Outer Longitudinal Member Shell On Entrance Replacement - Ar63.30-S-1102E
Model 447, 448
MODIFICATION NOTES
| 28.10.2021 | Method extended. | Operation steps 16 to 19 | AR63.30-S-1102-03E |
| 26.01.2022 | Sequence of operation steps revised. | Operation steps 6 to 10 |
| 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 engine 780 |
AS00.00-Z-0035-01A | |
| 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 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 engine 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 MB materials | AH98.00-P-9409-03A | ||
| Remove | |||
| 1 | Remove all detachable parts in area of repair point. | ||
| 2 | Cover all detachable parts remaining in vehicle with welding protection blankets. | ||
| 3.1 | Remove outer sliding door entrance. | Model 447, 448.7 with code T19 (Sliding door left) Left side of vehicle Model 447, 448 Right side of vehicle Model 448.8 Left side of vehicle |
AR63.30-S-0004E |
| 3.2 | Remove respective left sidewall paneling. | Model 447, 448.7 except code T19 (Sliding door left) Left side of vehicle MODEL 447.6 except CODE W16 (Left front window, stationary in side wall/sliding door) except CODE W29 (Stationary rear window) |
AR63.10-S-0100E |
| 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) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle Model 447.701/703/705 with code W18 (Sliding window front left in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Left side of vehicle Model 447.701/703/705 with code W18 (Sliding window front left in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle |
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) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle Model 447.701/703/705 with code W18 (Sliding window front left in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Left side of vehicle Model 447.701/703/705 with code W18 (Sliding window front left in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle |
AR63.10-S-0120E | ||
| 4 | Remove longitudinal member outer shell (1) at entrance. | Spot weld milling machine Rotary wire brush Wet and dry vacuum cleaner |
AR63.30-S-1102-01E |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 5 | Prepare longitudinal member outer shell (1) at entrance. | Hole punching pliers Rotary wire brush Wet and dry vacuum cleaner |
AR63.30-S-1102-02E |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 6 | Install and weld in longitudinal member outer shell (1) at entrance. | AR63.30-S-1102-03E | |
| 000 588 12 84 00 Welder | WS00.00-P-0318K | ||
| 000 588 13 84 00 Welder | Angle grinder Squeeze gun Rotary wire brush Wet and dry vacuum cleaner |
WS60.00-P-0437K | |
| *BE60.00-Z-1002-01KOJ | |||
| *BE60.00-Z-1004-01KOJ | |||
| Seam seal 300 ml in black or white | *BR00.45-Z-1003-01A | ||
| Fig 1 | |||
| 7 | Clean weld joints and sheet metal flanges with rotary wire brush. | ||
| 8.1 | Install respective left sidewall paneling. | Model 447, 448.7 except code T19 (Sliding door left) Left side of vehicle MODEL 447.6 except CODE W16 (Left front window, stationary in side wall/sliding door) except CODE W29 (Stationary rear window) |
AR63.10-S-0100E |
| 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) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle Model 447.701/703/705 with code W18 (Sliding window front left in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Left side of vehicle Model 447.701/703/705 with code W18 (Sliding window front left in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle |
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) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle Model 447.701/703/705 with code W18 (Sliding window front left in sidewall/sliding door) with code W29 (Window fixed behind) except code T19 (Sliding door left) Left side of vehicle Model 447.701/703/705 with code W18 (Sliding window front left in sidewall/sliding door) with code W32 (Rear passenger compartment electric pop-out windows) except code T19 (Sliding door left) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle 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) Left side of vehicle |
AR63.10-S-0120E | ||
| 8.2 | Install outer sliding door entrance. | Model 447, 448.7 with code T19 (Sliding door left) Left side of vehicle Model 447, 448 Right side of vehicle Model 448.8 Left side of vehicle |
AR63.30-S-0004E |
| 9 | Remove welding protection blankets. | ||
| 10 | Install dowels for the mounting rail of the longitudinal member panel. | Model 447, 448.8 with code CN1 (Exterior rocker panel) |
AR88.80-S-6005-01CH |
| Primer Teroson 150 (Terokal 150) | *BR00.45-Z-1179-02A | ||
| Teroson PU 6800 adhesive | *BR00.45-Z-1147-02A | ||
| 11 | 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-1002-01KOJ | Adjust gap dimensions | Fender to headlamp | Dimension "BA" | mm | 2 (±1) | 2 (±1) |
| Fender to bumper | Dimension "BB" | mm | 0, 3 (±0, 25) | 0, 3 (±0, 25) | ||
| Fender to A-pillar | Dimension "BC" | mm | 2, 6 (±1) | 2, 6 (±1) | ||
| Fender to front door | Dimension "BD" | mm | 4, 5 (±0, 8) | 4, 5 (±0, 8) | ||
| Fender to longitudinal member | Dimension "BE" | mm | 4, 5 (±1, 2) | 4, 5 (±1, 2) | ||
| For picture, see | AR60.00-S-0700-01E | AR60.00-S-0700-01E | ||||
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 | ||||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| 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-1147-02A | Teroson PU 6800 adhesive | A 000 989 15 02 09 |
| BR00.45-Z-1179-02A | Primer Teroson 150 (Terokal 150) | Henkel AG & Co. KGaA http://www.loctite.de |