Eliminate bodyshell complaint on door (repair stage 3)

AR97.00-P-1003F

Eliminate bodyshell complaint on door (repair stage 3)

15.11.11



Removing

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.

Deburr repair panels.

AS00.00-Z-0017-01A

Danger!

Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.

No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

1

Lower crank window

2

Loosen door frame seal (1) from window frame (2)

3

Remove cover from inner window frame (2)

4

Remove outside mirror completely

Models 202, 210:

AR88.70-P-9000E

Model 203

AR88.70-P-9000P

5

Remove outer sealing rail

Models 202, 210:

AR72.10-P-1700E

Model 203

AR72.10-P-1700P

6

Remove outside door handle

 Front door

Model 202

AR72.10-P-2400E

Model 210

AR72.10-P-2400F

Model 203

AR72.10-P-2400P

 Rear door

Models 202, 210:

AR72.12-P-2410E

Model 203

AR72.12-P-2410P

7

Remove protective strip in door center

8

Cover door

Tarp (fire-resistant)

9

Mask inner window frame (2) with adhesive tape

10

Separate bead from window frame (2)

 Completely separate bead on cut (D) over entire length of window frame (2).

AR97.00-P-1000-01F

 Device

*210589006600

 Spacer

*210589006601

 Cutting wheel

*210589006602

 Guard hood

*210589006603

Drill
gotis://K_58.1_04.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

11

Deburr window frame (2)

 Completely deburr window frame (2) inside and outside on cut.

 Use triangular scraper or pull scraper



Check

12

Check window frame (2) for remaining corrosion effect.

 Grind all damaged areas down to bare metal if corrosion effects are present.

Carbide pencil grinder

Round wire brush, braided, dia. 70 mm

13

Clean damaged area and door frame seal (1)

Cleaner

*BR00.45-Z-1025-04A

14

Install masking paper and adhesive tape on vehicle

AR98.00-P-0200A

15

Coat primer filler

 Use EP/thermal filler

 Observe manufacturer's specifications for setting and processing time of EP/thermal filler

16

Paint damaged in shaded area

 Paint front door and rear door up to protective strip (sedan)

Model 202, 203, 210

 Paint front door and rear door to protective strip (multipurpose vehicle)

Model 202, 203, 210



Service Information: Post-repair refinishing

SI98.00-P-0002A

17

Remove masking paper and adhesive tape from vehicle and inner window frame (2).



Install

18

Install cover on inner window frame (2)

19

Install protective strip in door center

20

Install outer door handle

 Front door

Model 202

AR72.10-P-2400E

Model 210

AR72.10-P-2400F

Model 203

AR72.10-P-2400P

 Rear door

Models 202, 210:

AR72.12-P-2410E

Model 203

AR72.12-P-2410P

21

Install outer sealing rail

Models 202, 210:

AR72.10-P-1700E

Model 203

AR72.10-P-1700P

22

Completely install outside mirror

Models 202, 210:

AR88.70-P-9000E

Model 203

AR88.70-P-9000P

23

Fasten door frame seal (1) on window frame (2)

24

Mask window frame (2) twice outside with adhesive tape

 Mask window frame (2) twice in visible area (A) up to approx. 1 mm below door frame seal (1).

25

Apply sealant

 To ensure proper adhesion, there must be no cleaning agent residues.

 Lift door frame seal (1) on outer window frame (2) and install sealant in free area of separated bead.

 Observe manufacturer's specifications for setting and processing time for sealant.

Seal set

*BR00.45-Z-1076-01A

1-component sealant cartridge 310 ml

*BR00.45-Z-1077-01A

Accelerant

*BR00.45-Z-1078-01A

26

Close door

27

Remove first adhesive tape from outer window frame (2).

 Carefully remove adhesive tape from visible area (A)

28

Clean visible area (A).

Cleaner

*BR00.45-Z-1025-04A

29

Remove second adhesive tape from outer window frame (2).

 Carefully remove adhesive tape from visible area (A)

Number

Designation

Order number

BR00.45-Z-1078-01A

Door corrosion protection accelerator

A 009 989 59 71

BR00.45-Z-1076-01A

Door corrosion protection seal set

A 009 989 57 71

BR00.45-Z-1077-01A

1-component sealant cartridge 310 ml

-

BR00.45-Z-1025-04A

Cleaner

A 005 989 19 71