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Home >> Mercedes Benz >> 2021 >> Metris Van Cargo >> Repair and Diagnosis >> Collision >> Body Panels >> Collision - Side Wall (1 Of 2) - 447 Chassis >> Side Wall Body Repair >> Left Side Wall Paneling Up To Window Cutout Install And Weld In - Ar63.10-S-0002-06E

Left Side Wall Paneling Up To Window Cutout Install And Weld In - Ar63.10-S-0002-06E

REFER TO SPECIAL TOOLS 000 588 01 84 00 Welder   WS60.00-P-0021K
REFER TO SPECIAL TOOLS 000 588 02 84 00 Welder   WS60.00-P-0022K

Model 447.603 

with code W16 (Window front left, fixed, in sidewall/sliding door) 

with code W29 (Window fixed behind) 

except code T19 (Sliding door left) 

Model 447.703 

with code W16 (Window front left, fixed, in sidewall/sliding door) 

with code W29 (Window fixed behind) 

except code T19 (Sliding door left) 

Model 447.703 

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) 

Model 447.703 

with code W18 (Sliding window front left in side/sliding door) 

with code W29 (Window fixed behind) 

except code T19 (Sliding door left) 

Model 447.703 

with code W18 (Sliding window front left in side/sliding door) 

with code W32 (Rear passenger compartment electric pop-out windows) 

except code T19 (Sliding door left) 

Model 447.813 

with code W16 (Window front left, fixed, in sidewall/sliding door) 

with code W29 (Window fixed behind) 

except code T19 (Sliding door left) 

Model 447.813 

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) 

MODIFICATION NOTES

28.02.2020 Repair materials reference BR00.45-Z-1001-07A added. Step 9  
28.02.2020 Repair materials reference BR00.45-Z-1003-01A added. Operation step 10  
28.02.2020 Repair materials reference BR00.45-Z-1039-13A added. Operation steps 20, 21  
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
ADJUST GAP DIMENSIONS

Number Designation Model 447, 448 with code W64, W65, W68
BE60.00-Z-1007-01KOJ Adjust gap dimensions Sidewall to liftgate Dimension "GA" mm 4, 5 (+1, 5/-0, 2)
Sidewall to cover on guide rail of sliding door Dimension "GB" mm 1, 5 (±0, 8)
Side wall to fuel filler flap Dimension "GC" mm 4, 5 (±1)
Glass pane in sidewall at front, all-round Dimension "GD" mm 3
Side wall to tail lamp Dimension "GE" mm 1, 2 (±0, 5)
Glass pane in sidewall at rear, all-round Dimension "GF" mm 3
For picture, see AR60.00-S-0700-01E
ADJUST GAP DIMENSIONS

Number Designation Model 447, 448 with code W64, W65, W68
BE60.00-Z-1008-01KOJ Adjust gap dimensions Rear window in liftgate, all-round Dimension "HA" mm 4 (±1)
Folding rear window in liftgate, all-round Dimension "HB" mm 4 (±1)
Liftgate to taillamp Dimension "HC" mm 4, 5 (±1)
Liftgate to bumper at side Dimension "HD" mm 4 (±1)
Liftgate to bumper at bottom Dimension "HE" mm 6 (±1, 5)
Liftgate to roof frame Dimension "HF" mm 5, 5 (±1)
For picture, see AR60.00-S-0700-01E
ADJUST GAP DIMENSIONS

Number Designation Model 447, 448 except code W64, W65, W68
BE60.00-Z-1009-01KOJ Adjust gap dimensions Left rear-end door to right rear-end door Dimension "IA" mm 6 (±1)
Rear-end door to bumper at side Dimension "IB" mm 4, 5 (±1)
Rear-end door to bumper at bottom Dimension "IC" mm 6 (±1, 5)
Rear-end door to tail lamp Dimension "ID" mm 6, 4 (±1)
Rear-end door to cover over taillamp Dimension "IE" mm 6, 4 (±1)
Rear-end door to roof frame Dimension "IF" mm 7 (±1, 5)
Rear window in rear-end door, all-round Dimension "IG" mm 4 (±1)
For picture, see AR60.00-S-0700-01E
Fig 1: Identifying Feeler Gauge (129 589 03 21 00)
G07469060Courtesy of MERCEDES-BENZ USA
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-1039-13A Blind rivet nut M5 N 000000 007333

IMPORTANT Refer to the superordinate service document for further information. Safety information in superordinate service document must be observed.

