BODY GENERAL.pdf

8/11/2019 BODY GENERAL.pdf

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1998-2004 GENINFO

Body - General - 170 Chassis

GENERAL INFORMATION

GENERAL INFORMATION ON REPAIRS TO BODY - AH60.00-N-0001-01A

All models

General information on repair instructions

The repair instructions form the basis for proper and competent maintenance and repair.

The content of the work procedures described is based on the training level of a fully qualified auto mechanicwith extensive product expertise. This level of knowledge is essential for carrying out the described work.

Basic prerequisites for properly performing body repairs include:

Use of genuine Mercedes-Benz parts.

Strict observance of the Mercedes-Benz guidelines for bodywork.

Workshop equipped with suitable special tools and workshop equipment.

Notes on repair method

Repair of damaged body panels is one of the most economical and time-saving measures and is preferable toreplacing assemblies.

A precise check should always be made to determine which repair procedure is most economical. Repair shouldalways be considered to be the "first choice", because this has the least effect on the strength, dimensionalaccuracy and corrosion resistance, etc. achieved at the factory

Work protection and safety information

In order to rule out any risk of personal injury, to avoid impairing the reliability and safety of the vehicle, and toprevent damage to the vehicle as a result of work improperly carried out, these instructions are to be readcarefully and complied with in full. Consequently, it is not possible for DaimlerChrysler AG to evaluate in thelast consequence every situation which might present a risk of injury for the operative. It is therefore urgent thateveryone who carries out repair operations on MB passenger cars applies their professional knowledge toensure that their own safety is not at risk and that the vehicle will not be adversely affected (in particular with

regards to safety) as a result of the repair procedure chosen It is therefore expressly pointed out that all work ofthe operations described shall be carried out only by complying with valid directives and instructions of thelocal, competent authorities and those relating to health and safety at work, and environmental protection.

Sectional repairs

2003 Mercedes-Benz SLK320

1998-2004 GENINFO Body - General - 170 Chassis




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We recommend the following procedure for repairing body sections or sectional repairs:

Inert gas welds which are not in the immediately visible area or which are concealed by installed parts when thevehicle is completed should not be ground down smooth or filled for reasons of economy and operatingstability..

Labor protection equipment

In addition to personal occupational clothing to include cap and safety shoes, working gloves, safety glasses, ear

protection, dust protection mask, etc. must be worn as required when working.

Battery

Before performing any type of welding work or other work causing sparks in the area of the vehicle battery,always remove the battery and store in a protected location.

Components.

During repair work following accidents, visually check electronic components, steering and seat belts.

Air conditioning

Do not weld or perform similar types of work on components in the closed air conditioning system or in itsimmediate vicinity.

Drill, saw

Before drilling or sawing, remove electric leads and pipes installed in cavities as well as reservoirs located inconcealed locations (e.g. battery) and electronic components from hazard area

Helicoil-compatible thread

Defective metric threads (>= M8) are helicoil-compatible in coordination with the DC development department

Vehicles

Shield vehicles located in the body repair area against possible damage to paint and glass surfaces as well as firehazard from flying sparks using dividing walls or cover with fire-resistant tarpaulin

Lifting platform

The vehicle can fall from the lifting platform due to weight transfer caused by removed parts (e.g. engine,shafts, etc.). Secure vehicle or add sand bags to compensate the weight.

Corrosion protection

After aintin treat areas affected b re air with a ro riate corrosion rotection measures e. . wax cavit




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sealing agent, underbody protection, if present).

Metal shavings

Do not use compressed air to blow away metal shavings produced by machining work on the body; remove withvacuum cleaner instead.

Engine and auxiliary equipment

Before performing any type of machining work on the body (e.g. with spherical cutter), cover engine includingall auxiliary assemblies (e.g. alternator, solenoids, etc.) to prevent damage from metal shavings.

Straightening work

When performing straightening work never stand in a direct line in front of the pull chains when introducingstraightening forces to in front of the pull chains when introducing straightening forces to the frame or body.

Secure pull chains with catch cables or chains to prevent it from snapping away.

Observe notes on straightening and verify position of check bores. If necessary, detach body from straighteningbench and realign.

Welding vapors

Evacuate health enhazarding gases, vapors, dust and welding smoke in the area where it occurs.

Welding and related work

During all welding work, observe accident prevention regulations for welding, cutting and related types of workIn addition, before performing arc welding work, observe safety precautions for electronic control units.

Moreover, remove easily combustible and flammable materials and liquids from the hazard area. Use shields toprotect against flying sparks and heat radiation and protect electric leads and tubes laid in hollow cavities.

