Remove/install outer side wall - AR63.10-P-0805TA: Notes

MODEL 211.2 

Fig 1: Identifying Outer Side Wall

	Remove
	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 undeburred vehicle parts. Deburr replacement panels.	AS00.00-Z-0017-01A
	Risk of death  caused by high voltage used for arc welding. Risk of explosion  caused by welding in the area of highly inflammable 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 hazard area. Use air extractor.	AS00.00-Z-0007-01A
	Risk of explosion  caused by fuel igniting, risk of poisoning  caused by inhaling and swallowing fuel as well as risk of injury  to eyes and skin caused by contact with fuel.	No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	General information on body repair		AH60.00-N-0001-01A
	Measures for preventing damage to vehicles or components during electro-welding		AH00.00-N-0005-01A
	Notes on paintwork repairs		AH98.00-P-9408-02A
	Guidelines for removing fuel tank when performing welding work on bodies		AH60.00-P-3000-01Z
	General information on MB materials		AH98.00-P-9409-03A
1	Remove detachable body components on outer side of rear fender
2.1	Install fuel filler neck covering	When replacing the right side wall with considerable damage.	AR63.50-P-1400-01TA
		Set of covers	Figure
		Cover panel	Figure
3	Remove detachable components in trunk, area of side wall
4	Remove detachable parts in vehicle interior (repair area)
5	Cover all detachable body components that remained in the vehicle (area to be repaired)	Tarpaulin (fireproof)	*WH58.30-Z-1001-40A
6	Equip straightening bench with modular members, cross members and straightening bracket set.	Observe enclosed set-up plans!
		Celette straightening bench M8S	*WE58.40-Z-1001-01E
		Celette straightening bench Sevenne	*WE58.40-Z-1001-01E
		Set of Celette modular members 955.940	*WE58.40-Z-1007-01E
		Celette additional member 955.908	*WE58.40-Z-1008-01E
		Car-Bench straightening bench BT 17	*WE58.40-Z-1003-01E
		Car-Bench straightening bench BT 43/1	*WE58.40-Z-1003-01E
		Car-Bench universal crossmember set A 296	*WE58.40-Z-1010-01E
		Multi-Z straightening set system MZ 450.000	*WE58.40-Z-1006-01E
		Celette straightening bench 7211.300 (for model 211)	*WE58.40-Z-1039-01A
		Car Bench straightening bracket set 82441 (for model 211)	*WE58.40-Z-1054-01A
		Celette 7211.309 supplementary straightening set for Celette straightening bracket set 7211.300 (for model S 211)	*WE58.40-Z-1045-01A
		Car Bench 82450 supplementary straightening set for Car Bench straightening bracket set 82441 (for model S 211)	*WE58.40-Z-1046-01A
		Celette 7211.308 supplementary straightening set for Celette straightening bracket set 7211.300 (for model 211 4MATIC)	*WE58.40-Z-1051-01A
		Car-Bench 82451 supplementary straightening set for Car-Bench straightening bracket set 82441 (for model 211 4MATIC)	*WE58.40-Z-1055-01A
7	Place vehicle on straightening bench using two-column lift	Two-column lift	*WE58.40-Z-1001-05A
8	Attach vehicle to straightening bench
9	Remove center roof paneling		AR65.10-P-1000TA
10	Separate outer side wall		AR63.10-P-0805-01TA
		Set of covers	Figure
		Cover panel	Figure
		Cutting templates	Figure
		Spot weld milling cutter	Figure
		Spherical milling cutter, dia. 12 mm	*WH58.30-Z-1002-01A
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Vario Drill WS 91 spot-weld loosening tool	*WH58.30-Z-1006-01A
		Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)	*WH58.30-Z-1024-04A
		Hot air blower - 3000 W	*WH58.30-Z-1004-20A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Straight grinder (electric/pneumatic)	*WE58.40-Z-1002-03A
		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
		Tarpaulin (fireproof)	*WH58.30-Z-1001-40A
		Two-column lift	*WE58.40-Z-1001-05A
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
11	Prepare outer side wall		AR63.10-P-0805-02TA
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
	Install
12.1	Install standard filler cap and fuel filler flap, tape gap	When replacing the right side wall.
13	Install outer side wall		AR63.10-P-0805-03TA
	General notes on riveting		AH60.00-P-0003-01N
		Side portal frame	Figure
		Test and welding device	Figure
		Feeler Gage	Figure
		Spacer	Figure
		Crimping iron	Figure
		Set of covers	Figure
		Cover panel	Figure
		Set of spacers	Figure
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Electrode miller	*WH58.30-Z-1003-01A
		PowerBird blind rivet tool	*WE58.40-Z-1003-14A
		Clamping pliers	*WH58.30-Z-1003-02A
		Hand riveter	*WH58.30-Z-1003-29A
		Manual temporary fastener, dia. 6.4 mm, clamping area 0 to 15 mm, identification color silver	*WH58.30-Z-1038-02A
		Abrasive disk, 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
		Angular grinder (electric/pneumatic)	*WE58.40-Z-1003-03A
		Straight grinder (electric/pneumatic)	*WE58.40-Z-1002-03A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Tarpaulin (fireproof)	*WH58.30-Z-1001-40A
		Wet/dry vacuum cleaner	*WE58.40-Z-1005-03A
		Two-column lift	*WE58.40-Z-1001-05A
		Polygrip flat/round head rivet, 6.4x14	*BR00.45-Z-1001-13A
14	Install center roof paneling		AR65.10-P-1000TA
15	Adjust gap dimensions on hoods, doors and lids		AR60.00-P-0700-01TA
		Rear fender/taillamp	*BE60.00-P-1003-01F
		Taillamp in tailgate and taillamp	*BE60.00-P-1005-01F
		Tailgate and rear fender	*BE60.00-P-1005-01F
		Rear window and D-pillar	*BE60.00-P-1005-01F
		Tank flap	*BE60.00-P-1004-01F
		Rear door to lower side section	*BE60.00-P-1002-01F
		Feeler gage	Figure
16	Unfasten vehicle from straightening bench
17	Lift vehicle with two-column lift	Two-column lift	*WE58.40-Z-1001-05A
18	Remove straightening bench.
19	Clean area to be repaired
20	Prime area to be repaired with primer/filler
21	Carry out seam sealing after repairs	Supplement standard sealant with MB body sealant	AR97.10-P-4000T
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
22	Paint repair areas and adjacent surfaces
23	Cavity preservation following repair work		AR97.20-P-1500T
	Notes on cavity preservation		AH97.20-P-0001-01B
		Cavity preservation gun Sata HRS no. 11072	*WE58.40-Z-1006-08A
		Preservation agent	*BR00.45-Z-1003-05A
24	Remove tarpaulin from all covered parts that remained in the vehicle	Tarpaulin (fireproof)	*WH58.30-Z-1001-40A
25	Install detachable body components on outside of rear fender
26	Install detachable body components in trunk, in area of rear fender
27	Install detachable body components in passenger compartment (area repaired)

