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

All models

General information on repair instructions

The repair instructions form the basis for proper and competent maintenance and repair.

The content of the work procedures described is based on the training level of a fully qualified auto mechanic with extensive product expertise. This level of knowledge is essential for carrying out the described work.

Basic prerequisites for properly performing body repairs include:

Use of genuine Mercedes-Benz parts.
Strict observance of the Mercedes-Benz guidelines for bodywork.
Workshop equipped with suitable special tools and workshop equipment.

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. A precise check should always be made to determine which repair procedure is most economical. Repair should always be considered to be the "first choice", because this has the least effect on the strength, dimensional accuracy and corrosion resistance, etc. achieved at the factory

If repair work is not possible, the connection type priorities should be observed as follows during the repair:

Resistance spot welding
Rivets
MAG plug welds and other weld joints

Work protection and safety information

In order to rule out any risk of personal injury, to avoid impairing the reliability and safety of the vehicle, and to prevent damage to the vehicle as a result of work improperly carried out, these instructions are to be read carefully and complied with in full.

Consequently, it is not possible for Daimler AG to evaluate in the last consequence every situation which might present a risk of injury for the operative. It is therefore urgent that everyone who carries out repair operations on MB passenger cars applies their professional knowledge to ensure that their own safety is not at risk and that the vehicle will not be adversely affected (in particular with regards to safety) as a result of the repair procedure chosen It is therefore expressly pointed out that all work of the operations described shall be carried out only by complying with valid directives and instructions of the local, competent authorities and those relating to health and safety at work, and environmental protection.

Sectional repairs

We recommend the following procedure for repairing body sections or sectional repairs:

Inert gas welds which are not in the immediately visible area or which are concealed by installed parts when the vehicle is completed should not be ground down smooth or filled for reasons of economy and operating stability.

Labor protection equipment

In addition to personal occupational clothing to include cap and safety shoes, working gloves, safety glasses, ear protection, dust protection mask, etc. must be worn as required when working.

Battery

Before performing any type of welding work or other work causing sparks in the area of the vehicle battery, always remove the battery and store in a protected location.

Components

During repair work 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.

Helicoil-compatible thread

Defective metric threads (as of M8) are helicoil-compatible in coordination with the Daimler development department. However, this is basically possible only with tubes produced according to MBN 10349. Tubes deviating from the standard, must be checked for repair suitability. Further information is given in the KG 00 "Notes on threaded connections with self-tapping screws".

Vehicles

Shield vehicles located in the body repair area against possible damage to paint and glass surfaces as well as fire hazard from flying sparks using dividing walls or cover with fire-resistant tarp

Lifting platform

The vehicle can fall from the lifting platform due to weight transfer caused by removed parts (e.g. engine, shafts, etc.). Secure vehicle or add sand bags to compensate the weight.

Corrosion protection

After painting, treat areas affected by repair with appropriate corrosion protection measures (e.g. wax, cavity sealing agent, underbody protection, if present).

Metal shavings

Do not use compressed air to blow away metal shavings produced by machining work on the body; remove with vacuum cleaner instead.

Engine and auxiliary equipment

Before performing any type of machining work on the body (e.g. with ball cutter), cover engine including all auxiliary assemblies (e.g. alternator, solenoids, etc.) to prevent damage from metal shavings.

Straightening work

When performing straightening work never stand in a direct line in front of the pull chains when introducing straightening forces to the frame or body.

Secure pull chains with catch cables or chains to prevent it from snapping away.

Observe notes on straightening and verify position of check bores.

If necessary, detach body from straightening bench and realign.

Welding vapors

Evacuate noxious gases, vapors, dust and welding smoke in the area where these occur.

Welding and related work

During all welding work, observe accident prevention regulations for welding, cutting and related types of work

In addition, before performing electric welding work, observe safety precautions for electronic control units.

Moreover, remove easily combustible and flammable materials and liquids from the hazard area. Use shields to protect against flying sparks and heat radiation and protect electric lines and piping installed in cavities.

When spot welding, maintain a spot weld interval of approx. 20 mm Clean, smooth electrode tips are required. Set the current time or power according to the sheet metal thickness (new part) on the spot welder.

Continuation: Welding and related procedures

Corresponding welding parameter settings on the Daimler AG tested and approved spot welders for each specific type are available in the WIS for the P Division. The parameters serve as a default setting for the spot welder.

Always observe these setting specifications to ensure operating stability A spot-weld sample must be made before the repair is conducted.

Standard bonded load-bearing sections

For standard bonded load-bearing sections that are not rebonded following accident repair, the number of spot welds is indicated in the specific repair description.

Always observe these specifications to ensure operating stability

Welding procedures, connections and symbols

Resistance spot welding

Single-row spot weld