L63.20-0207-06
| Remove | ||
Danger! | Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between the columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer. | |
Danger! | 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. | |
| General information on repairs to body | All models | |
| Guidelines for removing fuel tank when performing welding work on bodies | All models | |
| General information on riveting | Model 203, 209, 211, 215, 230, 240, 414 | |
1 | Remove detachable parts in A-pillar area | ||
2 | Remove detachable parts in vehicle interior (area to be repaired) | ||
3 | Cover all attached parts remaining in vehicle (area to be repaired) | ||
4 | Cut out A-pillar | ||
Spot weld milling cutter | |||
Vario Drill WS 91 spot weld removing tool | |||
Ball cutter, 12 mm | |||
Round wire brush, braided, 70 mm | |||
Cutting disk, 65 mm, 80 m/s (max. 23,500 rpm) | |||
Abrasive disk, 115 mm, 80 m/s (max. 13,250 rpm) | |||
Drill (electric/pneumatic) | |||
Angular grinder (electric/pneumatic) | |||
Body saw (electric/pneumatic) | |||
Tarpaulin (fire-resistant) | |||
Wet/dry vacuum cleaner | |||
Two-post lift | |||
Zinc dust paint suitable for spot welding | |||
5 | Completely prepare A-pillar for installation | ||
Spot weld milling cutter | |||
Round wire brush, braided, 70 mm | |||
Abrasive disk, 115 mm, 80 m/s, (max. 13,250 rpm) | |||
Cutting disk, 65 mm, 80 m/s (max. 23,500 rpm) | |||
Body saw (electric/pneumatic) | |||
Drill (electric/pneumatic) | |||
Angular grinder (electric/pneumatic) | |||
Wet/dry vacuum cleaner | |||
Tarpaulin (fire-resistant) | |||
Zinc dust paint suitable for spot welding | |||
6 | Set up Celette or Car-Bench straightening bench with modular and cross members | Observe enclosed setup plans! | |
7 | Set up Celette or Car-Bench straightening set | Observe enclosed setup plans! | |
8 | Set vehicle onto straightening bench using two-column lift and fasten | ||
| Install | ||
9 | Install new damping for sliding roof drain on A-pillar | ||
Danger! | Risk of death caused by high voltage used for arc welding. Risk of explosion caused by welding in the area of highly inflammable materials. Injury hazard from welding spatter and UV-light while welding. Risk of poisoning caused by inhaling welding vapors. | Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor. | |
10 | Install and weld in complete A-pillar | ||
Polygrip aluminum/steel flat head rivets 6.414 mm | |||
Polygrip steel/steel countersunk head rivets 510 mm | |||
Test and welding gauges for A-B-C-pillars | |||
Test and welding device | |||
Side portal frame | |||
Round wire brush, braided, 70 mm | |||
Abrasive disk, 115 mm, 80 m/s | |||
Clamps | |||
Clamping pliers | |||
Manual temporary fastener, dia. 5.0 mm - clamping range 0 - 6 mm, identification color black | |||
Screw-on pliers, dia. 6.4 mm - Clamping range 0-15 mm, identification color silver | |||
Pop rivet gun, model HN 1 | |||
Electrode miller | |||
Inert gas welder | |||
Spot welder | |||
Drill (electric/pneumatic) | |||
Angular grinder (electric/pneumatic) | |||
Wet/dry vacuum cleaner | |||
Tarpaulin (fire-resistant) | |||
Two-post lift | |||
Celette straightening bench M8S | |||
Celette straightening unit C8S | |||
Set of Celette modular members 955.940 | |||
Celette additional member 955.908 | |||
Celette straightening bench MT 10, (without old hole pattern, model 123 cannot be repaired) | |||
Car-Bench straightening bench BT 17 | |||
Car-Bench alignment and lifting platform CB 41 | |||
Car-Bench straightening unit PT 13 | |||
Car-Bench universal cross member set A 296/15 (all cross members 1500 mm long) | |||
Car-Bench straightening bracket set 82 423 (for model 168, 414) | |||
Celette straightening bracket set 7168.300 (for model 168, 414) | |||
Celette straightening set 7414.300 (for model 414) | |||
Celette 7414.309 supplementary straightening set for Celette straightening bracket set 7168.300 (for model 414) | |||
Car-Bench 82444 supplementary straightening set for Car-Bench straightening bracket set 82 423 (for model 414) | |||
| Measures for preventing damage to vehicles or components when performing arc welding work | All models | |
11 | Clean welds and metal flanges with wire brush. Clean repair areas | ||
12 | Prime repaired area with MB-2K priming filler | ||
