General Information On Body Repair - Ah60.00-N-0001-01A

Model 100, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 123, 124, 126, 129, 140, 156, 163, 164, 166, 167, 168, 169 (except 169.090), 170, 171, 172, 176, 177, 190, 197, 199, 201, 202, 203, 204, 205, 207, 208, 209, 210, 211, 212, 213, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 238, 240, 242, 243, 245 (except 245.286), 246, 247, 251, 253, 257, 290, 292, 293

Model all (4xWD, Heavy transporter, Light transporter, TRUCK, smart)

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:

Resistance spot welding
Riveting
MIG/MAG weld joints and other weld joints

Protective equipment and safety information

In order to rule out any risk of personal injury, to avoid impairing the reliability and safety of the vehicle, and to prevent damage to the vehicle as a result of work improperly carried out, these instructions are to be read carefully and complied with in full.

Consequently, it is not possible for Daimler AG to evaluate in the last consequence every situation which might present a risk of injury for the operative. It is therefore absolutely essential that everyone who carries out repair operations on MB vehicles applies their professional knowledge to ensure that their own safety is not at risk and that the vehicle will not be adversely affected (in particular with regards to safety) as a consequence of the chosen repair procedure.

It is therefore expressly pointed out that all execution of the operations described shall be carried out only by complying with valid directives and instructions of the local, competent authorities and those relating to health and safety at work, and environmental protection.

Labor protection equipment

In addition to personal occupational clothing which includes cap and safety shoes, working gloves, safety glasses, ear protection, dust protection mask, etc. must also be worn as required when working.

Welding vapors

Noxious gases, vapors, dust and welding smoke must be suctioned off in the area of origin.

Metal shavings

Metal shavings produced during and after bodywork that produces shavings must not be blown away with compressed air, but they must 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 reshaping work must be observed and check bores must be checked. If required, the body must be released from the straightening bench and realigned.

Battery

Before performing any type of welding work or other work causing sparks in the area of the on-board electrical system battery, always remove the battery and store in a protected location.

Drilling, sawing

Before drilling or sawing, electrical lines and pipes that are routed in cavities as well as containers located in concealed locations (e.g. battery) and electronic components must be removed from the hazard area.

Components

During repair work following accidents, visually check electronic components, steering and seat belts.

Air conditioning

Do not weld or perform similar types of work on components in the closed air conditioning system or in its immediate vicinity.

Vehicles

Shield vehicles located in the body repair area against possible damage to paint and glass surfaces as well as fire hazard from flying sparks using dividing walls or cover with fire-resistant tarp.

Lifting platform

The vehicle can fall from the lifting platform due to weight transfer caused by removed parts (e.g. engine, shafts, etc.). The vehicle must be secured or sandbags must be used for balancing the weight.

Engine and auxiliary assemblies

Before performing any type of bodywork that produces shavings (e.g. with ball cutter), cover the engine including all additional equipment (e.g. alternator, solenoids, etc.) to prevent consequential damage from metal shavings.

Used materials

Low-carbon steel: up to 300 N/mm2 tensile strength
High-strength steel: 300 to 550 N/mm2 tensile strength
State-of-the-art high-strength steel: 550 to 1000 N/mm2 tensile strength
Ultra high-strength steel: 1000 to 1500 N/mm2 tensile strength
Aluminum
Machining/treating magnesium:
Plastics

Always observe processing notes (see repair description).

Helicoil-compatible thread

Following coordination with the DC development department, defective metric threads (as of M8) are deemed to be helicoil-compatible.

However, this is basically possible only with tubes produced according to MBN 10349. Tubes deviating from the standard must be checked for repair suitability. Further information is given in the KG 00 "Notes on threaded connections with self-tapping screws".

Thread repair

A damaged thread must always be checked for repairability. For more information, please submit repair queries to your MPC (Market Performance Center).

Not every thread can be repaired.
If it is not possible to repair the thread, the next larger component part must be replaced.
A repaired thread must be documented in the VeDoc system.

Self-tapping threads

Thread rolling screws can be used several times.
Tapped threads can be repaired (e.g. Helicoil or Timesert).
Tapped threads should only be recut with a thread tap.
Only use original bolts.

Standard bonded load-bearing sections

Always restore standard glued structural areas during repair. For standard bonded load-bearing sections that cannot be rebonded following accident repair, the number of spot welds is indicated in the specific repair description.

Always observe these specifications to ensure operating stability.

Glue adhesive points

With glued multilayer sheet metal connections, ensure that the maximum permissible temperature does not exceed 120°C. Higher temperatures permanently destroy the glue.

Check temperature continuously when heating up (e.g. temperature measuring instrument). Prepare gluing points

The detailed work description included with the glue set must be strictly observed.

Otherwise protection of the adhesive joints is not ensured.

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 parts

Cut and replace structural parts only at standard joints and service separating points (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 repairing body sections or sectional repairs:

MIG/MAG weld joints which are not in the immediately visible area or which are concealed by installed assembly parts when the vehicle is completed should not be ground flat or smoothed for reasons of economy and durability.

Corrosion protection

After painting, treat the areas affected by repair with appropriate corrosion protection measures (e.g. wax, cavity preservation, underbody protection, if present).

Welding, soldering and related procedures

Perform welding or soldering test before repair. During all welding work, observe accident prevention regulations (UVV) for "welding, cutting and related types procedures". Before performing electric welding work, also observe safety precautions for electronic control units.

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.

When spot welding, maintain a spot weld interval of approx. 20 mm. Clean, smooth electrode tips are required. Set the current time or power according to the sheet metal thickness (new part) on the spot welder.

In the case of multilayer sheet-metal connections with hardened adhesive, it must be ensured that the resistance spot welds are positioned on the original spot welds.

The components to be welded can otherwise be damaged. Corresponding welding parameter settings on the spot welders tested and approved by Daimler AG for each specific type are available . The parameters serve as a default setting for spot welders. Always observe these setting specifications to ensure operating stability. A spot-weld sample must be made before the repair is conducted.

Welding procedures, connections and symbols

Resistance spot welding

Single-row spot weld