Side Longitudinal Member Paneling Partial Installation - Ar63.30-P-1040-03S

	000 588 04 39 00 Rivet press tool		WS60.00-P-0440B
	000 588 03 39 00 Rivet die		WS60.00-P-0386K

Model 223.0/1/9 

except code Z07 (B7 armoring on special protection version) 

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Countersunk-head rivet (Z) 

• Z₁ = countersunk-head rivet 6.4x14.0
• Z₂ = countersunk-head rivet 6.4x15.5
• Z₃ = countersunk-head rivet 6.4x17.0
• Z₄ = countersunk-head rivet 6.4x19.0
• Z₅ = countersunk-head rivet 6.4x21.0

Blind rivet (Y) 

• Y₁ = rivet 6.4x12
• Y₂ = rivet 6.5x12.5
• Y₃ = rivet 6.5x14.5
• Y₄ = Rivet 6.4M6
• Y₅ = Rivet 6.4
• Y₆ = rivet 6.5x13.5
• Y₇ = rivet 6.4x14
• Y₈ = rivet 6.4x17
• Y₉ = rivet 6.4x20

Flow-form rivet with countersunk head (X) 

• X₁ = Flow-form rivet with countersunk head 1.3 mm to 2.5 mm clamping range
• X₂ = Flow-form rivet with countersunk head 2.3 mm to 3.5 mm clamping range
• X₃ = Flow-form rivet with countersunk head 3.35 mm to 4.1 mm clamping range
• X₄ = Flow-form rivet with countersunk head 4 mm to 5.15 mm clamping range
• X₅ = Flow-form rivet with countersunk head 5.0 mm to 6.1 mm clamping range
• X₆ = Flow-form rivet with countersunk head 6.0 mm to 7.2 mm clamping range
• X₇ = Flow-form rivet with countersunk head 7.1 mm to 8.3 mm clamping range

Flow-form rivet (W) 

• W₁ = Flow-form rivet structure with 3.5 mm clamping range
• W₃ = Flow-form rivet structure 3.35 mm up to 4.1 mm clamping range
• W₄ = Flow-form rivet structure 4 mm up to 5.15 mm clamping range
• W₅ = Flow-form rivet structure 5.0 mm up to 6.1 mm clamping range
• W₆ = Flow-form rivet structure 6.0 mm up to 7.2 mm clamping range
• W₇ = Flow-form rivet structure 7.1 mm up to 8.3 mm clamping range

Blind rivet (V) 

• V₁ = rivet 3.2x4.5
• V₂ = rivet 3.2x6.5

Blind rivet (U) 

• U₁ = rivet 3.2x9.5

Blind rivet with countersunk head (T) 

• T₁ = blind rivet with countersunk head 3.0 mm to 5.0 mm clamping range
• T₂ = blind rivet with countersunk head 1.5 mm to 3.0 mm clamping range

Welding variants 

• EE = MIG seam weld
• FF = MIG plug weld

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The next steps are shown on the most comprehensive repair job be performed on model 223.1 on the left side of the vehicle and must be performed in the same way on the right side of the vehicle in the event of damage.

The superordinate service document as well as the safety information in the service document must be observed.

The graphics show the vehicle from the mechanic's perspective. At the same time, this perspective also specifies the direction in which the rivets must be placed.

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1. Transfer existing holes in body to longitudinal member paneling (1) using drill hole finder (areas A, C).
2. Install longitudinal member paneling (1), fit and fix in place.
3. Drill rivet holes in longitudinal member paneling (1) with a Ø 6.7 mm bit (areas A, B, C).
4. Punch rivet holes in longitudinal member paneling (1) with Ø 6.0 mm bit using a rivet press tool (areas G).
5. Countersink rivet hole in longitudinal member paneling (1) (areas B, C).
6. Remove longitudinal member paneling (1).
7. Drill rivet holes in crossmember (1) and deburr on body on both sides.
8. Remove drilling chips.

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9. Apply 2-component adhesive to body in cross-hatched areas.

   Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

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10. Install longitudinal member paneling (1) and fix in place.
11. Rivet longitudinal member paneling (1) using Ø 6.4x15.5 countersunk-head rivets (area Z₂ ).
12. Rivet longitudinal member paneling (1) using Ø 6.4x17.0 countersunk-head rivets (area Z₃ ).
13. Rivet longitudinal member paneling (1) using Ø 6.4x21.0 countersunk-head rivets (area Z₅ ).
14. Rivet longitudinal member paneling (1) with Ø 6.5x12.5 rivets (area Y₂ ).
15. Rivet longitudinal member paneling (1) with a flow-form rivets structure with a 4 mm to 5.15 mm clamping range (areas W₄ ).
16. Rivet longitudinal member paneling (1) with a flow-form rivets structure with a 5.0 mm to 6.1 mm clamping range (areas W₅ ).
17. Rivet longitudinal member paneling (1) with a flow-form rivets structure with a 7.1 mm to 8.3 mm clamping range (areas W₇ ).
18. Longitudinal member paneling (1) sg (areas E, F, G).
19. Face-grind shielding gas weld joints (areas E, F, G).
20. Smooth surfaces on longitudinal member paneling (1) with basic body filler (areas E, F, G).
21. Remove grinding dust.