AR01.10-P-2400PK
    Engine 112.912 in model 203.061/261 with transmission 716.6, 722.6
Engine 112.961 in model 203.065/265 with transmission 722.6
Engine 112.946 in model 203.064/264/764
Engine 112.912 in model 209.361/461 with transmission 716.6, 722.6
Engine 112.955 in model 209.365/465 with transmission 722.6		 AR01.10-P-2400PV
    Engine 112 in model 203.081/084/281/284 AR01.10-P-2400PW
    Engine 113.968 in model 209.375/475 with transmission 722.633
Engine 113.987 in model 209.376/476 with transmission 722.636		 AR01.10-P-2400Q
    Engine 113.988 in model 203.076/276 with transmission 722.6 AR01.10-P-2400AC
    Engine 271.940 in model 203.042/242 /742 with transmission 716.6
Engine 271.946 in model 203.046/246 /746 with transmission 716.6
Engine 271.948 in model 203.040/740 with transmission 716.6
Engine 271.940 in model 209.342 with transmission 716.6		 AR01.10-P-2400QK
    Engine 611.962 in model 203.004/006/204/206/706 AR01.10-P-2400PP
    Engine 612.962 in model 203.016/216
Engine 612.967 in model 209.316		 AR01.10-P-2400PD
    Engine 612.990 in model 203.018/218/718 AR01.10-P-2400PF
    Engine 646 in model 203 AR01.10-P-2400PM
37 Install exhaust system Engine 113 in model 203
Engine 113 in model 209.376 as of 24.4.04		 AR49.10-P-7000AC
    Engine 112 in model 203
Engine 112 in model 209
Engine 113.968 in model 209.375/475
Engine 113.987 in model 209.476, 209.376 up to 23.4.04		 AR49.10-P-7000PV
    Engine 111.951 in model 203.035/235/735
Engine 111.955 in model 203.045/245/745
Engine 111.981 in model 203.747		 AR49.10-P-7000PR
    Engine 646 in model 203 AR49.10-P-7000PM
    Engine 271.940 in model 203.042/242/742
Engine 271.946 in model 203.046/246/746
Engine 271.948 in model 203.040/240/740
Engine 271.940 in model 209.342/442		 AR49.10-P-7000QK
    Engine 611.962 in model
203.004/006/204/206/706
Engine 612.962 in model 203.016/216
Engine 612.967 in model 209.316		 AR49.10-P-7000PP
    Engine 612.990 in model 203.018/218/718 AR49.10-P-7000PF
    Engine 271.942 in model 209.3, 203 AR49.10-P-7000QD
38.1 Install instrument panel carrier Model 203
NOTES Secure heater or AC housing to prevent damage		 AR68.10-P-1111P
38.2 Install crossmember below instrument panel Model 209.3 AR68.10-P-1120Q
    Model 209.4
NOTES Secure heater or AC housing to prevent damage		 AR68.10-P-1120QA
39 Install electrical lines and vacuum lines in area to be repaired    
40 Install front seat Model 203 AR91.10-P-1000P
    Model 209 AR91.10-P-1000Q
41 Install floor mats    
42 Install engine hood Model 203 AR88.40-P-3000P
    Model 209 AR88.40-P-3000Q
43 Install front door Model 203 AR72.10-P-0500P
    Model 209 AR72.10-P-0500Q
44 Install front end assembly with front reinforcement   AR62.30-P-1570P 
45 Install front fender Model 203 AR88.10-P-1000P
    Model 209 AR88.10-P-1000Q
46 Install all removed detachable body components    

Special tools 

Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G04735111
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-1002-02A Hole punching pliers, dia. 7 mm
WH58.30-Z-1003-02A Clamping pliers
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-1001-40A Tarp (fire-resistant)
WORKSHOP EQUIPMENT

WE58.40-Z-1029-01A Celette straightening bracket set 7203.300 (model 203)
WE58.40-Z-1030-01A Car bench straightening bracket set 82434, (model 203)
WE58.40-Z-1031-01A Celette straightening bracket set 7203.309 (model 203), as supplement to 7203.300
WE58.40-Z-1032-01A Celette straightening bracket set 7203.310 (model 203), only with new ordering contains addition 7203.309
WE58.40-Z-1042-01A Celette straightening bracket set 7209.309 (model A 209), as supplement to 7203.300 (model 203), as well as 7203.310 (model C209)
WE58.40-Z-1047-01A Celette 7203.308 supplementary straightening set for Celette straightening bracket set 7203.310 (model 203 4MATIC)
WE58.40-Z-1048-01A Car-Bench 82445 supplementary straightening set for Car Bench straightening bracket set 82434 (model 203 4MATIC)
WE58.40-Z-1001-01E Celette straightening bench
WE58.40-Z-1003-01E Car-Bench straightening bench
WE58.40-Z-1006-01E Celette Multi-Z straightening set system
WE58.40-Z-1007-01E Celette module crossmember set 955.940
WE58.40-Z-1008-01E Celette additional member 955.908
WE58.40-Z-1010-01E Car-Bench universal cross member set A 296
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-1004-03A Body saw (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
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
scientia non olet · About LEMON Manuals