| Notes on paintwork repairs | Model 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463 | |
13 | Supplement standard seals with MB body sealant | Seam sealing after repairs | |
| General information on MB materials | All models | |
14 | Supplement standard underbody protection with MB permanent underbody sealant | Permanent underfloor protection | |
| General information on MB materials | All models | |
15 | Paint A-pillar and adjacent surfaces | ||
| Notes on paintwork repairs | Model 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463 | |
16 | Apply additional cavity preservation | ||
| Preservation | ||
17 | Reinstall all removed assembly parts |
210 589 17 23 00
Inspection and welding device
Side portal frame
Spot weld milling cutter
Test and welding gauges for A-B-C-pillars
201 589 00 51 00
168 589 11 23 00
168 589 00 23 00
Commercially available tools
Number | Designation | |
WH58.30-Z-1002-01A | Ball cutter, dia. 12 mm | |
WH58.30-Z-1003-01A | Electrode miller | |
WH58.30-Z-1006-01A | Vario Drill WS 91 spot weld removing tool | |
WH58.30-Z-1003-02A | Clamping pliers | |
WH58.30-Z-1031-02A | C-clamp | |
WH58.30-Z-1037-02A | Manual temporary fastener, 5.0 mm dia. - clamping range 0-6 mm, identification color black Firma Hausmann GmbH D-34346 Hann. Münden, Germany | |
WH58.30-Z-1038-02A | Manual temporary fastener, dia.6.4 mm - clamping range 0 -15 mm, identification color silver Firma Hausmann GmbH D-34346 Hann. Münden, Germany | |
WH58.30-Z-1001-03A | Round wire brush, braided, dia. 70 mm | |
WH58.30-Z-1021-04A | Cutting disk, dia. 65 mm, 80 m/s (max. 23,500 rpm) | |
WH58.30-Z-1024-04A | Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm) | |
WH58.30-Z-1001-29A | Lever riveting device | |
WH58.30-Z-1001-40A | Tarp (fire-resistant) |
Workshop equipment
WE58.40-Z-1010-01A | Celette straightening bracket set 7168.300 (model 168, model 414) |
WE58.40-Z-1011-01A | Car-Bench straightening bracket set 82 423 (model 168, model 414) |
WE58.40-Z-1040-01A | Celette 7414.309 supplementary straightening set for Celette straightening bracket set 7168.300 (model 414) |
WE58.40-Z-1043-01A | Celette straightening set 7414.300 (model 414) |
WE58.40-Z-1044-01A | Car-Bench 82444 supplementary straightening set for Car Bench straightening bracket set 82 423 (model 414) |
WE58.40-Z-1001-01E | Celette straightening bench |
WE58.40-Z-1002-01E | Celette straightening unit |
WE58.40-Z-1003-01E | Car-Bench straightening bench |
WE58.40-Z-1004-01E | Car-Bench straightening lifting platform |
WE58.40-Z-1005-01E | Car-Bench straightening equipment |
WE58.40-Z-1007-01E | Celette module crossmember set 955.940 |
WE58.40-Z-1008-01E | Celette additional member 955.908 |
WE58.40-Z-1011-01E | Car-Bench Universal crossmember set A 296/15 (all crossmembers 1500 mm long) |
WE58.40-Z-1001-02A | Inert gas welder |
WE58.40-Z-1002-02A | Spot welder |
WE58.40-Z-1001-03A | Drill (electric/pneumatic) |
WE58.40-Z-1003-03A | Angle grinder (electric/pneumatic) |
WE58.40-Z-1004-03A | Body saw (electric/pneumatic) |
WE58.40-Z-1005-03A | Wet/dry vacuum cleaner |
WE58.40-Z-1001-05A | Two-post lifting platform |
Repair materials
Number | Designation | Order number |
BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
Referenced documents
- ah0000n000501a Measures for preventing damage to vehicles or components when performing electric welding work
- ah6000n000101a General information on body repair
- ah6000p000301n General information on riveting
- ah6000p300001z Guidelines for removing fuel tank when performing welding work on bodies
- ah9800p940802a Notes on paintwork repairs
- ah9800p940903a General information on MB materials
- ap9720p0640a Preservation
- ar6320l110001va Cut out A-pillar
- ar6320l110009va Preparing complete A-pillar for installation
- ar6320l110010va Install and weld in complete A-pillar
- ar6320l1180va Replace damper for sliding roof drain on A-pillar
- ar9710l4000va Seam sealing following repair
- ar9720p050003a
- ar9720p050003a Processing permanent underbody protection for painting
- as0000z000701a 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
- as0000z001001a Risk of death caused by vehicle slipping or toppling off of the lifting platform.
- as0000z001701a Risk of injury caused by scraping or cutting body parts on sharp vehicle parts