Remove/install side paneling

AR63.10-D-5743NA

Remove/install side paneling

14.05.2019

Model

903.66/67, 904.66

with code ZU7 (National version for Canada)

Model

903.66/67, 904.66

with code ZU8 (National version for USA)

Model

903.66/67, 904.66

with code ZU9 (National version for Mexico)

Repair of right sidewall paneling on panel van with wheelbase 3550 mm is shown

1

Side wall paneling

2

Side wall bracings

3

Side wall reinforcements



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 sliding door

AR72.16-D-1260B

2

Remove guide rail for sliding door

AR72.16-D-7807D

3

Remove door seal

4

Remove rear bumper

AR88.20-D-2200NA

5

Remove rear door step

For code W73, Rear-end door step.

AR88.30-D-8832NA

6

Remove rear taillamp

AR82.10-D-4905AB

7

Remove side window

In case of side wall with window.

8

Remove side wall lining

For code VA1/ VA2, Side wall trim.

9

Remove other detachable parts in repair area

10

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

Tarp (fire-resistant)

11.1

Carefully heat side wall bracings (2) and side wall reinforcements (3) in load compartment with a heat gun and release bonded connections

In case of side wall without window.

11.2

Carefully heat side wall reinforcements (3) in load compartment with a heat gun and release bonded connections

In case of side wall with window.

12

Separate side wall paneling (1)

Model 903.66/67, 904.662

AR63.10-D-5886-01A

Model 904.663

AR63.10-D-5886-01E

Model 903.66/67, 904.662 with code RA5 (16 inch wheels)

AR63.10-D-5886-01C

AR64.20-D-0002A

 The repair instructions must be correspondingly applied for the left side of the vehicle

 Cut spot welds.

 Spot weld milling cutter

*201589005100



Install

13

Prepare connecting points of side wall paneling

AR63.10-D-5886-02A

14

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

15

Prepare side wall paneling (1) for installation

Model 903.66/67, 904.662

AR63.10-D-5886-03A

Model 904.663

AR63.10-D-5886-03C

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

 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

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

16.1

Weld in sidewall paneling (1)

In case of side wall without window

Model 903.66/67, 904.66

AR63.10-D-5886-04A

Model 904.663

AR63.10-D-5886-04E

Model 903.66/67, 904.662 with code RA5 (16 inch wheels)

AR63.10-D-5886-04I

16.2

Weld in sidewall paneling (1)

In case of side wall with window

Model 903.66/67, 904.66

AR63.10-D-5886-04C

Model 904.663

AR63.10-D-5886-04G

Model 903.66/67, 904.662 with code RA5 (16 inch wheels)

AR63.10-D-5886-04J

17

Grind off any residue welding material

18

Vacuum out hollow cavities

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

19.1

Bond side wall paneling (1) with side wall bracings (2) and side wall reinforcements (3)

In case of side wall without window.

19.2

Bond side wall paneling (1) with side wall reinforcements (3)

In case of side wall with window.

20

Clean areas repaired and priming with MB primer filler

21

Supplement standard seals with MB body sealant

AR97.10-D-4000A

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

22

Supplement standard underfloor protection with MB permanent underbody sealant

23

Paint repair area adjacent surfaces

24

Add cavity preserving agent

AR97.20-D-1500A

25

Apply standard sealant between outer corner pillar paneling and right side wall paneling (1)

26

Apply standard sealant between front paneling and right side wall paneling (1)

27

Install door seal

28

Install guide rail for sliding door

AR72.16-D-7807D

29

Install sliding door

AR72.16-D-1260B

30

Adjust sliding door

AR72.16-D-1023B

31

Install side window

In case of side wall with window.

32

Install side wall paneling

For code VA1/ VA2, Side wall trim

33

Install rear door step

For code W73, Rear-end door step.

AR88.30-D-8832NA

34

Install rear bumper

AR88.20-D-2200NA

35

Install rear taillamp

AR82.10-D-4905AB

36

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