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

Model 100, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 123, 124, 126, 129, 140, 156, 163, 164, 166, 168, 169 (except 169.090), 170, 171, 172, 176, 190, 197, 199, 201, 202, 203, 204, 205, 207, 208, 209, 210, 211, 212, 213, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 240, 242, 245 (except 245.286), 246, 251, 253, 292 

Protective equipment and safety information 

Always observe country-specific, general and valid 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
• Riveting
• MAG weld joints, MIG solder connections

Basic requirements for correct execution of a body repair are: 

• Use of genuine Mercedes-Benz replacement parts.
• Use of approved materials (see Repair descriptions).
• Use of approved tools and machines.
• Strict observance of repair descriptions.
• MAG weld 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 flat or smoothed 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 

With glued multilayer sheet metal connections, ensure that the maximum permissible temperature does not exceed 120 °C. Higher temperatures permanently destroy the glue.

Check temperature continuously when heating up (e.g. temperature measuring instrument).

Prepare gluing points 

The detailed work description included with the glue set must be strictly observed.

The bond connection will otherwise not be protected fully.

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 SG

In the case of multilayer sheet-metal connections with hardened adhesive, it must be ensured that the resistance spot welds are positioned on the original spot welds.

The components to be welded can otherwise be damaged.

Engine and auxiliary assemblies 

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

Metal shavings 

Remove metal shavings using a 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.

Drilling, sawing 

Before drilling or sawing, electrical lines installed in cavities and pipes as well as containers located in concealed locations (e.g. battery) and electronic components must be removed from the 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.

Self-tapping threads: 

• Thread rolling screws can be used several times.
• Tapped threads can be repaired (e.g. Helicoil or Timesert).
• Tapped 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: 300 to 550 N/mm ² tensile strength
• Modern high-strength steel: 550 to 1000 N/mm ² tensile strength
• Ultra high-strength steel: 1000 to 1500 N/mm ² tensile strength
• Aluminum
• Magnesium
• Plastics

Always observe processing notes (see repair description).