Replace rear side wall with longitudinal member complete

AR63.10-P-0650G

Replace rear side wall with longitudinal member complete

21.6.96



Remove



General information on body repair

All models

AH60.00-N-0001-01A

Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Remove fuel tank

AR47.10-P-4100G



Guidelines for removing fuel tank when performing welding work on bodies

All models

AH60.00-P-3000-01Z

2

Remove detachable parts on outside of rear fender

3

Remove detachable parts in trunk, in area of rear fender and bottom of rear center assembly

4

Remove Vario roof

AR77.50-P-3000G

5

Remove trunk lid

AR88.50-P-5000G

6

Remove tubular frame for trunk lid

AR88.50-P-5100G

7

Remove other detachable parts in vehicle interior (area to be repaired)

8

Cover all attached parts remaining in vehicle (area to be repaired)

9

Set up Celette straightening bench module members

Observe setup plans enclosed!

10

Set up Celette straightening bracket set

11

Set vehicle onto straightening bench with two-post lift and fasten.

12

Separate rear fender

 

AR63.50-P-1400-02G

13

Attach side portal

 

AR60.20-P-1550G

14

Cut rear side wall with side longitudinal member

 

AR63.10-P-0650-01G

15

Prepare new rear side wall with longitudinal member

 

AR63.10-P-0650-02G

16

Prepare new rear fender part



AR63.50-P-1400-03G



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

All models

AH00.00-N-0005-01A



Install

17

Install rear side wall with side longitudinal member and weld in

 

Observe fire safety measures.

AR63.10-P-0650-03G

18

Adjust trunk lid

AR88.50-P-5200G

19

Install rear fender and weld in

 

Observe fire safety measures.

AR63.50-P-1400-04G

20

Adjust gap dimensions on hoods, doors and lids



AR60.00-P-0700-01G

Dimensions

*BE60.00-P-1002-01A

*BE60.00-P-1003-01A

*BE60.00-P-1004-01A

*BE60.00-P-1005-01A

21

Detach side portal

22

Clean welds and metal flanges with wire brush. Clean repair areas.



23

Prime area to be repaired with priming filler



Notes on paintwork repairs

AH98.00-P-9408-02A

24

Supplement standard seals with MB body sealant

Seam sealing following repair

AR97.10-P-4000G

25

Supplement standard underbody protection with MB permanent underbody sealant

26

Paint repair areas and adjacent surfaces



Notes on paintwork repairs

AH98.00-P-9408-02A

27

Apply additional cavity preservation

Cavity preservation after repair work

AR97.20-P-1500G

28

Reinstall all removed assembly parts

Number

Designation

Model
170

BE60.00-P-1002-01A

Gap dimension

Front door to A-pillar

Dimension"B"

mm

-

Front door to fender

Dimension "H"

mm

4.0 (0.5)

Front door to rear door

Dimension "I"

mm

-

Front door to roof

Dimension"C"

mm

-

Rear door to top of side section

Dimension "D"

mm

-

Rear door to side section, bottom

Dimension "J"

mm

-

Fender to A-pillar

Dimension "Q"

mm

4.0 (1.6)

Front door to rear fender

Dimension"P"

mm

4.0 (0.5)

See picture in

AR60.00-P-0700-01G

BE60.00-P-1003-01A

Gap dimension

Trunk lid to rear fender, top

Dimension"F"

mm

-

Trunk lid to bottom of rear fender

Dimension "M"

mm

-

Trunk lid to rear fender

Dimension"F"

mm

5.0 (+1/-0)

Trunk lid to taillamp

Dimension "M"

mm

5.0 (+1/-0)

Trunk lid to bumper

Dimension "V"

mm

8.0 (0.5)

Rear fender to taillamp

Dimension "U"

mm

3.0 (0.5)

See picture in

AR60.00-P-0700-01G

BE60.00-P-1004-01A

Gap dimension

Rear-end door to roof

Dimension"E"

mm

-

Rear-end door to D-pillar

Dimension"F"

mm

-

Rear-end door to D-pillar

Dimension "G"

mm

-

Rear-end door to rear fender

Dimension "M"

mm

-

See picture in

-

BE60.00-P-1005-01A

Gap dimension

Fuel filler flap

Dimension "K"

mm

3.5 (0.5)

Dimension"L"

mm

-

See picture in

AR60.00-P-0700-01G

Number

Designation

WH58.30-Z-1002-01A

Ball cutter, dia. 12 mm

WH58.30-Z-1003-01A

Electrode miller

WH58.30-Z-1006-01A

Vario Drill WS 91 spot weld removing tool

WH58.30-Z-1001-02A

Hole punching pliers, dia. 6 mm.

WH58.30-Z-1003-02A

Clamping pliers

WH58.30-Z-1031-02A

C-clamp

WH58.30-Z-1001-03A

Round wire brush, braided, dia. 70 mm

WH58.30-Z-1021-04A

Cutting disk, dia. 65 mm, 80 m/s (max. 23,500 rpm)

WH58.30-Z-1024-04A

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

WH58.30-Z-1001-40A

Tarp (fire-resistant)

WE58.40-Z-1004-01A

Celette straightening bracket set 7170.309 (model 170), as supplement to 7202.300 (model 202)

WE58.40-Z-1005-01A

Car-Bench straightening bracket set 82 420 (model 170), as supplement to 82 415 (model 202)

WE58.40-Z-1033-01A

Celette 7170.308 supplementary straightening bracket for 7170.309 (model 170)

WE58.40-Z-1034-01A

Car Bench 82435 supplementary straightening bracket for 82420 (model 170)

WE58.40-Z-1001-01E

Celette straightening bench

WE58.40-Z-1002-01E

Celette straightening unit

WE58.40-Z-1003-01E

Car-Bench straightening bench

WE58.40-Z-1004-01E

Car-Bench straightening lifting platform

WE58.40-Z-1005-01E

Car-Bench straightening equipment

WE58.40-Z-1007-01E

Celette module crossmember set 955.940

WE58.40-Z-1011-01E

Car-Bench Universal crossmember set A 296/15 (all crossmembers 1500 mm long)

WE58.40-Z-1001-02A

Inert gas welder

WE58.40-Z-1002-02A

Spot welder

WE58.40-Z-1001-03A

Drill (electric/pneumatic)

WE58.40-Z-1002-03A

Straight grinder (electric/pneumatic)

WE58.40-Z-1003-03A

Angle grinder (electric/pneumatic)

WE58.40-Z-1004-03A

Body saw (electric/pneumatic)

WE58.40-Z-1005-03A

Wet/dry vacuum cleaner

WE58.40-Z-1008-03A

Pneumatic ratchet

WE58.40-Z-1001-05A

Two-post lifting platform