Remove/install waist rail paneling

AR62.40-D-6025NA

Remove/install waist rail paneling

14.05.2019

Model

903.61/62/66/67, 904.61/62/66

with code ZU9 (National version for Mexico)

Model

903.61/66/67, 904.61/66

with code ZU7 (National version for Canada)

Model

903.61/66/67, 904.61/66

with code ZU8 (National version for USA)

1

Waist rail paneling



Remove

 Warning

Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units.

Store airbag units with deployment side facing up; do not expose to temperatures greater than 100 °C. When working on these units, disconnect the power supply.

AS91.00-Z-0001-01D

Topical note

Notes on performing repair, body work and welding on vehicles with airbags and RTE units

AH91.00-P-0002-01M

Topical note

General information on body repair

AH60.00-N-0001-01A

1

Remove engine hood

AR88.40-D-3000NA

2

Remove wiper arms

AR82.30-D-6100A

3

Remove ventilation box

AR83.10-D-0010NA

4

Remove wiper motor

AR82.30-D-6800A

5

Remove wiper linkage

6

Remove windshield

AR67.10-D-1000A

7

Remove top part of dashboard

AR68.10-D-1020NA

8

Remove other detachable parts in repair area

9

Cover all detachable body components that remain in the area to be repaired

tarp (fire-resistant).

10

Separate waist rail (1) paneling

AR62.40-D-6025-01A

AR64.20-D-0002A

 Cut spot welds.

 Spot weld milling cutter

*201589005100



Install

11

Prepare connecting points of waistrail paneling

AR62.40-D-6025-02A

12

Align, grind off connecting plates and coat with zinc dust paint

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

13

Prepare waist rail paneling (1) for installation

AR62.40-D-6025-03A

 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

14

Weld in waist rail paneling (1)

AR62.40-D-6025-04A

Topical note

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

AH00.00-N-0005-01A

General notes on welding

AH60.00-N-0005-01A

15

Grind off any residue welding material

16

Vacuum out hollow cavities


Metal shavings and/or metallic grinding dust in cavities
can lead to corrosion damage.

17

Clean areas repaired and priming with MB primer filler

18

Supplement standard seals with MB body sealant

AR97.10-D-4000A

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

19

Supplement standard underfloor protection with MB permanent underbody sealant

20

Paint repair area adjacent surfaces

21

Add cavity preserving agent

AR97.20-D-1500A

22

Install windshield

AR67.10-D-1000A

23

Install upper section of dashboard

AR68.10-D-1020NA

24

Install wiper motor

AR82.30-D-6800A

25

Install wiper linkage

26

Install ventilation box

AR83.10-D-0010NA

27

Install engine hood

AR88.40-D-3000NA

28

Install wiper arms

AR82.30-D-6100A

29

Reinstall other detachable parts

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