Remove/Install Outer Side Wall - AR63.10-P-0805GQ

MODEL 166 

Shown on 166.0 

	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
	Risk of poisoning  caused by inhaling vapors or swallowing adhesive. Risk of injury  caused by adhesive coming into contact with skin and eyes	Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only.	AS00.00-Z-0016-01A
	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
	General information on body repair		AH60.00-P-0001-01A
	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A
	Remove
1	Remove all detachable parts in repair area
2	Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket	When replacing right outer side wall (1), the standard tank cap must be installed and the filler neck must be covered by a welding protection blanket (fire-resistant).
3	Separate outer sidewall (1)		AR63.10-P-0805-01GQ
		Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint	*BR00.45-Z-1001-07A
4	Prepare outer side wall (1) for installation		AR63.10-P-0805-02GQ
		Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint	*BR00.45-Z-1001-07A
	Install
5	Install outer side wall (1), fit and weld in		AR63.10-P-0805-03GQ
	General information on riveting		AH60.00-P-0003-01N
	000 588 02 84 00 Welder		WS60.00-P-0022K
		Commercially available devices/tools  Blind rivet tool Gap dimension	*BE60.00-P-1003-01Z
		Gap dimension	*BE60.00-P-1004-01Z
		Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint	*BR00.45-Z-1001-07A
		Blind rivet with polygrip countersunk head 6.4X14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)	*BR00.45-Z-1002-13A
		Feeler gauge	Fig 1
6	Set gap dimensions		AR60.00-P-0700-01GQ
		Gap dimension	*BE60.00-P-1003-01Z
		Gap dimension	*BE60.00-P-1004-01Z
		Feeler gauge	Fig 1
7	Clean weld joints and sheet metal flanges with rotary wire brush
8	Remove welding protection blankets	On all covered parts remaining in vehicle.
9	Clean repair area
10	Risk of explosion  caused by paint vapors igniting. Risk of poisoning  caused by inhaling paint vapors. Prime repair area using primer filler	No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. Use only primer filler approved by Daimler AG.	AS98.00-Z-0002-01A
11	Seal seam following repairs	Supplement standard seam seal.	AR97.10-P-4000GQ
12	Risk of explosion  caused by paint vapors igniting. Risk of poisoning  caused by inhaling paint vapors. Paint repair areas and adjacent surfaces	No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. Use only paints approved by Daimler AG.	AS98.00-Z-0002-01A
13	Add cavity preserving agent		AR97.20-P-1500GQ
14	Install all detachable parts in area to be repaired

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				Model 166
BE60.00-P-1003-01Z	Gap dimension	Liftgate to bumper at bottom	Dimension "L"	mm	5, 5 (±1, 5)
		Liftgate to rear fender	Dimension "J"	mm	4, 8 (±1)
		Liftgate to bumper at side	Dimension "K"	mm	4, 9 (±1, 3)
		Liftgate to roof	Dimension "W"	mm	5, 5 (±1, 5)
		Liftgate to rear window	Dimension "O"	mm	4, 0 (±1, 0)
		Rear fender to backup lamp	Dimension "M"	mm	1, 4 (±0, 7)
		D-pillar to rear window	Dimension "V"	mm	-
			For picture, see		AR60.00-P-0700-01GQ

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				Model 166
BE60.00-P-1004-01Z	Gap dimension	Fuel filler flap	Dimension "N"	mm	2, 7 (±0, 3)
			For picture, see	AR60.00-P-0700-01GQ

Fig 1: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint	A 000 986 34 42
BR00.45-Z-1002-13A	Blind rivet with polygrip countersunk head 6.4X14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)	A 003 990 86 97 05