General information on body repair - AH60.00-P-0001-01A

Work protection and safety information

Always observe country specific and generally applicable protective equipment/safety information

Notes on repair method

Repair of damaged body panels is one of the most economical and time-saving measures and is preferable to replacing assemblies. If repair work is not possible, the connection type priorities should be observed as follows during the repair:

Resistance spot welding
Rivets
MAG weld joints, MIG solder connections

Basic requirements for correct execution of a body repair are:

Use of genuine Mercedes-Benz parts.
Use of approved materials (see repair descriptions).
Use of approved tools and machines
Strict observance of repair descriptions
MAG welt joints and MIG solder connections which are not in the immediately visible area or which are concealed by installed assembly parts when the vehicle is completed should not be ground down smooth or filled for reasons of economy and operating stability.

Paneling

Separating points on paneling can generally be selected freely.

Separating points should not be located in the area of the foam pieces (for exceptions see repair description)

Structural parts

Cut and replace structural parts only at standard joints and service separating points (see repair description)

Standard bonded load-bearing sections

Always restore standard glued structural areas during repair

Structural foams/structural reinforcements

Always replace structural foams/structural reinforcements

Glue adhesive points

Ensure on glued multiple-layer sheet metal connections, that the maximum permissible temperature does not exceed 120 C°. Higher temperatures permanently destroy the glue.

Always check temperature during heating (e.g. temperature measuring instrument).

Prepare gluing points

Always observe detailed work instructions included in gluing set, otherwise secure bonding of the glued connection cannot be ensured.

Welding, soldering method

Perform welding or soldering test before repair

Welding procedures, connections and symbols

Resistance spot welding

Single-row spot weld RP

Double-row spot weld RP

Double-row spot weld offset RP

Inert gas welding (MAG/MIG method)

Stitch weld SG

Continuous weld SG

Continuous weld interrupted ^SG

Plug weld ^SG

Soldering (brazing, MIG soldering)

Soldering ^H

On multiple-layer sheet metal connections with hardened glue, ensure that the resistance spot welds coincide with the original spot welds, otherwise the components to be welded can be damaged.

Engine and auxiliary equipment

Before performing any type of machining work on the body, cover engine including all additional equipment (e.g. alternator, magnetic clutches, etc.) to prevent damage from metal chips.

Metal shavings

Remove metal shavings with vacuum cleaner only.

Corrosion protection

Apply preservation agent to repair points after body and paintwork.

Components

Following accidents, visually check electronic components, steering and seat belts.

Air conditioning

Do not weld or perform similar types of work on components in the closed air conditioning system or in its immediate vicinity.

Drill, saw

Before drilling or sawing, remove electric lines and pipes installed in cavities as well as reservoirs located in concealed locations (e.g. battery) and electronic components from hazard area.

Thread repair

Defective metric threads (as of M8) can be repaired (e.g. Helicoil or Timesert). However, this is only possible with threaded tubes.

Thread-rolling thread

Thread rolling screws can be used several times.
Thread-rolling thread can be repaired (e.g. Helicoil or Timesert).
Thread-rollling threads should only be recut with a thread tap.
Only use original bolts.
Used materials
Low-carbon steel
up to 300 N/mm ² tensile strength
High-strength steel
- 550 N/mm ² tensile strength
Modern high-strength steel
- 1000 N/mm ² tensile strength
Ultra-high-strength steel
1000- 1500 N/mm² tensile strength
Aluminum
Magnesium
Plastics

Always observe processing notes (see repair description).