Replace complete side roof paneling - AR65.10-P-1020WX
WARNING: This page does not describe the selected car, but rather 33 other vehicles, including the 2016 Mercedes-Benz E63 S AMG, 2016 Mercedes-Benz E400, 2016 Mercedes-Benz E350, 2016 Mercedes-Benz E300, and 2016 Mercedes-Benz E250. However, it is still accessible from the selected car via links, so may be relevant.
MODEL 204.9, 212.2
Illustrated on model 204.9
| Remove | |||
| 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 flammable materials from the hazard area. Use air extraction system. | AS00.00-Z-0007-01A | |
| 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 | |
| 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 | |
| General information on body repair | AH60.00-P-0001-01A | ||
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-N-0005-01A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1 | Prepare all workshop equipment and commercially available tools required for repair | ||
| 2 | Remove all detachable parts in repair area | ||
| 3 | Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket |
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| 4 | Remove center roof paneling | MODEL 204.9 without CODE 413 (Automatic panoramic sliding sunroof) |
AR65.10-P-1000WXA |
| MODEL 204.9 with CODE 413 (Automatic panoramic sliding sunroof) |
AR65.10-P-1000WXB | ||
| MODEL 212.2 without CODE 413 (Panoramic glass roof with top sliding roof) |
AR65.10-P-1000ESA | ||
| MODEL 212.2 with CODE 413 (Panoramic glass roof with top sliding roof) |
AR65.10-P-1000ESB | ||
| 5 | Cut off side roof paneling (1) | AR65.10-P-1020-01WX | |
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| General information on repair of vehicles with ultra-strength steels. | AH60.00-P-0024-01N | ||
Body jig saw
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Figure | |||
| 6 | Prepare side roof paneling (1) for installation | AR65.10-P-1020-02WX | |
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
Body jig saw
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 7 | Install side roof paneling (1), fit and weld in | AR65.10-P-1020-03WX | |
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| General information on repair of vehicles with ultra-strength steels. | AH60.00-P-0024-01N | ||
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| Gap dimension | *BE60.00-P-1002-01U | ||
| Gap dimension | *BE60.00-P-1005-01U | ||
| Adhesive kit, body, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| White sealing compound, 310 ml, DBL 6069.20 | *BR00.45-Z-1003-01A | ||
| Figure | |||
| Figure | |||
| 8 | Adjust gap dimensions on hoods, doors and lids | MODEL 204.9 | AR60.00-P-0700-01WX |
| MODEL 212.2 | AR60.00-P-0700-01EW | ||
| Gap dimension | *BE60.00-P-1002-01U | ||
| Gap dimension | *BE60.00-P-1005-01U | ||
| Gap dimension | *BE60.00-P-1002-01U | ||
| Figure | |||
| 9 | Install center roof paneling | MODEL 204.9 without CODE 413 (Automatic panoramic sliding sunroof) |
AR65.10-P-1000WXA |
| MODEL 204.9 with CODE 413 (Automatic panoramic sliding sunroof) |
AR65.10-P-1000WXB | ||
| MODEL 212.2 without CODE 413 (Panoramic glass roof with top sliding roof) |
AR65.10-P-1000ESA | ||
| MODEL 212.2 with CODE 413 (Panoramic glass roof with top sliding roof) | AR65.10-P-1000ESB | ||
| 10 | Clean weld joints and sheet metal flanges with rotary wire brush |
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| 11 | Clean repair area |
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| 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 skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 12 | Prime repair area using primer filler | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 13 | Carry out seam sealing after repairs | MODEL 204.9 | AR97.10-P-4000CW |
| MODEL 212.2 |
AR97.10-P-4000EW | ||
| White sealing compound, 310 ml, DBL 6069.20 | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 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 skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 14 | Paint repair areas and adjacent surfaces | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 15 | Apply additional cavity preservation | MODEL 204.9, 212.2 | |
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| MODEL 204.9 | AR97.20-P-1500CW | ||
| Cavity preservation, solvent-free (1 l container) Combination spray gun (corrosion protection) |
*BR00.45-Z-1003-05A | ||
| 16 | Remove welding protection blanket | ||
| 17 | Install all detachable body components in area to be repaired |
CHECK VALUES FOR GAP DIMENSIONS
| Number | Designation | MODEL 204.9 | MODEL 212.2 | |||
|---|---|---|---|---|---|---|
| BE60.00-P-1002-01U | Gap dimension | Front door to fender | Dimension "G" | mm | 4, 5 (X1) | 4 (+1/-0, 5) |
| Front door to rear door | Dimension "H" | mm | 4, 5 (X1) | 4, 5 (+1/-0, 5) | ||
| Front door to roof frame | Dimension "I" | mm | 10 (+2/-1) | 14 (X1, 5) | ||
| Rear door to roof frame | Dimension "J" | mm | 9, 5 (+2/-1) | 13 (X1, 5) | ||
| Rear door to side piece, bottom | Dimension "K" | mm | 4 (X1) | 4 (+1/-0, 5) | ||
| Driver door cover to rear door cover | Dimension "W" | mm | 4 (+1, 5/-0, 5) | 4 (X1) | ||
| Picture | AR60.00-P-0700-01WX | AR60.00-P-0700-01EW | ||||
CHECK VALUES FOR GAP DIMENSIONS
| Number | Designation | MODEL 204.9 | MODEL 212.2 | |||
|---|---|---|---|---|---|---|
| BE60.00-P-1005-01U | Gap dimension | Liftgate to roof | Dimension "R" | mm | - | - |
| Liftgate to roof (spoiler removed) | Dimension "R1" | mm | 8 (X1, 5) | 9, 5 (X1, 5) | ||
| Spoiler to roof | Dimension "R2" | mm | 5, 5 (X1, 5) | 5 (X1, 5) | ||
| Liftgate to rear fender | Dimension "S" | mm | 4 (X1) | 4 (+1, 5/-1) | ||
| Liftgate to taillamp | Dimension "T" | mm | 4 (X1) | - | ||
| Liftgate to bumper | Dimension "U" | mm | 5, 5 (X1, 5) | 6 (X1, 5) | ||
| Liftgate to D-pillar | Dimension "V" | mm | - | - | ||
| Rear window and D-pillar | Dimension "X" | mm | 4 (X1) | - | ||
| Top sliding roof to roof | Dimension "Y" | mm | 5 (X1, 5) | 5 (X1, 5) | ||
| Rear window to liftgate, bottom | Dimension "Z" | mm | 3, 5 (X1, 5) | 3 (X1, 5) | ||
| - | - | - | ||||
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 | White sealing compound, 310 ml, DBL 6069.20 | A 001 989 63 20 |
| BR00.45-Z-1003-05A | Cavity preservation, solvent-free (1 l container) | A 000 986 72 70 05 |
| BR00.45-Z-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 20 |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |