In 2010 the repair methods and repair times in paint repair have undergone a new assessment and they have been revised.
This adaptation shall be implemented and based on the following technological and process changes.
This takes the current Mercedes-Benz approved materials, aids, procedures and methods for paint repair into account. Further information on this is also available at:
https://xentryportal.i.daimler.com/
under the category "Paint technology".
This results in changes to design group 98 and is valid with the introduction of the Vito/Viano facelift model series 639, 172, 204.3, 218 and all subsequent models.
The new operation items and working hours have also been filed.
The following descriptions list the major content of the important operation items and they support you in terms of order preparation.
Preparatory work:
The following operation items are to be used to match the application case.
Depending on the repair case in question, usually only one of the operation items described below may be carried out once for each order.
Each individual operation item for preparatory work includes activities in a repair order that are carried out once. Combined repair orders such as, e.g. installed, repaired or welded-in parts in combination with removed metal or plastic parts are considered in the appropriate preparatory work.
The following additional operations must be added here.
The vehicles must be cleaned before they are brought into the painting facility.
Removed detachable parts must be cleaned from the inside and outside before they are brought in for painting: 98-1026 Remove dirt on detachable parts to be painted.
Cleaning before and after grinding is included in the painting operation items.
In the event of severe soiling in the interior and exterior area through grease, tar and wax, the preparatory work can be augmented by the following operation items:
98-1030 Remove any non-water-soluble dirt/preservation (grease, wax) from body panels to be painted.
Remove/install detachable parts for paintwork:
The scope of work for removing/installing detachable parts is listed in the WIS documents for design group 98 (Assembly and covering work when painting, e.g. AR98.00-P-0204EW Assembly and covering work when painting the hood).
Color matching should be carried out before beginning with the work:
98-9918 Perform color matching
Repolish adjacent component
Perform color matching with color sample/color-measuring instrument
One or more sample sheets may be required for determining the shade of color:
98-9925 Spray color sample.
98-1336 Conduct preparatory work for dual-layer paintwork of removed small parts:
Collect and return order, accept material card and work units.
Mix base coat and clean paint spray gun.
Prepare clear varnish and clean paint spray gun.
Remove cleaner and adhesive.
98-1337 Conduct preparatory work for single-layer paintwork of removed small parts:
Collect and return order, accept material card and work units.
Mix standard finish and clean paint spray gun.
Remove cleaner and adhesive.
98-1340 Carry out preparatory work for applying two-coat finish to installed body panels:
Check and correct order, accept material card and work units.
Collect and return vehicle/order.
Use additional mixing cup.
Prepare spray-on filler and clean paint spray gun.
Mix knifing filler.
Prepare primer and clean paint spray gun.
Prepare filler and clean paint spray gun.
Mix base coat and clean paint spray gun.
Prepare clear varnish and clean paint spray gun.
Remove cleaner and adhesive.
Put some cream on hands.
Fit and remove intermediate covering for spray-on filler, intermediate covering for filler, final covering (without contours, edges and openings).
Clean vehicle following polishing work (overspray, remove adhesive)
98-1341 Carry out preparatory work for applying single-coat finish to installed body panels:
Use additional mixing cup.
Check and correct order, accept material card and work units.
Collect and return vehicle/order.
Prepare spray-on filler and clean paint spray gun.
Mix knifing filler.
Prepare primer and clean paint spray gun.
Prepare filler and clean paint spray gun.
Mix standard finish and clean paint spray gun.
Remove cleaner and adhesive.
Put some cream on hands.
Fit and remove intermediate covering for spray-on filler, intermediate covering for filler, final covering (without contours, edges and openings).
Clean vehicle following polishing work (overspray, remove adhesive)
98-1345 Carry out preparatory work for applying two-coat finish to removed body panels:
Collect and return order, check order, correct it, accept material card and work units.
Prepare filler and clean paint spray gun.
Mix base coat and clean paint spray gun.
Prepare clear varnish and clean paint spray gun.
Remove cleaner and adhesive.
Put some cream on hands.
98-1346 Carry out preparatory work for single-layer painting of removed body panels:
Collect and return order, check order, correct it, accept material card and work units.
Prepare filler and clean paint spray gun.
Mix standard finish and clean paint spray gun.
Remove cleaner and adhesive.
Put some cream on hands.
98-1350 Carry out preparatory work for two-layer painting of removed plastic parts:
Collect and return order, check order, correct it, accept material card and work units.
Mix base coat and clean paint spray gun.
Prepare clear varnish and clean paint spray gun.
Remove cleaner and adhesive.
Put some cream on hands.
98-1351 Carry out preparatory work for applying one-coat finish to removed plastic parts:
Collect and return order, check order, correct it, accept material card and work units.
Mix standard finish and clean paint spray gun.
Remove cleaner and adhesive.
Put some cream on hands.
98-1358 Extra work for: Carry out preparation as of six body panels/plastic parts
Whether one or removed component parts
Additional work: check and correct order, accept material card and work units.
