L65.20-0103-06
| Removing | ||
Danger! | Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between the columns of the lifting platform and position the four support plates at 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 body repair | All models | |
| Guidelines for removing fuel tank when performing welding work on bodies | All models | |
| General information on riveting | ||
1 | Remove detachable body components in roof area | ||
2 | Remove detachable parts in vehicle interior (repair area) | ||
3 | Cover all detachable parts remaining in vehicle (area to be repaired) | Use fire-proof tarp. | |
4 | Separate center roof paneling | ||
5 | Remove rear roof frame | ||
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, 80m/s (max. 23,500 rpm) | |||
Abrasive disk, 115 mm, 80 m/s (max. 13,250 rpm) | |||
Drill | |||
Angle grinder | |||
Body jig saw | |||
Tarp (fire-resistant) | |||
Wet/dry vacuum cleaner | |||
Zinc dust paint suitable for spot welding | |||
6 | Prepare rear roof frame for installation | ||
Round wire brush, braided, 70 mm | |||
Abrasive disk, 115 mm, 80 m/s (max. 13,250 rpm) | |||
Drill | |||
Angle grinder | |||
Wet/dry vacuum cleaner | |||
Tarp (fire-resistant) | |||
Zinc dust paint suitable for spot welding | |||
| Install | ||
Danger! | Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding splatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. | Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. | |
7 | Install rear roof frame | ||
Polygrip aluminum flat head rivets 6.414 mm | |||
Polygrip aluminum/steel countersunk head rivets 4.010 mm | |||
Feeler gauge | |||
Round wire brush, braided, 70 mm | |||
Abrasive disk, 115 mm, 80 m/s (max. 13,250 rpm) | |||
C-clamps | |||
Clamping pliers | |||
Manual temporary fastener, dia. 4.0 mm - clamping range 0 - 6 mm, identification color yellow | |||
Manual temporary fastener, dia. 6.4 mm - clamping range 0 - 15 mm, identification color silver | |||
Pop rivet gun, model HN 1 | |||
Electrode miller | |||
MIG MAG gas welder (steel, brazing, aluminum) | |||
Inverter spot welder | |||
Drill | |||
Angle grinder | |||
Wet/dry vacuum cleaner | |||
Tarp (fire-resistant) | |||
Two-post lifting platform 3.0-3.5 t, electromechanical | |||
| Measures for preventing damage to vehicles or components when performing electric welding work | All models | |
8 | Install and weld in center roof paneling | ||
9 | Adjust gap dimensions on hoods, doors and lids | ||
Gap dimensions | |||
Feeler gauge | |||
10 | Clean welds and sheet metal flange with wire brush, clean repair areas. | | |
11 | Prime areas to be repaired with MB-2K primer filler. | ||
| Notes on paintwork repairs | ||
12 | Supplement standard sealant using MB body sealant | Seam sealing after repairs. | |
| General information on MB materials | All models | |
13 | Supplement standard underfloor protection with MB permanent underbody sealant | Permanent underbody protection agent | |
| General information on MB materials | All models | |
14 | Paint roof and adjacent surfaces | ||
| Notes on paintwork repairs | ||
15 | Apply additional cavity preservation | ||
| Preservation | ||
16 | Reinstall all removed assembly parts |
Seal body joints with aluminum adhesive tape type 3M no. 425 in area of the rear portal seal |
Test and adjustment values, gap dimensions at hoods, doors and covers
Number | Designation | Type | |||
BE60.00-P-1011-01A | Gap dimension | Liftgate to taillamp unit | Dimension "G" | mm | 5.0 (0.5) |
Rear-end door to bumper | Dimension "I" | mm | 7.0 (0.5) | ||
Liftgate to liftgate | Dimension "L" | mm | 7.0 (0.5) | ||
Liftgate to rear spoiler | Dimension "M" | mm | 5.0 (0.5) | ||
Rear spoiler to roof | Dimension "T" | mm | 7.0 (0.5) | ||
See picture | - | ||||
129 589 03 21 00
Feeler gauge
Spot weld milling cutter
201 589 00 51 00
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
- ar6000l070001va Gaps around hoods, doors, and lids
- ar6510l100004va Install and weld in center roof paneling
- ar6510l1000va
- ar6510l1000va Replace complete center roof paneling
- ar6520l100801va Removing rear roof frame
- ar6520l100802va Preparing rear roof frame for installation
- ar6520l100803va Install rear roof frame
- 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