When spot welding, maintain a spot weld interval of approx. 20 mm Clean, smooth electrode tips are required.Set the current time or power according to the sheet metal thickness (new part) on the spot welder.

Standard bonded load-bearing sections

For standard bonded load-bearing sections that are not rebonded following accident repair, the number of spotwelds is indicated in the specific repair description.

Always observe these specifications to ensure operating stability

Welding procedures, connections and symbols

Resistance s ot weldin




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Single-row spot weld:

Double-row spot weld:

Double-row spot weld offset:

Brazing:

MIG welding

Stitch weld:

Continuous weld:

Continuous weld interrupted:

Plug weld:

Fig. 1: Assembly Examples For Spot Welding Fittings

Assembly examples for spot welding fittings

VIN NUMBER AND PRODUCT LIABILITY - AH60.00-P-0800

Product liability, trademark and traffic laws - AH60.00-P-0800-01Z

Model 163, 164, 168, 169, 170, 171, 202, 203, 208, 209, 210, 211, 215, 219, 220, 221, 230, 240, 245.2, 251,414.700, 690.6, 638, 639, 901, 902, 903, 904, 905, Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3,XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7




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For legal reasons (product liability, trademark and traffic laws) and to prevent negative effects to the Mercedes-

Benz corporation and employees of the specific Mercedes-Benz dealerships, we recommend that the vehicleidentification number and Mercedes stars at the end (trademark) only be marked on vehicles when the body orvehicle has been replaced or repaired within the Mercedes-Benz service organization.

This recommendation is based on the following factors:

Some companies have specialized in rebuilding Mercedes-Benz vehicles with used or new bodies and oftenfinishing these vehicles with second-hand parts from various accident vehicles of the same model.

Cases are repeatedly reported where other companies have then asked service outlets or authorized workshopsto mark the vehicle with the vehicle identification number of the original (accident) vehicle

We request you to never perform such work, even when the other company assures that they have rebuilt thevehicle for themselves or at the request of a customer.

Legal problems in context with the protection of our trademark could result from marking such vehicles with

the vehicle identification number with stars at the end (trademark) without reservations.

The new product liability laws consider the manufacturer to be the company who attaches its trademark to aproduct, regardless of whether the product was actually produced by this manufacturer.

Moreover, Mercedes-Benz could, under certain circumstances, be considered to be the manufacturer and beliable in the event of damage.

Assembly of used or new bodies with various parts is the equivalent of new production. If such assembly isperformed by another company, Mercedes-Benz does not consider itself to be the manufacturer.

For this reason it is necessary for the registration authorities to issue a new vehicle title, which is legallypossible, in which the assembling company is entered as the manufacturer and the serial number of the technicaltesting point becomes the vehicle identification number.

Moreover, such rebuilt vehicles usually require an operating permit. According to Section 59, Paragraph 2 of

the German vehicle licensing regulations (StVZO), this requires notification of the responsible registrationauthority.

On the other hand, if a dealership or authorized workshop marks the rebuilt vehicle with the vehicleidentification number of the original (accident) vehicle, the assembling company would be given theopportunity of circumventing its liability according to Section 59, Paragraph 2 of the German vehicle licensingregulations.

Companies requesting that rebuilt vehicles be marked with the vehicle identification number should be advisedaccordingly and referred to the responsible registration authority.

Vehicle identification number - AH60.00-P-0800-02B

All vehicles with USA version, code 491, 494




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Fig. 2: Identifying Vehicle Identification Number

The vehicle identification number starts and ends with the "Mercedes star" trademark (1, 19) and has 19punched numbers with a total length of 103 mm.

If, in case of repair, the area where the vehicle identification number has been embossed is replaced, it isnecessary to punch in the vehicle identification number at the same point.

This involves a change to the vehicle which is subject to compulsory notification. In the Federal Republic ofGermany immediately inform the vehicle licensing authority in writing.

The vehicle owner is required to complete a certificate for the vehicle licensing authority which indicates thatthe vehicle identification number has been re-stamped after completing body repairs.

As prove, the original vehicle identification number cut out of the old part, may also be enclosed.

A vehicle identification number incompletely punched in by the workshop must be crossed out and pinched incorrectly in the spare field on the right crossmember, the right side of the drive shaft tunnel, the rear partitionwall or the firewall.

This procedure should be noted additionally in the certificate for the vehicle licensing authority as follows:

"The incorrectly or incompletely punched vehicle identification number was crossed out and the correct vehicleidentification number punched in the spare field."

