Remove/install waist rail paneling

AR62.40-D-6025A

Remove/install waist rail paneling

14.05.2019

Model

901, 902, 903 (except 903.61/62/66/67), 904 (except 904.61/62/66), 905

Model

903.61/66/67, 904.61/66

except code ZU7 (National version for Canada)

except code ZU8 (National version for USA)

except code ZU9 (National version for Mexico)

Model

903.62, 904.62

except code ZU9 (National version for Mexico)

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

Model 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4

AR88.40-D-3000A

MODEL 901.6, 902.6, 903.6, 904.6, 905.6

AR88.40-D-3000NA

2

Remove wiper arms

AR82.30-D-6100A

3

Remove ventilation box

Model 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4

AR83.10-D-0010A

MODEL 901.6, 902.6, 903.6, 904.6, 905.6

AR83.10-D-0010B

4

Remove wiper motor

AR82.30-D-6800A

5

Remove wiper linkage

6

Remove windshield

AR67.10-D-1000A

7

Remove instrument panel cover

Model 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4

AR68.10-D-3512A

MODEL 901.6, 902.6, 903.6, 904.6, 905.6

AR68.10-D-1020B

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

22

Install windshield

AR67.10-D-1000A

23

Install instrument panel cover

Model 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4

AR68.10-D-3512A

MODEL 901.6, 902.6, 903.6, 904.6, 905.6

AR68.10-D-1020B

24

Install wiper motor

AR82.30-D-6800A

25

Install wiper linkage

26

Install ventilation box

Model 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4

AR83.10-D-0010A

MODEL 901.6, 902.6, 903.6, 904.6, 905.6

AR83.10-D-0010B

27

Install engine hood

Model 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4

AR88.40-D-3000A

MODEL 901.6, 902.6, 903.6, 904.6, 905.6

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