General Information On Body Repair - Ah60.00-P-0001-01S

Model 190, 197, 223.0/1/9, 231, 232, 297 

General information on repair instructions 

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

The nature in which the operations are described is based on the training standard of a fitter who has completed vocational training and has good knowledge of our products. 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 replacement parts
• Use of approved materials (see Repair descriptions)
• 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 must always be made to determine which procedure is most economical. Repair must always be considered to be the "first choice" because this has the least effect on the strength, dimensional accuracy, 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:

Riveting

MIG weld joints

We recommend training at a local specialist welding institute for aluminum sheet component parts (e.g. sidewall paneling).

A special qualification measure (MIG welding of aluminum materials) is required for welding on structural components whose MIG welding is created for reasons of operational and crash strength. Individuals may not perform any welding on vehicles if they are not verified as having participated in special qualification measures, have not completed special body-specific training or are not authorized.

Metal shavings 

Metal shavings produced during and after bodywork that might cause them must not be blown away using compressed air: They should instead be removed using a vacuum cleaner.

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 check cables or chains to prevent it from snapping away.

Notes on straightening and shape restoration work must be observed and check bores must be checked. If required, the body must be released from the straightening bench and realigned.

Paneling (e.g. sidewall paneling) 

Separating points on paneling can generally be selected freely.

Separating points should not be located in the area around the insulation (for exceptions see repair description).

Structural components 

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

Structural foams/structural reinforcements 

Always replace structural foams/structural reinforcements (for exceptions see repair description).

Sectional repairs 

We recommend the following procedure for body section repairs:

For reasons of durability and costs weld joints not located in the immediate visible area or covered up by assembly parts after completing vehicle should not be ground down flat or smoothened.

Corrosion protection 

The areas affected by the repair should be treated with the appropriate anti-corrosion protection measures (e.g. wax, cavity preservation, underbody protection, if present) after painting.

Weld 

Welding on vehicles with aluminum body is divided into different repair stages.

Repair stage 3+ consists of welded structural components whose MIG welding is created for reasons of operational and crash strength and for which a special qualification measure (MIG welding of aluminum materials) is required.

Repair stage 3 consists of welded aluminum sheet component parts, e.g. sidewall paneling, weld seams created for ground connection, or MIG weld seams on theft-relevant parts that are not created for reasons of strength. For this, we recommend training at a local specialist welding institute.

During all welding work, observe accident prevention regulations (UVV) for "welding, cutting and related types procedures".

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

The corresponding repair stages must be taken into account to match the activity performed at the vehicle. Repair welding on aluminum body/body panels cannot be compared to conventional sheet steel weld joints. It is therefore absolutely necessary to prepare the welding areas observing extreme cleanliness and to create a weld specimen (e.g. cut off from an old part) before welding on the vehicle or component part.

A weld specimen must be made before the repair is conducted.

Before performing electric welding work, also observe safety precautions for electronic control units.

Welding procedures, connections and symbols 

Continuous weld SG 

Plug weld SG