Export countries must observe their relevant vehicle licensing provisions and legal regulations.

GUIDELINES FOR REMOVING FUEL TANK WHEN PERFORMING WELDING WORK ONBODIES - AH60.00-P-3000-01Z

All models

When a repair or partial rebuilding of the listed parts is being carried out, a supervisor must decide whether to




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radiator grille

Radiator grill toheadlamp

Dim. "N" mm5.0 (+1/-0.5)Fig., see AR60.00-P-

0700-01G

BE60.00-P-1002-01A

Gap dimension Front door to A-pillar

Dim. "B" mm-

Front door tofender

Dim. "H" mm4.0 ( 0.5)

Front door to rear

door

Dim. "I" mm-

Front door to roof Dim. "C" mm-

Rear door toupper side section

Dim. "D" mm-

Rear door tolower side section

Dim. "J" mm-

Fender to A-pillar Dim. "Q" mm4.0 ( 1,6)

Front door to rearfender

Dim. "P" mm4.0 ( 0.5)Fig., see AR60.00-P-

0700-01G

BE60.00-P-1003-01A

Gap dimension Trunk lid to topof rear fender

Dim. "F" mm-

Trunk lid tobottom of rearfender

Dim. "M" mm-

Trunk lid to rearfender

Dim. "F" mm5.0 (+1/-0)

Trunk lid totaillamp

Dim. "M" mm5.0 (+1/-0)

Trunk lid tobumper

Dim. "V" mm8.0 ( 0.5)

Rear fender to

taillamp

Dim. "U" mm3.0 ( 0.5)

Fig., see AR60.00-P-0700-01G

BE60.00-P-1005-01A

Gap dimension Fuel filler flap Dim. "K" mm3.5 ( 0.5)

Dim. "L" mm-

Fig., see AR60.00-P-0700-01G

BE60.00-P-1006-01A

Gap dimension Roof towindshield frame

Dim. "S" mm9.0 (+0/-2)

Roof to rearwindow frame

Dim. "T" mm7.0 (+0/-2)

Fig., see AR60.00-P-0700-01G




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Fig. 3: Identifying Feeler Gage (129 589 03 21 00)

Adjust hoods, doors and trunk lids as shown in the drawings. The gap should not run wedge-shaped or be toonarrow at points. Deviations from parallel gap should be max. 0.5 mm over the entire length. If the insideclearance is too large or too small, the movable body parts must be centered accordingly. The referencemeasurements apply only for repair work on bodies damaged in accidents.

Fig. 4: Identifying Hoods, Doors And Trunk Lids Parallel Gap Measuring Points (Front Side)




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Fig. 5: Identifying Hoods, Doors And Trunk Lids Parallel Gap Measuring Points (Rear Side)

APPLYING VEHICLE IDENTIFICATION NUMBER - AR60.00-P-0800G

MODEL 170

Fig. 6: Identifying Vehicle Identification Number Location



2003 M d B SLK320


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Fig. 7: Identifying Number Punch Guide (170 589 01 63 00)

Fig. 8: Identifying Set Of Steel Stamping Numbers (140 589 26 63 00)

Fig. 9: Identifying Set Of Steel Stamping Letters (140 589 26 63 05)

Stamping in vehicle identification number - AR60.00-P-0800-02G

Product liability,

trademarks and trafficlaws

AH60.00-P-0800-01Z

Vehicle identificationnumber

EC vehicles AH60.00-P-0800-02A

USA vehicles AH60.00-P-0800-02B

1 Stamping in vehicleidentification number

AR60.00-P-0800-02G

2 Crossing out vehicle

identification no. andstamping in new numberin spare space

AR60.00-P-0800-05G



2003 Mercedes Benz SLK320


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1. Start with "Mercedes star" punch in window plate at top left (arrow)

The tip of the Mercedes star should point upward in relation to the lettering.

2. Then position the "W" stamp with the left edge flush with the first mark in the window plate and stamp.

3. Move ahead one mark on the window plate with each subsequent stamp until the complete vehicleidentification number and final Mercedes star have been stamped in.





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Fig. 13: Mercedes Star Punch In Window Plate At Top Left

Fig. 14: Identifying Mercedes Star Mark On Window Plate At Top Left

Crossing out vehicle identification no. and stamping in new number in spare space - AR60.00-P-0800-05G







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1. Cross out incorrect vehicle identification number with "X" stamp and stamp new vehicle identificationnumber into the spare space below as follows.

2. Start with "Mercedes star" punch in window plate at bottom left (arrow)

The tip of the Mercedes star should point upward in relation to the lettering.

