Replace complete side roof paneling - AR65.10-P-1020PC
MODEL 203.0
Without replacing center roof paneling
| 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 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 | |
| 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 | |
| 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 repair area | ||
| 2 | Cover all detachable parts that remain in the repair area | Tarp (fire-resistant) | |
| 3 | Remove roof paneling at side | AR65.10-P-1020-01PC | |
| Figure | |||
| Figure | |||
| Ball cutter, ø 12 mm 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) Drill (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Straight grinder (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 |
|||
| Hot-air gun Wet/dry vacuum cleaner, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
|||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 4 | Prepare roof paneling at side | AR65.10-P-1020-02PC | |
| Round wire brush, braided, ø 70 mm Hole punching pliers, ø 7 mm Drill (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Body saw (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
|||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 5 | Weld in side roof paneling | AR65.10-P-1020-03PC | |
| General information on riveting | AH60.00-P-0003-01N | ||
| Gap dimensions | *BE60.00-P-1002-01E | ||
| Figure | |||
| Round wire brush, braided, ø 70 mm Clamping pliers Electrode miller Hand riveter Manual temporary fasteners ø6.4 mm - clamping range 0-15 mm, identification color silver |
|||
| Polygrip flat round head rivet, 6.4 x 14 mm Abrasive disk, ø 115 mm, 80 m/s (max. 13,250 rpm) 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 Angle grinder (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Zinc dust paint suitable for spot welding |
*BR00.45-Z-1001-13A | ||
| 6 | Clean repair areas and prime using primer filler | ||
| 7 | Seam seal following repair | AR97.10-P-4000P | |
| Sealant | *BR00.45-Z-1003-01A | ||
| 8 | Paint repair areas and adjacent surfaces | ||
| 9 |
Apply additional cavity preservation | AP97.20-P-0640-01A | |
| Notes on cavity preservation | Model 124, 126, 129, 140, 170, 201, 202, 203, 208, 210, 215, 220, 463, 671 | AH97.20-P-0001-01B | |
| 10 | Install all removed detachable body components |
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS
| Number | Designation | Model 203.004/006/007/008/016/018/020/035/040/042/043/045/046/052/056/061/064/065/081/084/087 | |||
|---|---|---|---|---|---|
| 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 | - | ||
| 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-0700-01P | ||||
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 |
| BR00z.45-Z-1001-13A | Rivet | A 003 990 35 97 |