Remove/install outer sidewall - AR63.10-P-0805PB

MODEL 203.7

Fig 1: Identifying Outer Side Wall - Model 203.7

	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
	Notes on paintwork repairs	All models	AH98.00-P-9408-02A
	Guidelines for removing fuel tank when performing welding work on bodies	All models	AH60.00-P-3000-01Z
	General information on MB materials	All models	AH98.00-P-9409-03A
1	Install fuel filler neck covering	When replacing right rear fender.	AR63.50-P-1400-01P
		Catches	Figure
2	Remove rear-end door		AR72.20-P-3500PB
3	Remove detachable parts in area to be repaired
4	Cover all detachable body components remaining in vehicle (area to be repaired)	Tarp (fire-resistant)	*WH58.30-Z-1001-40A
5	Equip straightening bench with module members or crossmembers and straightening bracket set	Observe assembly plans provided
		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 set 7203.310 (for model 203), only for new orders, includes supplement 7203.309	*WE58.40-Z-1032-01A
		Car-Bench universal crossmember set A 296	*WE58.40-Z-1010-01E
		Car-bench straightening set 82434 (for model 203)	*WE58.40-Z-1030-01A
		Multi-Z straightening set system MZ 450.000	*WE58.40-Z-1006-01E
6	Set vehicle onto straightening bench using two-column lift and fasten	Two-post lift	*WE58.40-Z-1001-05A
7	Separate outer sidewall		AR63.10-P-0805-01PB
		Spot weld milling cutter	Figure
		Ball cutter, dia. 12 mm	*WH58.30-Z-1002-01A
		Vario Drill WS 91 spot weld removing tool	*WH58.30-Z-1006-01A
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)	*WH58.30-Z-1024-04A
		Hot-air gun -3000 W	*WH58.30-Z-1004-20A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Angle grinder (electric/pneumatic)	*WE58.40-Z-1003-03A
		Body saw (electric/pneumatic)	*WE58.40-Z-1004-03A
		Wet/dry vacuum cleaner	*WE58.40-Z-1005-03A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
8	Prepare new outer side wall		AR63.10-P-0805-02PB
		Round wire brush, braided, dia. Ø 70 mm	*WH58.30-Z-1001-03A
		Hole punching pliers, dia. Ø 6 mm.	*WH58.30-Z-1001-02A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
9	Install and weld in outer side wall		AR63.10-P-0805-03PB
	General information on riveting		AH60.00-P-0003-01N
		Feeler gauge	Figure
		Bending iron	Figure
		Inspection and welding device	Figure
		Side portal frame	Figure
		Electrode miller	*WH58.30-Z-1003-01A
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)	*WH58.30-Z-1024-04A
		Clamping pliers	*WH58.30-Z-1003-02A
		Hand riveter	*WH58.30-Z-1003-29A
		Power Bird blind rivet tool	*WE58.40-Z-1003-14A
		Screw-on pliers, dia. 6.4 mm -Clamping range 0-15 mm, identification color silver	*WH58.30-Z-1038-02A
		Rivet	*BR00.45-Z-1001-13A
		Inert gas welder	*WE58.40-Z-1001-02A
		Spot welder	*WE58.40-Z-1002-02A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Sealant	*BR00.45-Z-1003-01A
10	Adjust gap dimensions on hoods, doors and lids		AR60.00-P-0700-01PB
		Front door/rear fender	*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
		Feeler gauge	Figure
11	Install roof	Steel roof
12	Detach vehicle from straightening bench and lift with two-column lift. Remove straightening bench.	Two-post lift	*WE58.40-Z-1001-05A
13	Clean areas to be repaired and prime with primer filler
14	Seam sealing following repair	Supplement standard seals with MB preservative.	AR97.10-P-4000P
		Sealant	*BR00.45-Z-1003-01A
15	Paint repair areas and adjacent surfaces
16	Install tailgate		AR72.20-P-3500PB
17	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
18	Remove covers for filler fitting	When replacing right rear fender.	AR63.50-P-1400-01P
19	Install all removed assembly parts

TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number	Designation				Model 203.706/707/ 708/718/735/ 740/742/743/ 745/746/747/ 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 section, 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)
BE60.00-P-1005-01E	Gap dimension	Fuel filler flap	See picture		AR60.00-P-0700-01PB

Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Fig 3: Identifying Catches (203 589 00 91 00)

Fig 4: Identifying Bending Iron (129 589 00 27 00)

Fig 5: Identifying Feeler Gauge (129 589 03 21 00)

Fig 6: Identifying Inspection And Welding Device (203 589 00 23 00)

Fig 7: Identifying Side Portal Frame (210 589 17 23 00)

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-1001-02A	Hole punching pliers, dia. 6 mm.
WH58.30-Z-1003-02A	Clamping pliers
WH58.30-Z-1038-02A	Manual temporary fastener, dia. 6.4 mm - span range 0...15 mm, identification color silver 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-1004-20A	Hot-air gun
WH58.30-Z-1003-29A	Hand riveter
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-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
WE58.40-Z-1003-14A	Blind rivet tool

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-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42
BR00.45-Z-1001-13A	Rivet	A 003 990 35 97