3. Then position the "W" stamp with the left edge flush with the first mark in the window plate and stamp.

4. Move ahead one mark on the window plate with each subsequent stamp until the complete vehicleidentification number and final Mercedes star have been stamped in.

Fig. 18: Crossing Out Vehicle Identification No. And Stamping In New Number In Spare Space

INSTALLING SIDE PORTAL - AR60.20-P-1550G





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MODEL 170

Disassembling,assembling

The side portal can onlybe used in combinationwith a straighteningsystem approved by MBand the associated

straightening set.

1 Set up straightening benchwith modular members

Observe set-up plansincluded withstraightening set!

2 Set up straightening benchwith straightening set

Observe set-up plansincluded withstraightening set!

Celette straightening set *WE58.40-Z-1009-01E

Car Bench straighteningset

*WE58.40-Z-1001-01A

Use supplementarystraightening set model170! See

Celette supplementarystraightening set

*WE58.40-Z-1004-01A

Celette supplementarystraightening set *WE58.40-Z-1033-01A

Car-Benchsupplementarystraightening set

*WE58.40-Z-1005-01A

Car-Benchsupplementarystraightening set

*WE58.40-Z-1034-01A

3 Set vehicle ontostraightening bench withlifting platform and fasten

Align vehicle exactlyaccording to controlholes and fasten tightly tostraightening set.

Two-column lift *WE58.40-Z-1001-05A

4 Instal side portal withportal straightening set

Celette straightening setCar bench straighteningset

AR60.20-P-1550-01G

5 Disassemble in oppositeorder





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Fig. 19: Identifying Portal Straightening Set (170 589 02 23 00)

Fig. 20: Identifying Portal Frame (129 589 03 23 00)

Workshop equipment

WE58.40-Z-1001-01A Car bench straightening bracket set 82415, (model202)

WE58.40-Z-1002-01A Car bench straightening bracket set 82417, (model

210)WE58.40-Z-1004-01A Celette straightening bracket set 7170.309 (model

170), as supplement to 7202.300 (model 202)

WE58.40-Z-1005-01A Car-Bench straightening bracket set 82 420 (model170), as supplement to 82 415 (model 202)

WE58.40-Z-1033-01A Celette 7170.308 supplementary straighteningbracket for 7170.309 (model 170)

WE58.40-Z-1034-01A Car Bench 82435 supplementary straighteningbracket for 82420 (model 170)

WE58.40-Z-1001-01E Celette straightening bench

WE58.40-Z-1002-01E Celette straightening unit

WE58.40-Z-1003-01E Car-Bench straightening bench

WE58.40-Z-1004-01E Car-Bench straightening lifting platform

WE58.40-Z-1005-01E Car-Bench straightening equipment

WE58.40-Z-1007-01E Celette module crossmember set 955.940

WE58.40-Z-1008-01E Celette additional member 955.908

WE58.40-Z-1009-01E Celette straightening bracket set 7202.300

WE58.40-Z-1010-01E Car-Bench universal cross member set A 296

WE58.40-Z-1011-01E Car-Bench Universal crossmember set A 296/15 (allcrossmembers 1500 mm lon




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Attaching side portal with portal straightening set - AR60.20-P-1550-01G

Illustration: Celette straightening system

Fig. 21: Identifying Celette Straightening System

Illustration: Car-Bench straightening system

Installation sequence for side portal

Installation positions and designations for Car-Bench straightening system in brackets [...].

1. Position universal cross members U1, U2 in grid fields 56-58 and 63-65. (Car-Bench only)

2. Install side extensions (21, 22) on modular members [cross members ] grid fields 17, 33 [ 56-58, 63-65 ]hole pattern 2.- 4. [3.- 6 ].

3. Install multi-Z-elements MZ 601/602 (20) on side extensions (21, 22).

Arrow must point toward front!

WE58.40-Z-1001-05A Two-post lifting platform




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Fig. 22: Identifying Installation Sequence For Side Portal

4. Install cylindrical mount (19) in MZ 601/602 (20, upper hole).

5. Install cylindrical mount (18) (special mount from portal straightening set) in MZ 601/602 (20).

Arrow must point toward front!

6. Align portal longitudinal member (23) on cylindrical mounts (18, 19) at front with 8 [5] and at rear withposition number 9 [3] and fasten with M12 x35 bolts.

In contrast to the usual installation schematic for portal frames it is necessary to install the portallongitudinal member with the flange surface pointing down (position numbers upside down).

