Replace longitudinal member outer shell on entrance

AR63.30-S-1102E

Replace longitudinal member outer shell on entrance

10.09.2020

Model

447, 448

1

Outer longitudinal member shell

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.Model 447 with engine 780

AS00.00-Z-0035-01A

 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

 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

General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment

Model 447 with engine 780

AH00.00-Z-0300-01A

Topical note

Special instructions for lifting and supporting vehicle

AH00.60-N-0100-01A

Topical note

General information on body repair

AH60.00-N-0001-01A

Topical note

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

AH60.00-P-0001-02A

General information on MB materials

AH98.00-P-9409-03A



Remove

1

Remove all detachable parts in area of repair point.

2

Cover all detachable parts remaining in vehicle with welding protection blankets.

 Commercially available devices/tools
Welding protection blanket

3.1

Remove outer sliding door entrance.

Model 447, 448.7
with code T19 (Sliding door left)
Left side of vehicleModel 447, 448
Right side of vehicleModel 448.8Left side of vehicle

AR63.30-S-0004E

3.2

Remove respective left sidewall paneling.

Model 447, 448.7
except code T19 (Sliding door left)Left side of vehicle

MODEL 447.6 except CODE W16 (Left front window, stationary in side wall/sliding door) except CODE W29 (Stationary rear window)

AR63.10-S-0100E

Model 447.601/603/605
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W18 (Sliding window front left in sidew./sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W18 (Sliding window front left in sidew./sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
Left side of vehicleModel 447.811/813/815
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.811/813/815
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
Left side of vehicleModel 448.705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 448.705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)Left side of vehicle

AR63.10-S-0002E

Model 447.601/603/605
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W18 (Sliding window front left in sidew./sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W18 (Sliding window front left in sidew./sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
Left side of vehicleModel 447.811/813/815
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.811/813/815
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
Left side of vehicleModel 448.705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 448.705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)Left side of vehicle

AR63.10-S-0120E

4

Remove longitudinal member outer shell (1) at entrance.

AR63.30-S-1102-01E

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

5

Prepare longitudinal member outer shell (1) at entrance.

AR63.30-S-1102-02E

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

6

Install dowels for mounting rail of longitudinal member panel.

Model 447.8, 448.8

AR88.80-S-6005-01CH

Topical note

Notes on removing adhesive residues and foils on paint and metal surfaces with surface conditioning disks

AH00.00-P-0013-01AK

 Commercially available devices/tools
Surface conditioning disk Ø 100 mm

Primer Teroson 150 (Terokal 150)

*BR00.45-Z-1179-02A

Teroson PU 6800 adhesive

*BR00.45-Z-1147-02A

Cleaner

*BR00.45-Z-1025-04A

Primer stick

*BR00.45-Z-1012-07A



Install

7

Install and weld in longitudinal member outer shell (1) at entrance.

AR63.30-S-1102-03E



000 588 01 84 00 Welder

WS60.00-P-0021K



000 588 02 84 00 Welder

WS60.00-P-0022K

 Commercially available devices/tools
Clamping pliers (Standard)
Angular grinder
Squeeze gun
Rotary wire brush
Wet and dry vacuum cleaner

Gap dimensions

*BE60.00-N-1002-01J

Gap dimensions

*BE60.00-N-1004-01J

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

 Feeler gauge

*129589032100

8

Clean weld joints and sheet metal flanges with rotary wire brush.

 Commercially available devices/tools
Rotary wire brush

9.1

Install respective left sidewall paneling.

Model 447, 448.7
except code T19 (Sliding door left)Left side of vehicle

MODEL 447.6 except CODE W16 (Left front window, stationary in side wall/sliding door) except CODE W29 (Stationary rear window)

AR63.10-S-0100E

Model 447.601/603/605
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W18 (Sliding window front left in sidew./sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W18 (Sliding window front left in sidew./sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
Left side of vehicleModel 447.811/813/815
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.811/813/815
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
Left side of vehicleModel 448.705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 448.705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)Left side of vehicle

AR63.10-S-0002E

Model 447.601/603/605
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W18 (Sliding window front left in sidew./sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.701/703/705
with code W18 (Sliding window front left in sidew./sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
Left side of vehicleModel 447.811/813/815
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 447.811/813/815
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)
Left side of vehicleModel 448.705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W29 (Window fixed behind)
except code T19 (Sliding door left)
Left side of vehicleModel 448.705
with code W16 (Window front left, fixed, in sidewall/sliding door)
with code W32 (Rear passenger compartment electric pop-out windows)
except code T19 (Sliding door left)Left side of vehicle

AR63.10-S-0120E

9.2

Install outer sliding door entrance.

Model 447, 448.7
with code T19 (Sliding door left)
Left side of vehicleModel 447, 448
Right side of vehicleModel 448.8Left side of vehicle

AR63.30-S-0004E

10

Remove welding protection blankets.

 Commercially available devices/tools
Welding protection blanket

11

Install all detachable parts in area of repair point.

Gap dimensions

Number

Designation

Model 447, 448 except code W64, W65, W68

Model 447, 448 with code W64, W65, W68

BE60.00-N-1002-01J

Gap dimensions

Fender to headlamp

Dimension "BA"

mm

2 (1)

2 (1)

Fender to bumper

Dimension "BB"

mm

0,3 (0,25)

0,3 (0,25)

Fender to A-pillar

Dimension "BC"

mm

2,6 (1)

2,6 (1)

Fender to front door

Dimension "BD"

mm

4,5 (0,8)

4,5 (0,8)

Fender to longitudinal member

Dimension "BE"

mm

4,5 (1,2)

4,5 (1,2)

For picture, see

AR60.00-S-0700-01E

AR60.00-S-0700-01E

Gap dimensions

Number

Designation

Model 447, 448 except code W64, W65, W68

Model 447, 448 with code W64, W65, W68

BE60.00-N-1004-01J

Gap dimensions

Front door to longitudinal member

Dimension "DA"

mm

6 (+2/-1)

6 (+2/-1)

Front door to sidewall

Dimension "DB"

mm

4 (1)

4 (1)

Front door to sliding door

Dimension "DC"

mm

4 (+1,2/-0,8)

4 (+1,2/-0,8)

Front door to A-pillar

Dimension "DD"

mm

4,5 (+1,5/-1)

4,5 (+1,5/-1)

Front door to fuel filler door

Dimension "DE"

mm

4 (1)

4 (1)

For picture, see

AR60.00-S-0700-01E

AR60.00-S-0700-01E

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-1012-07A

Primer stick

A 000 986 27 50

BR00.45-Z-1025-04A

Cleaner

A 005 989 19 71

BR00.45-Z-1147-02A

Teroson PU 6800 adhesive

A 000 989 15 02 09

BR00.45-Z-1179-02A

Primer Teroson 150 (Terokal 150)

Henkel AG & Co. KGaA
http://www.loctite.de