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 |
D62.40-0001-06
| 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. | |
Topical note | Notes on performing repair, body work and welding on vehicles with airbags and RTE units | ||
Topical note | General information on body repair | ||
1 | Remove engine hood |
| |
MODEL 901.6, 902.6, 903.6, 904.6, 905.6 | |||
2 | Remove wiper arms | ||
3 | Remove ventilation box |
| |
MODEL 901.6, 902.6, 903.6, 904.6, 905.6 | |||
4 | Remove wiper motor | ||
5 | Remove wiper linkage | ||
6 | Remove windshield | ||
7 | Remove instrument panel cover |
| |
MODEL 901.6, 902.6, 903.6, 904.6, 905.6 | |||
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 | ||
Cut spot welds | |||
Spot weld milling cutter | |||
| Install | ||
11 | Prepare connecting points of waistrail paneling | ||
12 | Align, grind off connecting plates and coat with zinc dust paint | Zinc dust paint suitable for spot welding | |
13 | Prepare waist rail paneling (1) for installation | ||
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. | |
14 | Weld in waist rail paneling (1) | ||
Topical note | Measures for preventing damage to vehicles or components when performing electric welding work | ||
General notes on welding | |||
15 | Grind off any residue welding material | ||
16 | Vacuum out hollow cavities | | |
17 | Clean areas repaired and priming with MB primer filler | ||
18 | Supplement standard seals with MB body sealant | ||
White sealing compound, 310 ml, DBL 6069.20 | |||
19 | Supplement standard underfloor protection with MB permanent underbody sealant | ||
20 | Paint repair area adjacent surfaces | ||
21 | Add cavity preserving agent | ||
22 | Install windshield | ||
23 | Install instrument panel cover |
| |
MODEL 901.6, 902.6, 903.6, 904.6, 905.6 | |||
24 | Install wiper motor | ||
25 | Install wiper linkage | ||
26 | Install ventilation box |
| |
MODEL 901.6, 902.6, 903.6, 904.6, 905.6 | |||
27 | Install engine hood |
| |
MODEL 901.6, 902.6, 903.6, 904.6, 905.6 | |||
28 | Install wiper arms | ||
29 | Reinstall other detachable parts |
201 589 00 51 00
Spot weld milling cutter