Replace damper for sliding roof drain on A-pillar

AR63.20-L-1180VA

Replace damper for sliding roof drain on A-pillar

11.4.03



Remove

Danger!

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

Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist support points specified by the 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 untrimmed vehicle parts.

AS00.00-Z-0017-01A



General information on repairs to body

All models

AH60.00-N-0001-01A



Guidelines for removing fuel tank when performing welding work on bodies

All models

AH60.00-P-3000-01Z



General notes on riveting

Models 203, 209, 211, 215, 230, 240, 414

AH60.00-P-0003-01N

1

Remove detachable body components in area of A-pillar

2

Remove detachable body components in vehicle interior (area to be repaired)

3

Cover detachable body components remaining in vehicle (area to be repaired)

*WH58.30-Z-1001-40A

4

Cut center A-pillar lug (a)

 Dimension for cut in front of center
A-pillar lug (a) = 10 mm.

Round wire brush, braided, dia.
70 mm 

*WH58.30-Z-1001-03A

 Cutting disc,  65 mm, 80 m/s
(max. 23,500 rpm)

*WH58.30-Z-1021-04A

Sanding sheet, 115 mm  , 80 m/s (max. 13,250 rpm)

*WH58.30-Z-1024-04A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Angular grinder (electric/pneumatic)

*WE58.40-Z-1003-03A

Body saw (electric/pneumatic)

*WE58.40-Z-1004-03A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

5

Expose spot welds in area (b) and cut out

Welding spot milling cutter

*201589005100

 Round wire brush, braided,  70 mm

*WH58.30-Z-1001-03A

Spherical cutter, 12 mm dia. 

*WH58.30-Z-1002-01A

Vario Drill WS 91 spot-weld loosening tool

*WH58.30-Z-1006-01A

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

*WH58.30-Z-1024-04A

Body saw (electric/pneumatic)

*WE58.40-Z-1004-03A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Angular grinder (electric/pneumatic)

*WE58.40-Z-1003-03A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

6

Fold up A-pillar section

7

Pull sliding roof drain hose out through upper A-pillar assembly opening (3)

8

Remove sliding roof drain damper (2)



Install

 Danger!

Risk of death caused by high voltage used for arc welding. Risk of explosion caused by welding in the area of high combustible materials. Risk of injury caused by welding spatter and UV-light while welding. Risk of poisoning caused by inhaling welding vapors.

Use insulating mats. Wear protective clothing, safety glasses, and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor.

AS00.00-Z-0007-01A

9

Remove sliding roof drain damper plug (5)

10

Install sliding roof drain hose through upper A-pillar assembly opening (3)

11

Slide sliding roof drain damper (2) onto sliding roof drain hose and press into A-pillar

 Distance of inner upper A-pillar cut to installation position of sliding roof drain damper (c) = 50 mm.

12

Install bottom sliding roof drain hose

13

Fold down A-pillar section and weld in

 Round wire brush, braided,  70 mm

*WH58.30-Z-1001-03A

 Grinding disc, 115 mm, 80 m/s

*WH58.30-Z-1024-04A

 Clamps

*WH58.30-Z-1031-02A

 Clamping pliers

*WH58.30-Z-1003-02A

 Electrode miller

*WH58.30-Z-1003-01A

Inert gas welder

*WE58.40-Z-1001-02A

Spot welder

*WE58.40-Z-1002-02A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Angular grinder (electric/pneumatic)

*WE58.40-Z-1003-03A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A



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

All models

AH00.00-N-0005-01A

14

Clean welds and metal flanges with wire brush. Clean areas to be repaired

15

Prime areas to be repaired with
2-component MB primer/filler



Notes on paintwork repairs

Models 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463

AH98.00-P-9408-02A

16

Supplement standard sealing with MB body sealant

Seam sealing after repairs

AR97.10-L-4000VA



General information on MB materials

All models

AH98.00-P-9409-03A

17

Supplement standard underfloor protection with MB permanent underfloor protection agent

Permanent underfloor protection

AR97.20-P-0500-03A



General information on MB materials

All models

AH98.00-P-9409-03A

18

Paint A-pillar and adjacent surfaces



Notes on paintwork repairs

Models 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463

AH98.00-P-9408-02A

19

Supplement hollow cavity preservation



Preservation

AP97.20-P-0640A

20

Reinstall all removed assembly parts

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-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-1001-02A

Inert gas welder

WE58.40-Z-1002-02A

Spot welder

WE58.40-Z-1001-03A

Drill (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

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42