Left Side Wall Paneling Up To Window Cutout Removal And Installation - Ar63.10-S-0002E
Model 447.601/603/605
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Model 447.701/703/705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Model 447.701/703/705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
Model 447.701/703/705
with code W18 (Sliding window front left in side/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Model 447.701/703/705
with code W18 (Sliding window front left in side/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
Model 447.811/813/815
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Model 447.811/813/815
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
Model 448.705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Model 448.705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
MODIFICATION NOTES
| 28.02.2020 | Repair materials reference BR00.45-Z-1001-07A added. | Operation step 19 | AR63.10-S-0002-01E |
| 28.02.2020 | Repair materials reference BR00.45-Z-1001-07A added. | Operation step 21 | AR63.10-S-0002-01EB |
| 28.02.2020 | Repair materials reference BR00.45-Z-1001-07A added. | Operation steps 6, 10 | AR63.10-S-0002-03E |
| 28.02.2020 | Repair materials reference BR00.45-Z-1001-07A added. | Operation steps 6, 10 | AR63.10-S-0002-03EB |
| 28.02.2020 | Repair materials reference BR00.45-Z-1001-07A added. | Step 9 | AR63.10-S-0002-06E |
| 28.02.2020 | Repair materials reference BR00.45-Z-1001-07A added. | Step 9 | AR63.10-S-0002-06EB |
| 28.02.2020 | Repair materials reference BR00.45-Z-1003-01A added. | Operation step 10 | AR63.10-S-0002-06E |
| 28.02.2020 | Repair materials reference BR00.45-Z-1003-01A added. | Operation step 10 | AR63.10-S-0002-06EB |
| 28.02.2020 | Repair materials reference BR00.45-Z-1039-13A added. | Operation steps 20, 21 | AR63.10-S-0002-06E |
| 28.02.2020 | Repair materials reference BR00.45-Z-1039-13A added. | Operation steps 20, 21 | AR63.10-S-0002-06EB |
| The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases | Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system. | AS00.00-Z-0007-01A | |
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC) | Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines. Model 447 with Motor 780 |
AS00.00-Z-0035-01A | |
| 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 | |
| Notice | General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment | Model 447 with Motor 780 | AH00.00-Z-0300-01A |
| Notice | Special instructions for lifting and supporting vehicle | AH00.60-S-0100-01KOA | |
| Notice | General information on body repair | AH60.00-P-0001-01KOA | |
| Notice | Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | |
| General information on riveting | AH60.00-P-0003-01N | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| Remove | |||
| 1 | Remove all detachable parts in area of repair point. | ||
| 2 | Cover all detachable parts that remain in the vehicle with fire-resistant welding protection blankets. | Welding protection blankets |
|
| 3 | Remove soundproofing. | AR60.00-S-1752E | |
| 4 | Cut off left sidewall paneling (1) up to window cutout. | with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.703 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.703 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.703 with code W18 (Sliding window front left in side/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.703 with code W18 (Sliding window front left in side/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.813 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.813 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) |
AR63.10-S-0002-01E |
| Model 447.601 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.701 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.701 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.701 with code W18 (Sliding window front left in side/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.701 with code W18 (Sliding window front left in side/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.811 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.811 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) |
AR63.10-S-0002-01EA | ||
| Model 447.605 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.705 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.705 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.705 with code W18 (Sliding window front left in side/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.705 with code W18 (Sliding window front left in side/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.815 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.815 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 448.705 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 448.705 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) |
