Removing, installing left side paneling up to window cutout

AR63.10-S-0002A

Removing, installing left side paneling up to window cutout

20.2.97



Removal

Danger!

The high voltage used for arc welding presents a lethal hazard. Risk of explosion when welding near extremely flammable materials. Risk of injury from weld spatter and UV light when welding. Risk of poisoning if welding gasses are inhaled

Use insulating mats. Wear protective clothing, safety glasses and safety mask. Keep flammable substances away from the danger zone. Use evacuation system.

AS00.00-Z-0007-01A



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

All models

AH00.00-N-0005-01A



General notes on body repair

All models

AH60.00-N-0001-01A



General notes on welding

Models 638, 901, 902, 903, 904, 950, 952, 953, 954

AH60.00-N-0005-01A

1

Removing rear bumper

2

Removing rear left-hand lamp cluster

3

Remove detachable body components from the repair area

4

Cover all detachable body components remaining in repair area

Tarpaulin

*WH58.30-Z-1001-40A

5

Releasing side wall stiffeners (3) in load compartment

 Carefully heat using hot air gun and undo glued joints.

*WH58.30-Z-1004-20A

6

Detach left side wall paneling (1) up to window cutout

AR63.10-S-0002-01A



*201589005100

Drill

*WE58.40-Z-1001-03A

Body saw

*WE58.40-Z-1004-03A



Installation

7

Prepare left side wall paneling connecting points up to window cutout

AR63.10-S-0002-02A

Straight grinder

*WE58.40-Z-1002-03A

Angular grinder

*WE58.40-Z-1003-03A

Zinc dust paint

8

Prepare left side wall paneling (1) up to window cutout for installation

AR63.10-S-0002-03A

Body saw

*WE58.40-Z-1004-03A

Straight grinder

*WE58.40-Z-1002-03A

Angular grinder

*WE58.40-Z-1003-03A

Zinc dust paint



Gap dimensions on hoods, doors and covers

Model 638

AR60.00-S-0700-01V

9

Vacuum out hollow cavities

 Metal chips and grinding dust in hollow cavities can lead to corrosion damage.

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

10

Install filler neck housing (3) into left side wall paneling (1)

AR63.10-S-0002-05A

Drill

*WE58.40-Z-1001-03A

Straight grinder

*WE58.40-Z-1002-03A

Angular grinder

*WE58.40-Z-1003-03A

Inert gas welding device

*WE58.40-Z-1001-02A

Zinc dust paint

Body sealing compound

11

Apply adhesive to side wall stiffeners

12

Weld in left side wall paneling (1) up to window cutout

AR63.10-S-0002-04A

Inert gas welding device

*WE58.40-Z-1001-02A

Spot welder

*WE58.40-Z-1002-02A

Multifunction device

*WE58.40-Z-1003-02A



Copper plate for welding in sheet metal parts

All models

WF58.50-N-6310-01A

13

Grind off protruding welding material

Straight grinder

*WE58.40-Z-1002-03A

Angular grinder

*WE58.40-Z-1003-03A

14

Cut out window cutout

AR63.10-S-5892-05A

Drill

*WE58.40-Z-1001-03A

Body saw

*WE58.40-Z-1004-03A

15

Apply solder to connecting points in window area

16

Clean repaired areas and prime with MB primer/filler

17

Supplement standard seals with MB body sealant

See painting manual

18

Supplement standard underfloor protection with MB permanent underfloor protection agent

19

Paint area repaired and adjacent surfaces

20

Supplement hollow cavity preservation

21

Attaching rear bumper

22

Installing rear left-hand lamp cluster

23

Install attached parts

Number

Designation

WH58.30-Z-1004-20A

Hot-air gun

WH58.30-Z-1001-40A

Tarp (fire-resistant)

WE58.40-Z-1001-02A

Inert gas welder

WE58.40-Z-1002-02A

Spot welder

WE58.40-Z-1003-02A

Multifunction device

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