Remove/install outer side wall - AR63.10-P-0805PA
MODEL 203.2
| Removing | |||
| 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 lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding spatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. | Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. | 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 repairs to body | All models | AH60.00-N-0001-01A | |
| Measures for preventing damage to vehicles or components when performing electric welding work | All models | AH00.00-N-0005-01A | |
| Guidelines for removing fuel tank when performing welding on bodies | All models | AH60.00-P-3000-01Z | |
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1.1 | Install filler neck covering | When replacing right rear fender. | AR63.50-P-1400-01P |
| Fig 8 | |||
| 2 | Remove detachable parts in repair area | ||
| 3 | Cover all detachable parts that remain in the repair area | Tarp (fire-resistant) | |
| 4 | Equip straightening bench with module members or crossmembers and straightening bracket set | Celette straightening bench M8S, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Celette straightening bench Sevenne, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Set of Celette module members 955.940, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Celette auxiliary member 955.908, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Celette straightening bracket set 7203.300 (for model 203), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Car-Bench straightening bench BT 17, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Car-Bench straightening bench BT 43/1, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Celette straightening bracket set 7203.309 (for model 203), as supplement to 7203.300, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Celette straightening bracket set 7203.310 (for model 203), only for new orders includes supplement 7203.309, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Celette 7203.308 supplementary straightening set for Celette straightening bracket set 7203.310 (for model 203 4MATIC), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Car-Bench universal crossmember set A 296, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Car-Bench straightening bracket set 82434 (for model 203), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Car-Bench 82445 supplementary straightening set for Car-Bench straightening bracket set 82434 (for model 203 4MATIC), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Multi-Z straightening set system MZ 450.000, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
|
| 5 | Set vehicle onto straightening bench using two-post lift and fasten | Two-post lift, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
|
| 6 | Separate outer side wall | AR63.10-P-0805-01PA | |
| Fig 9 | |||
Vario Drill WS 91 spot weld removing tool Round wire brush, braided, Ø 70 mm Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 rpm) Hot air gun - 3000 W Drill (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Angle grinder (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Body saw (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Wet/dry vacuum cleaner, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
Fig 10 | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 7 | Prepare outer side wall | AR63.10-P-0805-02PA | |
Hole punching pliers, Ø 6 mm. Round wire brush, braided, Ø 70 mm Drill (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Body saw (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
Fig 9 | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 8 | Install outer side wall | AR63.10-P-0805-03PA | |
| General information on riveting | AH60.00-P-0003-01N | ||
| Fig 11 | |||
| Fig 12 | |||
| Fig 13 | |||
Electrode miller Round wire brush, braided, Ø 70 mm Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 rpm) Clamping pliers Hand riveter Power Bird blind rivet tool, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Manual temporary fastener, Ø 6.4 mm - clamping range 0 - 15 mm, identification color silver |
Figure | ||
| Polygrip flat round head rivet, 6.4 x 14 mm Insert gas welder, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Spot welder, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Drill (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Wet/dry vacuum cleaner, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
*BR00.45-Z-1001-13A | ||
| MB body sealant for seam sealant (paintable/310 ml cartridge) | *BR00.45-Z-1003-01A | ||
| 9 | Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01PA | |
| Rear door to C-pillar | *BE60.00-P-1002-01E | ||
| Rear fender to taillamp | *BE60.00-P-1003-01E | ||
| Rear-end door to rear fender | *BE60.00-P-1004-01E | ||
| Fuel filler flap | *BE60.00-P-1005-01E | ||
| Fig 13 | |||
| 10 | Release vehicle from straightening bench and lift with two-column lift, remove straightening bench | Two-post lift, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
|
| 11 | Clean repair areas and prime using primer filler | ||
| 12 | Seam seal following repair | AR97.10-P-4000P | |
| MB body sealant for seam sealant (paintable/310 ml cartridge) | *BR00.45-Z-1003-01A | ||
| 13 | Paint repair areas and adjacent surfaces | ||
| 14 | Apply additional cavity preservation | ||
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Processing instructions for cavity preservation | AP97.20-P-0640-01A | ||
| 15.1 | Remove covers for filler neck | When replacing right rear fender. | AR63.50-P-1400-01P |
| 16 | Install all removed assembly parts |
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS
| Number | Designation | Model 203.204/206/ 207/208/216/ 218/220/235/ 240/242/243/ 245/246/252/ 254/256/261/ 264/265/281/ 284/287/292 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01E | Gap dimension | Front door to A-pillar | Dimension "B" | mm | 6.5 (+1) |
| Front door to fender | Dimension "H" | mm | 3.5 (-0.5/+1) | ||
| Front door to rear door | Dimension "I" | mm | 4 (-0.5/+1) | ||
| Front door to roof | Dimension "C" | mm | 6.5 (+1) | ||
| Rear door to C-pillar | Dimension "T" | mm | 6 (+1) | ||
| Rear door to side piece, bottom | Dimension "J" | mm | 3.5 (+1) | ||
| Front door to rear fender | Dimension "P" | mm | - | ||
| See picture | AR60.00-P-0700-01PA | ||||
| BE60.00-P-1003-01E | Gap dimension | Trunk lid to rear fender, top | Dimension "F" | mm | - |
| Trunk lid to taillamp | Dimension "M" | mm | - | ||
| Rear fender to taillamp | Dimension "U" | mm | 2 (0.5) | ||
| See picture | AR60.00-P-0700-01PA | ||||
| BE60.00-P-1004-01E | Gap dimension | Rear-end door to roof | Dimension "E" | mm | 6.5 (± 1) |
| Rear-end door to rear fender | Dimension "M" | mm | 3.5 | ||
| Rear-end door to taillamp | Dimension "L" | mm | 4 | ||
| Rear-end door to bumper | Dimension "S" | mm | 5.5 | ||
| Rear-end door to D-pillar | Dimension "Q" | mm | - | ||
| See picture | AR60.00-P-0700-01PA | ||||
| BE60.00-P-1005-01E | Gap dimension | Fuel filler flap | Dimension "K" | mm | 3.5 (-0.5/+0.5) |
| See picture | AR60.00-P-0700-01PA | ||||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | Sealant | A 001 989 63 20 |
| 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 |