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Sidewall Paneling Up To Window Cutout Installation - Ar63.10-S-5893-03EB

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 447.605 

with code T19 (Sliding door left) 

with code W29 (Window fixed behind) 

Left side of vehicle 

Model 447.605 

with code W29 (Window fixed behind) 

Right side of vehicle 

Model 447.705 

with code T19 (Sliding door left) 

with code W29 (Window fixed behind) 

with code ZK4 (Mixto) 

Left side of vehicle 

Model 447.705 

with code W29 (Window fixed behind) 

with code ZK4 (Mixto) 

Right side of vehicle 

Model 447.815 

Right side of vehicle 

Model 447.815 

with code T19 (Sliding door left) 

Left side of vehicle 

Model 448.705 

with code T19 (Sliding door left) 

with code W29 (Window fixed behind) 

Left side of vehicle 

Model 448.705 

with code W29 (Window fixed behind) 

Right side of vehicle 

Model 448.815 

Right side of vehicle 

Model 448.815 

with code T19 (Sliding door left) 

Left side of vehicle 

MODIFICATION NOTES

28.10.2021 Method extended. Operation steps 28 to 31  
ADJUST GAP DIMENSIONS

Number Designation Model 447, 448 except code W64, W65, W68 Model 447, 448 with code W64, W65, W68
BE60.00-Z-1006-01KOJ Adjust gap dimensions Sliding door to roof frame Dimension "FA" mm 4, 5 (±1, 4) 4, 5 (±1, 4)
Sliding door to sidewall Dimension "FB" mm 4 (+1, 2/-0, 8) 4 (+1, 2/-0, 8)
Glass pane in sliding door, all-round Dimension "FC" mm 3 3
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
BR00.45-Z-1092-02A Adhesive kit, body, 2-component adhesive A 012 989 17 71

IMPORTANT Refer to the superordinate service document for further information.

Safety information in superordinate service document must be observed.

IMPORTANT The following steps are shown on the left side of the vehicle and must be accomplished analogously on the right side in the event of damage.

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

    Model 447, 448 HAND-HELD TESTER Gap dimensions "FA", "FB"

    Model 447, 448 with code W65 (tailgate), model 447.7/8, 448.8 with code W64 (rear window to be opened separately), model 447.8, 448.8 with code W68 (electrically actuated tailgate) HAND-HELD TESTER Gap dimensions "GA", "GC"

    Model 447, 448 with code W65 (tailgate), model 447.7/8, 448.8 with code W64 (rear window to be opened separately), model 447.8, 448.8 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"

    Shown on model 447.6/7 except for code W65 (Liftgate) and except for code W68 (Electrically actuated liftgate) 

    G16506962Courtesy of MERCEDES-BENZ USA
  3. Fix sidewall paneling (1) in place.
  4. Remove sliding door, liftgate 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 W65 (Liftgate) except CODE W68 (Electrically actuated liftgate)

    Drill ø 7.1 mm rivet hole in side wall paneling (1) at defined punch marks (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.
    G16506963Courtesy of MERCEDES-BENZ USA
  10. Apply sealant to body and lock striker reinforcement (2).
  11. Apply 2-component adhesive to the body (area C).

    IMPORTANT Observe pretreatment of bonding surface (area C). Refer to the manufacturer's information for the curing and working times of 2-component adhesive.

  12. Install side wall paneling (1) and fit.
  13. Fix sidewall paneling (1) in place.
  14. Side wall paneling (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas D to H).
  15. Drill side wall paneling (1) before shielding gas welding (arrows).
  16. Side wall paneling (1) SHIELDED GAS PLUG WELD (areas K and L).
  17. Side wall paneling (1) SHIELDED GAS SEAM WELD (areas I and J).

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

    G16506964Courtesy of MERCEDES-BENZ USA
    G16506965Courtesy of MERCEDES-BENZ USA
  18. Side wall paneling (1) SHIELDED GAS PLUG WELD (areas M and N).
  19. Scribe separating point (area O).
  20. Cut separating point (area O).
  21. Remove separated section from side wall paneling (1).
  22. Grind shielding gas welds and shielding gas spot welds down flat.
  23. Clean weld joints.
  24. Restore and smooth surfaces on sidewall paneling (1).
  25. Remove shavings and drill chips.

    Shown on model 447.6/7 except for code W65 (Liftgate) and except for code W68 (Electrically actuated liftgate) 

    G16506966Courtesy of MERCEDES-BENZ USA
  26. Position blind rivet nuts M5 (area P).
  27. MODEL 447.6/7 except CODE W65 (Liftgate) except CODE W68 (Electrically actuated liftgate)

    Position blind rivet nut M5 (area Q).

    G16483395Courtesy of MERCEDES-BENZ USA

    Shown on model 447.811 

  28. Model 447, 448.8 with code CN1 (Exterior door sill) Position and align rail (X).
  29. Model 447, 448.8 with code CN1 (Exterior door sill) Transfer hole from rail (X) to body.

    IMPORTANT Then remove rail (X).

  30. Model 447, 448.8 with code CN1 (Exterior door sill) Drill and center punch hole (arrow).

    IMPORTANT Number of holes can vary depending on design.

  31. Model 447, 448.8 with code CN1 (Exterior door sill) Deburr holes and remove drill chips.
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