Remove/install left side wall paneling up to window cutout

AR63.10-S-0002C

Remove/install left side wall paneling up to window cutout

22.11.2019

Model

415.603/703

except code T19 (Sliding door left)

Model

415.605

except code T19 (Sliding door left)

Modification notes

11.11.2015

GOTIS links replaced by reference to workshop equipment

Operation steps 4 and 6

23.11.2015

Method extended

Operation steps 9 and 10

1

Left side wall paneling to window cutout

 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

 Warning

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

 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

 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

Special instructions for lifting and supporting vehicle

AH00.60-N-0100-01TS

Topical note

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

AH60.00-P-0001-02A

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 all detachable parts in area to be repaired

2

Cover all detachable parts remaining in vehicle with welding protection blankets

 Commercially available devices/tools
Welding protection blanket

3

Partially remove end crossmember external part

AR64.20-S-1115C

4

Separate left side wall paneling up to window cutout (1)

Model 415.603/703
except code T19 (Sliding door left)

AR63.10-S-0002-01C

Model 415.605
except code T19 (Sliding door left)

AR63.10-S-0002-01CA



000 588 00 84 00 Heat gun

WS54.00-P-0049B

 Commercially available devices/tools
Spot weld milling machine
Hand drill
Body power jigsaw
Rotary wire brush
Wet and dry vacuum cleaner

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

5

Prepare left side wall paneling up to window cutout (1) for installation

Model 415.603/703
except code T19 (Sliding door left)

AR63.10-S-0002-03C

Model 415.605
except code T19 (Sliding door left)

AR63.10-S-0002-03CA

 Commercially available devices/tools
Hole punching pliers
Hand drill
Body power jigsaw
Rotary wire brush
Wet and dry vacuum cleaner

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

6

Install and weld in left side wall paneling up to window cutout (1)

Model 415.603/703
except code T19 (Sliding door left)

AR63.10-S-0002-06C

Model 415.605
except code T19 (Sliding door left)

AR63.10-S-0002-06CA



000 588 01 84 00 Welder

WS60.00-P-0021K



000 588 02 84 00 Welder

WS60.00-P-0022K

 Commercially available devices/tools
Hand drill
Angular grinder
Rotary wire brush
Wet and dry vacuum cleaner
Clamping pliers

Check gap dimensions

*BE60.00-N-1003-01D

Check gap dimensions

*BE60.00-N-1004-01D

Check gap dimensions

*BE60.00-N-1005-01D

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

 Feeler gauge

*129589032100

 Bending pliers

*202589003700

 Insert

*415589003100

7

Clean weld joints and sheet metal flanges with rotary wire brush

 Commercially available devices/tools
Rotary wire brush

8

Partially install end crossmember external part

AR64.20-S-1115C

9

Remove welding protection blankets from vehicle

10

Install all detachable body components in area to be repaired

Test and adjustment values for gap dimensions

Number

Designation

Model 415.603/605/703/705

BE60.00-N-1003-01D

Check gap dimensions

Front door to roof paneling

Dimension "I"

mm

4 (1,5)

Front door to rocker panel

Dimension "J"

mm

4 (1,5)

Front door to sidewall

Dimension "K"

mm

4 (1,5)

Front door to sliding door

Dimension "L"

mm

4,5 (2)

For picture, see

AR60.00-S-0700-01C

Test and adjustment values for gap dimensions

Number

Designation

Model 415.603/605/703/705

BE60.00-N-1004-01D

Check gap dimensions

Sliding door to sidewall

Dimension "M"

mm

4,5 (1,5)

Sliding door to rocker panel

Dimension "N"

mm

4 (1,5)

Sliding door to cover for sliding door track

Dimension "O"

mm

4,5 (2)

Sliding door to rear side window

Dimension "P"

mm

5 (1,5)

Sliding door to roof paneling

Dimension "Q"

mm

4 (1,5)

For picture, see

AR60.00-S-0700-01C

Test and adjustment values for gap dimensions

Number

Designation

Model 415.603/605/703/705

BE60.00-N-1005-01D

Check gap dimensions

Sidewall to taillamp

Dimension "R"

mm

2 (1,5)

Sidewall to rear side window

Dimension "S"

mm

4 (2)

Sidewall to cover for sliding door rail

Dimension "T"

mm

2 (1,8)

For picture, see

AR60.00-S-0700-01C

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-1092-02A

Adhesive kit, body, 2-component adhesive

A 012 989 17 71