AR63.10-S-0002-01EB | ||
| 000 588 00 84 00 Heat gun | Spot weld milling machine Body power jigsaw Hand drill Rotary wire brush Sheet metal crimping pliers Wet and dry vacuum cleaner |
WS54.00-P-0049B | |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 5 | Prepare left sidewall paneling (1) up to window cutout for installation. | Model 447.603 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.703 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.703 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.703 with code W18 (Sliding window front left in side/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.703 with code W18 (Sliding window front left in side/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.813 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.813 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) |
AR63.10-S-0002-03E |
| Model 447.601 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.701 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.701 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.701 with code W18 (Sliding window front left in side/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.701 with code W18 (Sliding window front left in side/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.811 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.811 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) |
AR63.10-S-0002-03EA | ||
| Model 447.605 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.705 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.705 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.705 with code W18 (Sliding window front left in side/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.705 with code W18 (Sliding window front left in side/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.815 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.815 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 448.705 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 448.705 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Body power jigsaw Rotary wire brush Hole punching pliers Wet and dry vacuum cleaner |
AR63.10-S-0002-03EB | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 6 | Mark hole for the end stop of the magnetic door holder. | Model 447.6/7 with code W54 (Double-wing rear-end door, 270 degrees) Hand drill Graduated drill Wet and dry vacuum cleaner |
AR63.10-S-0126-04E |
| 7 | Cut cutout for fresh water and 230 V socket. | Model 447.813 with code ZK7 (MARCO POLO equipment line) | AR63.10-S-0120-05E |
| Template for cutout for fresh water and 230 V socket | Model 447.813 with code ZK7 (MARCO POLO equipment line) Hand drill Body power jigsaw Wet and dry vacuum cleaner |
WF58.50-S-6310-03E | |
| Install | |||
| 8 | Install left sidewall paneling (1) up to window cutout and weld in. | Model 447.603 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.703 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.703 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.703 with code W18 (Sliding window front left in side/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.703 with code W18 (Sliding window front left in side/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.813 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.813 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) |
AR63.10-S-0002-06E |
| Model 447.601 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.701 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.701 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.701 with code W18 (Sliding window front left in side/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.701 with code W18 (Sliding window front left in side/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.811 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.811 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) |
AR63.10-S-0002-06EA | ||
| Model 447.605 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.705 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.705 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.705 with code W18 (Sliding window front left in side/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.705 with code W18 (Sliding window front left in side/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 447.815 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 447.815 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Model 448.705 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Model 448.705 with code W16 (Window front left, fixed, in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) |