  1. Install side wall paneling (1), driver door, tailgate or rear-end door, seal and lock striker and fit.
  2. Check gaps using SPECIAL TOOL feeler gauge and adjust.

    Model 447 HAND-HELD TESTER Gap dimension "DB"

    Model 447 with code W65 (tailgate), model 447.7/8 with code W64 (rear window to be opened separately), model 447.7/8 with code W68 (electrically actuated tailgate) HAND-HELD TESTER Gap dimension "GA"

    Model 447 with code W65 (tailgate), model 447.7/8 with code W64 (rear window to be opened separately), model 447.7/8 with code W68 (electrically actuated tailgate) HAND-HELD TESTER Gap dimension "HF"

    Model 447.6/7 except code W64 (rear window to be opened separately) except code W65 (tailgate) except code W68 (electrically actuated tailgate) HAND-HELD TESTER Gap dimensions "IA, IF"

    G16483370Courtesy of MERCEDES-BENZ USA
  3. Fix sidewall paneling (1) in place.
  4. Remove driver door, tailgate or rear-end door, seal and lock striker.
  5. Drill ø 7.1 mm rivet holes on side wall paneling (1) at defined punch marks (area A).
  6. Model 447.6/7 except code W64 (rear window to be opened separately) except code W65 (tailgate) except code W68 (electrically actuated tailgate) Drill ø 7.1 mm rivet hole in side wall paneling (1) at defined punch mark (area B).
  7. Remove side wall paneling (1).
  8. Deburr rivet holes on both sides.
  9. Coat insides of riveted joints with zinc dust paint.

    Shown on model 447.6 except code W65 (tailgate) and except code W68 (electrically actuated tailgate) 

  10. Apply sealant to body.
    G16483371Courtesy of MERCEDES-BENZ USA
    G16483372Courtesy of MERCEDES-BENZ USA
  11. Install side wall paneling (1) and fit.
  12. Fix sidewall paneling (1) in place.

    IMPORTANT Inert gas weld in intervals and allow to cool down in between. Reduces heat distortion.

  13. Side wall paneling (1) POLARIZATION RESISTANCE (areas C to E).
  14. Side wall paneling (1) SHIELDED GAS SEAM WELD (areas F to H).
  15. Side wall paneling (1) SHIELDED GAS PLUG WELD (areas I to K).
    G16483373Courtesy of MERCEDES-BENZ USA

    Shown on model 447.6 except code W65 (tailgate) and except code W68 (electrically actuated tailgate) 

  16. Sidewall paneling (1) POLARIZATION RESISTANCE (area L).
  17. Side wall paneling (1) SHIELDED GAS SEAM WELD (area N).

    IMPORTANT Inert gas weld in intervals and allow to cool down in between. Reduces heat distortion.

  18. Drill side wall paneling (1) before shielding gas welding (arrows).
  19. Side wall paneling (1) SHIELDED GAS PLUG WELD (areas M, O and P).
  20. Install blind rivet nuts M5 (areas R and R1 ).
  21. Model 447.6/7 except code W64 (rear window to be opened separately) except code W65 (tailgate) except code W68 (electrically actuated tailgate)

    Install blind rivet nut M5 (area Q).

    G16483374Courtesy of MERCEDES-BENZ USA
  22. Scribe separating points (areas S and T).
  23. Cut separating points (areas S and T).
  24. Remove separated sections on side wall paneling (1).
  25. Grind shielding gas welds and shielding gas spot welds down flat.
  26. Clean weld joints.
  27. Restore and smooth surfaces on sidewall paneling (1).
  28. Remove shavings and drill chips.
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