Installation sequence for portal straightening set for A-pillar and cross member console




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Fig. 23: Identifying Installation Sequence For Portal Straightening Set For A-Pillar And CrossMember Console

7. Position check and welding gauge for bottom A-pillar (1, 2) on no. 10 [8].

When replacing A-pillar insert spacer plate (e).

8. Screw cross member console mount (3, 4) to check and welding gauge for A-pillar (1, 2).

9. Position check and welding gauge for upper A-pillar (5, 6) to no. 5 [3].

Installation sequence for portal straightening set for top and bottom A-pillar




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Fig. 24: Identifying Installation Sequence For Portal Straightening Set For Top And Bottom A-Pillar

10. Position check and welding gauge for bottom A-pillar (7, 8) on no. 1 [3] (rear).

When replacing wheelhouse insert spacer plate (d).

11. Screw top B-pillar mount onto check and welding gauge for main Vario roof mount (11/12).

Use screw supplied for upper mounting point on B-pillar (upper belt guide console).

Installation sequence for portal straightening set for main Vario roof mount, rear fender andtubular console frame

Fig. 25: Identifying Installation Sequence For Portal Straightening Set For Main Vario Roof MountAnd Frame

12. Position check and welding gauge for main Vario roof mount (11, 12) to no. 4 [6].

13. Screw rear fender mount (13, 14) onto check and welding gauge (11, 12).

14. Position check and welding gauge for tubular console frame (15, 16) on no. 8 [10].

TEST & ADJUSTMENT VALUES

GAP DIMENSIONS - BE60.00-P-1000-01A

Model 168, 170, 202, 208, 210, 215, 220, 230, 414

Modification notes



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Front door to roof Dimension "C" mm-

Rear door to top of

side section

Dimension "D" mm-

Rear door to lowerside section

Dimension "J" mm-

Fender to A-pillar Dimension "Q" mm2.0 (0,5)

Front door to rearfender

Dimension "P" mm5.0 (0,5)

Fig. see -

BE60.00-P-1003-01A

Size of gap Trunk lid to top ofrear fender

Dimension "F" mm-

Trunk lid to bottomof rear fender

Dimension "M" mm-

Trunk lid to rearfender

Dimension "F" mm-

Trunk lid totaillamp

Dimension "M" mm-

Trunk lid to bumper Dimension "V" mm-Rear fender totaillamp

Dimension "U" mm-

Fig. see -

BE60.00-P-1004-01A

Size of gap Tailgate and roof Dimension" E" mm-

Tailgate and D-pillar

Dimension "F" mm-

Tailgate and D-pillar

Dimension" G" mm-

Tailgate and rearfender

Dimension "M" mm-

Fig. see -

BE60.00-P-1005-01A

Size of gap Fuel filler flap Dimension "K" mm4.0 (0,5)

Dimension "L" mm-

Fig. see -

BE60.00-P-1006-01A

Size of gap Roof to windshieldframe

Dimension "S" mm5.0 (0,5)

Roof to rearwindow frame

Dimension "T" mm-

Fig. see -

BE60.00-P-1007-01A

Size of gap Soft top towindshield frame

Dimension "S" mm-

Soft top to soft topcompartment cover

Dimension "W" mm-

Fig. see -

BE60.00-P-1008-01A

Size of gap Soft topcompartment cover

Dimension "X" mm-




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to rear fender

Soft top

compartment coverto trunk lid

Dimension "Y" mm-

Fig. see -

BE60.00-P-1009-01A

Size of gap Front door windowto soft top

Dimension "Z" mm-

Front door windowto rear side window

Dimension "N" mm-

Fig. see -BE60.00-P-1010-01A

Size of gap Sliding door to frontdoor

Dimension "C" mm5.0 (0,5)

Sliding door toouter rocker panelcover

Dimension "D" mm5.0 (0,5)

Sliding door to rearfender

Dimension" E" mm8.0 (0,5)

Sliding door to roofedge

Dimension "F" mm5.0 (0,5)

Fig. see -

BE60.00-P-1011-01A

Size of gap Tailgate to taillampunit

Dimension" G" mm5.0 (0,5)

Tailgate to bumper Dimension "I" mm7.0 (0,5)

Tailgate to tailgate Dimension "L" mm7.0 (0,5)

Tailgate to rearspoiler Dimension "M" mm5.0 (0,5)

Rear spoiler to roof Dimension "T" mm 7.0 (0,5)

Fig. see -

BE60.00-P-1012-01A

Size of gap Center door to frontdoor

Dimension "R" mm-

Center door to reardoor

Dimension "S" mm-

Center door to roof Dimension "T" mm

Fig. see -

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