AR63.10-S-0002-06EB | ||
| 000 588 01 84 00 Welder | WS60.00-P-0021K | ||
| 000 588 02 84 00 Welder | Hand drill Squeeze gun Angle grinder Rotary wire brush Blind riveting tool (set force > 19 kN) Clamping pliers (Standard) Wet and dry vacuum cleaner |
WS60.00-P-0022K | |
Adjust gap dimensions |
*BE60.00-Z-1004-01KOJ | ||
Adjust gap dimensions |
*BE60.00-Z-1007-01KOJ | ||
Adjust gap dimensions |
*BE60.00-Z-1008-01KOJ | ||
Adjust gap dimensions |
*BE60.00-Z-1009-01KOJ | ||
| Seam seal 300 ml in black or white | *BR00.45-Z-1003-01A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Blind rivet nut M5 | *BR00.45-Z-1039-13A | ||
| Fig 2 | |||
| 9 | Remove welding protection blankets. | Welding protection blankets |
|
| 10 | Install mounting bolts. | AR63.10-S-0100-05E | |
| *BA63.10-Z-1001-01KOA | |||
| Thread locking adhesive, Loctite 241 | *BR00.45-Z-1001-02A | ||
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 11 | Prime repair area with a primer filler. | ||
| Notice | Notes on paintwork repairs | Repair area must be free of dust and grease. Otherwise adhesion problems may occur. |
AH98.00-P-9408-02A |
| 12 | Seal seam after repair. | AR97.10-S-4000E | |
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 13 | Paint repair area and adjacent surfaces. | ||
| Notice | Notes on paintwork repairs | AH98.00-P-9408-02A | |
| 14 | Supplement cavity preservation. | AR97.20-S-1500E | |
| 15 | Install soundproofing. | AR60.00-S-1752E | |
| 16 | Install all detachable parts in area of repair point. |
ADJUST GAP DIMENSIONS
| Number | Designation | Model 447, 448 except code W64, W65, W68 | Model 447, 448 with code W64, W65, W68 | |||
|---|---|---|---|---|---|---|
| BE60.00-Z-1004-01KOJ | Adjust gap dimensions | Front door to longitudinal member | Dimension "DA" | mm | 6 (+2/-1) | 6 (+2/-1) |
| Front door to sidewall | Dimension "DB" | mm | 4 (±1) | 4 (±1) | ||
| Front door to sliding door | Dimension "DC" | mm | 4 (+1, 2/-0, 8) | 4 (+1, 2/-0, 8) | ||
| Front door to A-pillar | Dimension "DD" | mm | 4, 5 (+1, 5/-1) | 4, 5 (+1, 5/-1) | ||
| Front door to fuel filler door | Dimension "DE" | mm | 4 (±1) | 4 (±1) | ||
| For picture, see | AR60.00-S-0700-01E | AR60.00-S-0700-01E | ||||
ADJUST GAP DIMENSIONS
| Number | Designation | Model 447, 448 with code W64, W65, W68 | |||
|---|---|---|---|---|---|
| BE60.00-Z-1007-01KOJ | Adjust gap dimensions | Sidewall to liftgate | Dimension "GA" | mm | 4, 5 (+1, 5/-0, 2) |
| Sidewall to cover on guide rail of sliding door | Dimension "GB" | mm | 1, 5 (±0, 8) | ||
| Side wall to fuel filler flap | Dimension "GC" | mm | 4, 5 (±1) | ||
| Glass pane in sidewall at front, all-round | Dimension "GD" | mm | 3 | ||
| Side wall to tail lamp | Dimension "GE" | mm | 1, 2 (±0, 5) | ||
| Glass pane in sidewall at rear, all-round | Dimension "GF" | mm | 3 | ||
| For picture, see | AR60.00-S-0700-01E | ||||
ADJUST GAP DIMENSIONS
| Number | Designation | Model 447, 448 with code W64, W65, W68 | |||
|---|---|---|---|---|---|
| BE60.00-Z-1008-01KOJ | Adjust gap dimensions | Rear window in liftgate, all-round | Dimension "HA" | mm | 4 (±1) |
| Folding rear window in liftgate, all-round | Dimension "HB" | mm | 4 (±1) | ||
| Liftgate to taillamp | Dimension "HC" | mm | 4, 5 (±1) | ||
| Liftgate to bumper at side | Dimension "HD" | mm | 4 (±1) | ||
| Liftgate to bumper at bottom | Dimension "HE" | mm | 6 (±1, 5) | ||
| Liftgate to roof frame | Dimension "HF" | mm | 5, 5 (±1) | ||
| For picture, see | AR60.00-S-0700-01E | ||||
ADJUST GAP DIMENSIONS
| Number | Designation | Model 447, 448 except code W64, W65, W68 | |||
|---|---|---|---|---|---|
| BE60.00-Z-1009-01KOJ | Adjust gap dimensions | Left rear-end door to right rear-end door | Dimension "IA" | mm | 6 (±1) |
| Rear-end door to bumper at side | Dimension "IB" | mm | 4, 5 (±1) | ||
| Rear-end door to bumper at bottom | Dimension "IC" | mm | 6 (±1, 5) | ||
| Rear-end door to tail lamp | Dimension "ID" | mm | 6, 4 (±1) | ||
| Rear-end door to cover over taillamp | Dimension "IE" | mm | 6, 4 (±1) | ||
| Rear-end door to roof frame | Dimension "IF" | mm | 7 (±1, 5) | ||
| Rear window in rear-end door, all-round | Dimension "IG" | mm | 4 (±1) | ||
| For picture, see | AR60.00-S-0700-01E | ||||
SIDE WALL
| Number | Designation | Model 447, 448 | |
|---|---|---|---|
| BA63.10-Z-1001-01KOA | Mounting bolt to sidewall | Nm | 6 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1001-02A | Thread locking adhesive, Loctite 241 | A 002 989 94 71 |
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
| BR00.45-Z-1003-01A | Seam seal 300 ml in black or white | A 005 989 63 20 |
| BR00.45-Z-1039-13A | Blind rivet nut M5 | N 000000 007333 |