Remove/install outer sidewall

AR63.10-P-0805RT

Remove/install outer sidewall

2.11.11



Removing

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

 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



General information on body repair

All models

AH60.00-N-0001-01A

1

Remove detachable parts in the repair area

2

Cover detachable parts remaining in vehicle (area to be repaired).

Tarp (fire-resistant)

3

Set up straightening bench and position vehicle on straightening bench

 Use straightening bench to replace outer side wall (1)

AR60.10-P-1060RT

4.1

Remove center roof paneling

 Vehicles without panoramic glass roof with top sliding roof, code 413.

AR65.10-P-1000RT

4.2

Remove panoramic roof frame

 Vehicles with panoramic glass roof with top sliding roof, code 413.

AR77.21-P-0800RT

5

Separate outer sidewall (1)

AR63.10-P-0805-01RT

 Spot weld milling cutter

*201589005100

 Cutting template

*251589032300

 Set of cutting templates

*251589062300

Ball cutter, dia. 12 mm

Vario Drill WS 91 spot weld removing tool

Round wire brush, braided, dia. 70 mm

Cutting disk, dia. 50 mm, 80 m/s (max. 30,600 rpm)

Drill
gotis://K_58.1_04.0

Straight grinder
gotis://K_58.0_03.0

Body jig saw
gotis://K_58.1_01.0

Hot-air gun

6

Prepare mating surfaces on vehicle for outer sidewall (1)

AR63.10-P-0805-04RT

Round wire brush, braided, dia. 70 mm

Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 rpm)

Drill
gotis://K_58.1_04.0

Angle grinder
gotis://K_58.1_07.0

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

7

Prepare outer sidewall (1)

AR63.10-P-0805-02RT

 Cutting template

*251589032300

 Set of cutting templates

*251589062300

Hole punching pliers, dia. 7 mm

Round wire brush, braided, dia. 70 mm

Drill
gotis://K_58.1_04.0

Body jig saw
gotis://K_58.1_01.0

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



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.

AS00.00-Z-0007-01A

8

Install outer sidewall (1)

 Observe general information on riveting.

AR63.10-P-0805-03RT



Measures for preventing damage to vehicles or components when performing electric welding work

All models

AH00.00-N-0005-01A

Clamping pliers

Round wire brush, braided, dia. 70 mm

Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 rpm)

Abrasive disk, dia. 50 mm, 80 m/s (max. 23,000 rpm)

Blind rivet/punch riveting method
gotis://K_68-80_06.0

MIG MAG gas welder (steel, brazing, aluminum)
gotis://K_60-65_17.1

Inverter spot welder
gotis://K_60-65_16.0

Drill
gotis://K_58.1_04.0

Straight grinder
gotis://K_58.0_03.0

Angle grinder
gotis://K_58.1_07.0

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

Rivet

*BR00.45-Z-1001-13A

9.1

Install center roof paneling

 Vehicles without panoramic glass roof with top sliding roof, code 413.

AR65.10-P-1000RT

10

Remove vehicle from straightening bench

AR60.10-P-1060RT

11

Clean repair areas

12

Prime repair area using primer filler

13

Perform seam sealing after repair

AR97.10-P-4000RT

14

Paint repair areas and adjacent surfaces

15

Apply additional cavity preservation

AR97.20-P-1500RT

16.1

Install panoramic roof frame

 Vehicles with panoramic glass roof with top sliding roof, code 413.

AR77.21-P-0800RT

17

Remove tarp from vehicle

Tarp (fire-resistant)

18

Reinstall all detachable parts removed

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42

BR00.45-Z-1001-13A

Blind rivet 6.414

A 003 990 35 97