TEST VALUES FOR GAPS ON HOODS, DOORS AND LIDS

Number	Designation				Model 211.2
BE60.00-P-1002-01F	Size of gap	Rear door to lower side section	Dimension "I"	mm	3.5 (-0.5/+1)
			Fig. see		AR60.00-P-0700-01TA
BE60.00-P-1003-01F	Size of gap	Rear fender to taillamp	Dimension "M"	mm	2.5 (± 1)
			Fig. see		AR60.00-P-0700-01TA
BE60.00-P-1004-01F	Size of gap	Tank flap	Dimension "O"	mm	3.5 (± 0.5)
			Fig. see		AR60.00-P-0700-01TA
BE60.00-P-1005-01F	Size of gap	Tailgate and rear fender	Dimension "Q"	mm	4.5 (± 1)
		Taillamp in tailgate and taillamp	Dimension "R"	mm	5 (± 1)
		Rear window and D-pillar	Dimension "T"	mm	4.5 (± 1)
			Fig. see		AR60.00-P-0700-01TA

Fig 2: Identifying Cutting Templates (211 589 05 23 00)

Fig 3: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Fig 4: Identifying Feeler Gage (129 589 03 21 00)

Fig 5: Identifying Bending Jig (129 589 00 27 00)

Fig 6: Identifying Set Of Spacers (211 589 12 23 00)

Fig 7: Identifying Spacer (000 589 87 63 00)

Fig 8: Identifying Cover Panel (211 589 02 91 00)

Fig 9: Identifying When Replacing Right Rear Fender (211 589 00 91 00)

Fig 10: Identifying Side Portal Frame (210 589 17 23 00)

Fig 11: Identifying Inspection And Welding Device (211 589 00 23 00)

COMMERCIALLY AVAILABLE TOOLS

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-1038-02A	Manual temporary fastener, dia.6.4 mm - clamping range 0 -15 mm, identification color silver Firm Hausmann GmbH D-34346 Hann. Munden, Germany
WH58.30-Z-1001-03A	Round wire brush, braided, dia. 70 mm
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-1003-29A	Hand riveter
WH58.30-Z-1001-40A	Tap (fire-resistant)

WORKSHOP EQUIPMENT

WE58.40-Z-1039-01A	Celette straightening bracket set 7211.300 (model 211)
WE58.40-Z-1045-01A	Celette 7211.309 supplementary straightening set for Celette straightening bracket set 7211.300 (model S 211)
WE58.40-Z-1046-01A	Car-Bench 82450 supplementary straightening set for Car Bench straightening bracket set 82441 (model S 211)
WE58.40-Z-1051-01A	Celette 7211.308 supplementary straightening set for Celette straightening bracket set 7211.300 (model 211 4Matic)
WE58.40-Z-1054-01A	Car bench straightening bracket set 82441, (model 211)
WE58.40-Z-1055-01A	Car-Bench 82451 supplementary straightening set for Car-Bench straightening bracket set 82441 (model 211 4Matic)
WE58.40-Z-1001-01E	Celette straightening bench
WE58.40-Z-1003-01E	Car-Bench straightening bench
WE58.40-Z-1006-01E	Celette Multi-Z straightening set system
WE58.40-Z-1007-01E	Celette module crossmember set 955.940
WE58.40-Z-1008-01E	Celette additional member 955.908
WE58.40-Z-1010-01E	Car-Bench universal cross member set A 296
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-1002-03A	Straight grinder (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-1001-05A	Two-post lifting platform
WE58.40-Z-1006-08A	Cavity preservation gun
WE58.40-Z-1003-14A	Blind rivet tool

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1041-01A	Seam sealant, sprayable 310 ml	A 002 989 84 20
BR00.45-Z-1003-01A	Sealant	A 001 989 63 20
BR00.45-Z-1003-05A	Preservation agent	A 000 986 72 70 05
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42
BR00.45-Z-1001-13A	Rivet	A 003 990 35 97