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 . | |
| Topical note | Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A . | |
| Topical note | General information on body repair | AH60.00-N-0001-01A | |
| Remove | |||
| 1 | Remove all detachable parts in repair area | ||
| 2 | Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket | ||
| 3 | Separate outer sidewall (1) | AR63.10-P-0805-01GQ . | |
| Zinc dust paint suitable for spot welding | *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 | *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 . | ||
| Blind rivet tool | |||
| Gap dimension | *BE60.00-P-1003-01Z . | ||
| Gap dimension | *BE60.00-P-1004-01Z . | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A . | ||
| Blind rivet with poly grip countersunk head 6.4 X14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN) | *BR00.45-Z-1002-13A . | ||
| 6 | Set gap dimensions | AR60.00-P-0700-01GQ . | |
| Gap dimension | *BE60.00-P-1003-01Z . | ||
| Gap dimension | *BE60.00-P-1004-01Z . | ||
| 7 | Clean weld joints and sheet metal flanges with rotary wire brush | ||
| 8 | Remove welding protection blankets | ||
| 9 | Clean repair area | ||
| 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 . | |
| 10 | Prime repair area using primer filler | Use only primer filler approved by Daimler AG: | |
| 11 | Seal seam following repairs | AR97.10-P-4000GQ . | |
| 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 . | |
| 12 | Paint repair areas and adjacent surfaces | Use only paints approved by Daimler AG | |
| 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 . | ||||
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-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 |