Replace longitudinal member outer shell on entrance

AR63.30-P-1102CLW

Replace longitudinal member outer shell on entrance

30.04.2019

Model

205.3

1

Outer longitudinal member shell

4

Foam parts

2

Reinforcement

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Caution

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

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

General information on body repair

AH60.00-N-0001-01A

Topical note

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

General information on MB materials

AH98.00-P-9409-03A



Remove

1

Remove detachable parts in area to be repaired

2

Cover all detachable parts remaining on vehicle with spark protection blankets

3

Remove side longitudinal member paneling

AR63.30-P-1040CLW

4

Remove rear fender

If the damage of the longitudinal member outer shell (1) is located in the area of the rear fender.

AR63.50-P-1400CLW

5

Set up straightening bench with straightening bench crossmembers and straightening tool set



000 588 01 23 00 Body straightening system

WS60.00-P-0023K

6

Place vehicle on straightening bench and fasten

7

Remove reinforcement (2) and longitudinal member outer shell (1)

AR63.30-P-1102-01CLW



000 588 00 84 00 Heat gun

WS54.00-P-0049B

 Commercially available devices/tools
Round wire brush
Body power jigsaw
Spot weld milling machine
Wet/dry vacuum cleaner

1K-zinc dust paint

*BR00.45-Z-1056-07A

8

Prepare longitudinal member outer shell (1) and reinforcement (2)

AR63.30-P-1102-02CLW



000 588 00 84 00 Heat gun

WS54.00-P-0049B

 Commercially available devices/tools
Round wire brush
Body power jigsaw
Spot weld milling machine

1K-zinc dust paint

*BR00.45-Z-1056-07A



Install

 Danger

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 inflammable materials from the hazard area. Use air extraction system.

AS00.00-Z-0007-01A

Topical note

Measures for preventing damage to components when performing electric welding and soldering work

AH60.00-P-0001-02A

General information on riveting

AH60.00-P-0003-01N

9

Install longitudinal member outer shell (1) and reinforcement (2)

AR63.30-P-1102-03CLW



000 588 01 84 00 Welder

WS60.00-P-0021K



000 588 02 84 00 Welder

WS60.00-P-0022K



000 588 01 23 00 Body straightening system

WS60.00-P-0023K

 Commercially available devices/tools
Round wire brush
Manual temporary fastener, 6.35 mm
Blind rivet gun (minimum pull-off force 19 kN)
Wet/dry vacuum cleaner

1K-zinc dust paint

*BR00.45-Z-1056-07A

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

Parts kit for 2-component adhesive for body

*BR00.45-Z-1162-02A

Blind rivet 6.412 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN)

*BR00.45-Z-1035-13A

Blind rivet 6.512.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)

*BR00.45-Z-1012-13A

Blind rivet 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN)

*BR00.45-Z-1034-13A

Blind rivet 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN)

*BR00.45-Z-1032-13A

10

Clean welds and sheet metal flanges

 Commercially available devices/tools
Round wire brush

11

Install rear fender

If the damage of the longitudinal member outer shell (1) has been located in the area of the rear fender.

AR63.50-P-1400CLW

12

Install side longitudinal member paneling

AR63.30-P-1040CLW

13

Install all detachable body components in area to be repaired

Repair materials

Number

Designation

Order number

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1012-13A

Blind rivet 6.512.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)

A 004 990 16 97

BR00.45-Z-1032-13A

Blind rivet 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN)

A 003 990 81 97

BR00.45-Z-1034-13A

Blind rivet 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN)

A 003 990 80 97

BR00.45-Z-1035-13A

Blind rivet 6.412 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN)

A 000 991 76 32

BR00.45-Z-1056-07A

1K-zinc dust paint

A 000 986 28 00

BR00.45-Z-1162-02A

Parts kit for 2-component adhesive for body

A 012 989 17 71