Remove/install outer sidewall - AR63.10-P-0805TA
MODEL 211.2
| 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 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 caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel | 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 | AH60.00-N-0001-01A | ||
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-N-0005-01A | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| Guidelines for removing fuel tank when performing welding work on bodies | AH60.00-P-3000-01Z | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1 | Remove detachable parts on outer side of rear fender | ||
| 2.1 | Install filler neck covering | AR63.50-P-1400-01TA | |
| *211589009100 | |||
| *211589029100 | |||
| 3 | Remove detachable components in trunk, area of side wall | ||
| 4 | Remove detachable parts in vehicle interior (repair area) | ||
| 5 | Cover all detachable body components remaining in vehicle (area to be repaired) | Tarp (fire-resistant) | |
| 6 | Equip straightening bench with module members, cross members and straightening bracket set. | Celette straightening bench M8S http://gotis.aftersales.mercedes-benz.com Sevenne Celette straightening bench http://gotis.aftersales.mercedes-benz.com Set of Celette modular members 955.940 http://gotis.aftersales.mercedes-benz.com Celette auxiliary cross member 955.908 http://gotis.aftersales.mercedes-benz.com Car-Bench straightening bench BT 17 http://gotis.aftersales.mercedes-benz.com Car-Bench straightening bench BT 43/1 http://gotis.aftersales.mercedes-benz.com Car-Bench universal crossmember set A 296 http://gotis.aftersales.mercedes-benz.com Multi-Z straightening set system MZ 450.000 http://gotis.aftersales.mercedes-benz.com Celette straightening tool set 7211.300 (for model 211) http://gotis.aftersales.mercedes-benz.com Car-Bench straightening tool set 82441 (for model 211) http://gotis.aftersales.mercedes-benz.com Celette 7211.309 supplementary straightening tool to Celette straightening tool set 7211.300 for model S 211 http://gotis.aftersales.mercedes-benz.com Car-Bench 82450 supplementary straightening tool to Car-Bench straightening tool set 82441 (for model S 211) http://gotis.aftersales.mercedes-benz.com Celette 7211.308 supplementary straightening tool to Celette straightening tool set 7211.300 (for model 211 4Matic) http://gotis.aftersales.mercedes-benz.com Car-Bench 82451 supplementary straightening tool to Car-Bench straightening tool set 82441 (for model 211 4Matic) http://gotis.aftersales.mercedes-benz.com |
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| 7 | Place vehicle on straightening bench using two-column lift | Two-post lift http://gotis.aftersales.mercedes-benz.com |
|
| 8 | Fasten vehicle to straightening bench | ||
| 9 | Separate center roof paneling | AR65.10-P-1000TA | |
| 10 | Separate outer sidewall | AR63.10-P-0805-01TA | |
| *211589009100 | |||
| *211589029100 | |||
| *211589052300 | |||
Ball cutter, dia. 12 mm Round wire brush, braided, dia. 70 mm Vario Drill WS 91 spot weld removing tool Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 RPM) Hot air gun - 3000 W Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Angle grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Body saw (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com Tarp (fire-resistant) Two-post lift http://gotis.aftersales.mercedes-benz.com |
*201589005100 | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 11 | Prepare outer sidewall | AR63.10-P-0805-02TA | |
| Round wire brush, braided, dia. 70 mm Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 12.1 | Install standard filler cap and fuel filler flap, tape gap | ||
| 13 | Install outer sidewall | AR63.10-P-0805-03TA | |
| General information on riveting | AH60.00-P-0003-01N | ||
| *210589172300 | |||
| *211589002300 | |||
| *129589032100 | |||
| *000589876300 | |||
| *129589002700 | |||
| *211589009100 | |||
| *211589029100 | |||
Round wire brush, braided, dia. 70 mm Electrode miller PowerBird blind rivet tool http://gotis.aftersales.mercedes-benz.com Clamping pliers Hand riveter Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 RPM) Inert gas welder http://gotis.aftersales.mercedes-benz.com Spot welder http://gotis.aftersales.mercedes-benz.com Angle grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Tarp (fire-resistant) Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com Two-post lift http://gotis.aftersales.mercedes-benz.com |
*211589122300 | ||
| Polygrip flat round head rivet, 6.4 14 | *BR00.45-Z-1001-13A | ||
| 14 | Install center roof paneling | AR65.10-P-1000TA | |
| 15 | Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01TA | |
| Rear fender and taillamp | *BE60.00-P-1003-01F | ||
| Taillamp in rear-end door to taillamp | *BE60.00-P-1005-01F | ||
| Rear-end door to rear fender | *BE60.00-P-1005-01F | ||
| Rear window and D-pillar | *BE60.00-P-1005-01F | ||
| Fuel filler flap | *BE60.00-P-1004-01F | ||
| Rear door to side section, bottom | *BE60.00-P-1002-01F | ||
| *129589032100 | |||
| 16 | Unfasten vehicle from straightening bench | ||
| 17 | Lift vehicle with two-post lift | Two-post lift http://gotis.aftersales.mercedes-benz.com |
|
| 18 | Remove straightening bench. | ||
| 19 | Clean area to be repaired | ||
| 20 | Prime area to be repaired with primer filler | ||
| 21 | Carry out seam sealing after repairs | AR97.10-P-4000T | |
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 22 | Paint repair areas and adjacent surfaces | ||
| 23 | Cavity preservation following repair work | AR97.20-P-1500T | |
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Cavity preservation gun, Sata HRS no. 11072 http://gotis.aftersales.daimlerchrysler.com |
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| Preservation agent | *BR00.45-Z-1003-05A | ||
| 24 | Remove tarp from all covered parts that remained in the vehicle. | Tarp (fire-resistant) | |
| 25 | Install detachable parts on outside of rear fender | ||
| 26 | Install detachable parts in luggage compartment, in area of rear fender | ||
| 27 | Install detachable parts in passenger compartment (repair area) |
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS
| Number | Designation | Model 211.2 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01F | Gap dimension | Front door to A-pillar | Dimension "D" | mm | 4.5 (-0.5/+1) |
| Front door to fender | Dimension "E" | mm | 4 (-0.5/+1) | ||
| Front door to rear door | Dimension "F" | mm | 4 (-0.5/+1) | ||
| Front door to roof | Dimension "G" | mm | 4.5 (-0.5/+1) | ||
| Rear door to top of side section | Dimension "H" | mm | - | ||
| Rear door to side section, bottom | Dimension "I" | mm | 3.5 (-0.5/+1) | ||
| See picture | AR60.00-P-0700-01T A | ||||
| BE60.00-P-1003-01F | Gap dimension | Trunk lid to rear fender, top | Dimension "J" | mm | - |
| Trunk lid to rear lamp unit | Dimension "K" | mm | - | ||
| Trunk lid to bumper | Dimension "L" | mm | - | ||
| Rear fender to rear lamp unit | Dimension "M" | mm | 2.5 (±1) | ||
| Trunk lid license plate panel to rear lamp unit | Dimension "N" | mm | - | ||
| See picture | AR60.00-P-0700-01T A | ||||
| BE60.00-P-1004-01F | Gap dimension | Fuel filler flap | Dimension "O" | mm | 3.5 (±0.5) |
| See picture | AR60.00-P-0700-01T A | ||||
| BE60.00-P-1005-01F | Gap dimension | Liftgate spoiler/roof | Dimension "P" | mm | 7 (-0.5/+1) |
| Rear-end door to rear fender | Dimension "Q" | mm | 4.5 (±1) | ||
| Taillamp in rear-end door to taillamp | Dimension "R" | mm | 5 (±1) | ||
| Rear-end door to bumper | Dimension "S" | mm | 6 (±1.5) | ||
| Rear window and D-pillar | Dimension "T" | mm | 4.5 (±1) | ||
| Front door to roof | Dimension "U" | mm | 4.5 (-0.5/+1) | ||
| See picture | AR60.00-P-0700-01T A | ||||
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, white, 310 ml, DB supply specification 6069.20 | A 001 989 63 20 |
| BR00.45-Z-1003-05A | Cavity preservation, solvent-free (1 l container) | 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 | Blind rivet 6.4 14 | A 003 990 35 97 |