Additional work: further filler mixing cups, base coat, clearcoat
Additional work: Apply spray-on filler
Additional work: Apply primer
Additional work: Apply filler
Additional work: Mix base coat
Additional work: Apply clearcoat
981353 Extra work for: Carry out preparation as of four installed body panels:
Intermediate covering for installed body panels for priming/spray-on fillers.
Intermediate covering for installed body panels for fillers.
Remove intermediate covering.
On vehicles with four or more installed, repaired or welded-in body components, the operation item 981353 can also be used.
98-1361 Extra preparatory work, prepare additional colors:
Mix base coat/mix material with standard finish and clean paint spray gun.
98-1362 Extra preparatory work, cover removed assembled parts:
Detachable parts remaining on the component.
98-1370 Extra preparatory work, cover installed assembled parts:
Detachable parts remaining on the vehicle.
The paint operation includes all activities that have to be performed on the component to be painted.
In accordance with the respective paint stages, the grinding, priming, filling, filler job, painting, polishing and cleaning as well as the masking of any contours are part of the scope of work.
Align and fasten components on painting stands.
The number of assistants required is listed in the painting operation items.
All required cleaning procedures before and after the individual processing stages and the handling of all tools, aids and cleaning agents are included in the painting work.
Paint stage 1-E: Replaced body panel (weld-in part)
Grind connecting points.
Apply and grind down knifing or spray-on filler.
Grind cathodic dip painting primer.
Grind feather-edge sanded areas.
Apply and grind filler.
Perform single or two-coat finish.
Remove dust inclusions and polish and clean entire component surface.
Processing areas (connecting points), that extend beyond the demarcated paint surface when replacing a welded-in body panel, are temporarily included for the welding part. An exception hereto are the operation items 987015, 7083, 7415, 7483 Painted rear fender, Stage 1E MET/UNI. If, for these operation items, the painting of the processed area of the connecting part is insufficient, then operation item 98 8210 rear Paint center section from outside towards vehicle center, Stage 2 MET/UNI can be set, where it has not yet been repaired.
Paint stage 1-J: Replaced inner door panel and inside area
Roughen surface.
Perform single or two-coat finish.
Paint stage 1-M: Replaced body panel (assembly part)
Outer surface
Grind cathodic dip painting primer.
Apply and grind filler.
Perform single or two-coat finish.
Remove dust inclusions and polish and clean entire component surface.
Inside area
Grind cathodic dip painting primer.
Apply and grind filler.
Perform single or two-coat finish.
Paint stage 2: Surface painting (without filler and filling work)
Grind old paint surface.
Perform single or two-coat finish.
Remove dust inclusions and polish and clean entire component surface.
Paint stage 3: Repaired body panels
Grind damaged areas.
Apply and grind down knifing or spray-on filler.
Grind feather-edge sanded areas.
Apply and grind filler.
Perform single or two-coat finish.
Remove dust inclusions and polish and clean entire component surface.
The filler areas for paint stage 3 have been reassessed. In other words, the following tabular values are used:
Component surface < 100 dm2 from 20.0 % to 10.0 %
Component surface < 250 dm2 from 12.0 % to 6.0 %
Component surface < 500 dm2 from 7.5 % to 4.0 %
Component surface > 500 dm2 from 5.0 % to 3.0 %
If, in paint stage 3, the filling area exceeds the specified percentage values for the areas to be painted, then the operation item 98-9914 Repair body surface with knifing filler, repair sq. dm: ... must also be carried out.
In stage 3, it is possible that most of the paintwork structure has to be repaired (e. g. stone marks, damages due to vandalism). The operation item 98-9910 Paintwork structure, replace sq. dm: ... can be used for this.
For vehicles with three-layer paintwork (Bright), the operation item 98-9545 Additional work for special paint finish during paintwork can additionally be calculated.
For vehicles with matt clear varnish (Magno), the operation item 98-9545 Additional work for special paint finish during paintwork can additionally be calculated in special cases (technical information from the paint manufacturer approved by Mercedes-Benz).
For matching colors the operation items from paint stage 2 must always be used.
Plastic parts are always to be assessed on the basis of paint stage 2.
The plastic repair on plastic parts to be painted encompasses all activities required to rectify damage in the form of scratches (abrasion), cracks and holes.
If, for plastic parts. the scope of work exceeds stage 2 (surface painting), then - depending on the application case - the extra operation items must also be used:
98-9980 Repair detachable plastic parts with crack formation without bead (part removed)
or
98-9981 Repair detachable plastic parts with crack formation with bead (part removed)
or
98-9982 Repair detachable plastic parts with breakthrough damage without bead (part removed)
or
98-9983 Repair detachable plastic parts with breakthrough damage with bead (part removed)
or
98-9984 Repair detachable plastic parts with scratch damage without bead (part removed)
or
98 9985 Repair detachable plastic parts with scratch damage with bead (part removed)
and
98-1620 Prime plastic, metal parts, number of parts:..... (removed)
and
98-1625 Spackle plastic, metal parts, number of spackle applications: ..... (removed)
and
98-1630 Fill plastic, metal parts, number of parts:..... (removed)