LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 2007 >> C230 Automatic >> Repair and Diagnosis >> Collision >> General Collision Information >> Body Panels -- Testing & Repair -- 203 Chassis - 2 Of 2 >> Testing & Repair >> Install outer side wall - AR63.10-P-0805-03PB

Install outer side wall - AR63.10-P-0805-03PB

TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number Designation Model 203.706/707/ 708/718/730/ 735/740/742/ 743/745/746/ 747/752/756/ 764
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 -
Front door to roof Dimension "C" mm -
Rear door to C-pillar Dimension "T" mm -
Rear door to side piece, bottom Dimension "J" mm -
Front door to rear fender Dimension "P" mm 3.5 (+1.0/-0.5)
  See picture   AR60.00-P-0700-01PB
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 2.5 (± 0.5)
  See picture   AR60.00-P-0700-01PB
BE60.00-P-1004-01E Gap dimension Rear-end door to roof Dimension "E" mm 8.5 (+1)
Rear-end door to rear fender Dimension "M" mm 3.5 (± 1)
Rear-end door to taillamp Dimension "L" mm 4 (± 1)
Rear-end door to bumper Dimension "S" mm 6.5 (-1.5)
Rear-end door to D-pillar Dimension "Q" mm -
  See picture   AR60.00-P-0700-01PB
BE60.00-P-1005-01E Gap dimension Fuel filler flap Dimension "K" mm 3.5 (± 1)
See picture   AR60.00-P-0700-01PB
Fig 1: Identifying Side Portal Frame (210 589 17 23 00)
G04738747
Fig 2: Identifying Inspection And Welding Device (203 589 00 23 00)
G04738748
Fig 3: Identifying Feeler Gauge (129 589 03 21 00)
G04738749
Fig 4: Identifying Bending Iron (129 589 00 27 00)
G04738750
REPAIR MATERIALS

Number Designation Order number
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-1001-13A Rivet A 003 990 35 97
  1. Apply MB body sealant to foam parts and outer wheel well.

    IMPORTANT Remove and replace damaged foam parts.

    Fig 5: Identifying MB Body Sealant On Outer Wheel Well
    G04738751
  2. Install outer side wall as well as side portal frame, check and welding gage, fit and fix in place.
  3. Install rear-end door, rubber seal and rear lamp.
  4. Check gaps and adjust.

    Outer side wall/taillamp.

    Outer side wall/rear-end door.

    IMPORTANT Use feeler gauge!

    Fig 6: Identifying Outer Side Wall And Side Portal Frame Installed
    G04738752
    Fig 7: Identifying Outer Side Wall Spot Welds Area (1 Of 3)
    G04738753
  5. Drill Ø 6 mm holes on outer longitudinal member, rear fender and outer longitudinal member using steel/steel flat head rivets, Ø 6 x 14 mm (area E).
  6. Outer side wall POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas G, H, I, L, M, N, O and R).
    Fig 8: Identifying Outer Side Wall Spot Welds Area (2 Of 3)
    G04738754
  7. Readjust spot weld flange on wheel well using crimping iron.

    IMPORTANT Spot welding flange position analog to undamaged side of vehicle.

  8. Outer side wall on wheel well POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas F and G).
    Fig 9: Identifying Outer Side Wall Spot Welds Area (3 Of 3)
    G04738755
  9. Remove side portal frame, inspection and welding device.
  10. Outer side wall POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas C, P, Q and T).
  11. Outer side wall SHIELDED GAS STITCH WELD (areas A and B).
  12. Outer side wall SHIELDED GAS PLUG WELD (areas D and S).
  13. Clean weld joints using wire brush.
  14. Fill rear fender with body solder in cross-hatched area and smooth.
    Fig 10: Identifying Rear Fender Filling Area
    G04738756
scientia non olet · About LEMON Manuals