Remove/install outer side wall

AR63.10-L-0805VB

Remove/install outer side wall

30.4.01



Remove

Danger!

Risk of death. Death may result if vehicle slips or topples from the lifting platform.

Align vehicle between columns of lifting platform and position the four support plates below support points specified by 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. Deburr metal repairs.

AS00.00-Z-0017-01A



General information on repairs to body

AH60.00-N-0001-01A



Guidelines for removing fuel tank when performing welding work on bodies

AH60.00-P-3000-01Z



General notes on riveting

AH60.00-P-0003-01N

1

Remove detachable body components from outside of side wall

2

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

3

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

Use fire-proof tarpaulin to avoid damage from flying sparks

*WH58.30-Z-1001-40A

4

Separate outer side wall

AR63.10-L-0805-01VB

Welding spot milling cutter

*201589005100

 Vario Drill WS 91 spot-weld loosening tool

*WH58.30-Z-1006-01A

 Hot air blower - 3000 W

*WH58.30-Z-1004-20A

 Ball-type miller cutter, dia. 12 mm

*WH58.30-Z-1002-01A

 Round wire brush, braided, dia. 70 mm

*WH58.30-Z-1001-03A

 Cutting disc, dia. 65 mm, 80 m/s

*WH58.30-Z-1021-04A

 Abrasive disc, dia. 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

Tarpaulin (fireproof)

*WH58.30-Z-1001-40A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

5

Prepare outer side wall

AR63.10-L-0805-02VB

 Round wire brush, braided, dia. 70 mm

*WH58.30-Z-1001-03A

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

*WH58.30-Z-1024-04A

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

*WH58.30-Z-1021-04A

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

Body saw (electric/pneumatic)

*WE58.40-Z-1004-03A

Tarpaulin (fireproof)

*WH58.30-Z-1001-40A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

6

Install side portal straightening set

AR60.20-L-1700VA



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

7

Install outer side wall

Tailgate

AR63.10-L-0805-03VB

Rear hinged door

AR63.10-L-0805-03VC

Polygrip aluminum/steel countersunk head rivets

Dia. 410 mm

Feeler gage

*129589032100

Flange crimping pliers

*168589023700

Pop rivet gun, model HN 1

*WH58.30-Z-1001-29A

 Electrode miller

*WH58.30-Z-1003-01A

 C-clamps

*WH58.30-Z-1031-02A

 Clamping pliers

*WH58.30-Z-1003-02A

 Round wire brush, braided, dia. 70 mm

*WH58.30-Z-1001-03A

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

*WH58.30-Z-1024-04A

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

8

Adjust gap dimensions on hoods, doors and lids

AR60.00-L-0700-01VA

Feeler gage

*129589032100

9

Clean welds and welding flange with wire brush and clean area to be repaired.



10

Remove side portal element.

AR60.20-L-1700VA

11

Prime areas to be repaired with MB 2-component priming filler



Notes on paintwork repairs

AH98.00-P-9408-02A

12

Supplement standard sealing with MB body sealing adhesive

Seam sealing after repairs

AR97.10-L-4000VA



General information on MB materials

AH98.00-P-9409-03A

13

Supplement standard underfloor protection with MB permanent underfloor protection agent

AR97.20-P-0500-03A

 Jumbotherm K-25-R flat nozzle hot air equipment with integrated scraper

*WH58.30-Z-1004-20A

 Replacement scraper for Jumbotherm K-25-R hot air equipment

*WH58.30-Z-1005-20A

Teroson-record 106 84 N underfloor protection spray gun for 1 kg one-way screw-top can

*WE58.40-Z-1002-08A

SATA-UBE underfloor protection spray gun for 1 kg one-way screw-top can

*WE58.40-Z-1002-08A

Underfloor protection spray gun for 30 kg pressurized canister

*WE58.40-Z-1003-08A

Airless unit

*WH58.30-Z-1001-41A



General information on MB materials

AH98.00-P-9409-03A

14

Paint side wall and adjacent surfaces



Notes on paintwork repairs

AH98.00-P-9408-02A

15

Supplement hollow cavity preservation



Preservation

AP97.20-P-0640A

16

Reinstall all removed assembly parts

Number

Designation

Model
414.700

BE60.00-P-1002-01A

Gap dimensions

Front door to A-pillar

Dimension "B"

mm

5.0 (0.5)

Front door to fender

Dimension "H"

mm

5.0 (0.5)

Front door to rear door

Dimension "I"

mm

-

Front door to roof

Dimension "C"

mm

-

Rear door to upper side section

Dimension "D"

mm

-

Rear door to lower side section

Dimension "J"

mm

-

Fender to A-pillar

Dimension "Q"

mm

2.0 (0.5)

Front door to rear fender

Dimension "P"

mm

5.0 (0.5)

Fig.,, see

-

BE60.00-P-1011-01A

Gap dimensions

Tailgate to taillamp unit

Dimension "G"

mm

5.0 (0.5)

Tailgate to bumper

Dimension "I"

mm

7.0 (0.5)

Tailgate to tailgate

Dimension "L"

mm

7.0 (0.5)

Tailgate to rear spoiler

Dimension "M"

mm

5.0 (0.5)

Rear spoiler to roof

Dimension "T"

mm

7.0 (0.5)

Fig., see

-

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-1004-20A

Hot-air gun

WH58.30-Z-1005-20A

Replacement scraper for heat gun

WH58.30-Z-1001-29A

Lever riveting device

WH58.30-Z-1001-40A

Tarp (fire-resistant)

WH58.30-Z-1001-41A

Airless unit

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

WE58.40-Z-1002-08A

Underfloor protection-spray gun for 1 kg one-way screw-type unit

WE58.40-Z-1003-08A

Underbody protection spray gun for 30 kg pressurized canister

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42