1415) on the centre bolt of the belt tensioner idler
pulley, rotate the adjuster against spring tension.
3. Whilst holding the tensioner against spring tension, pass the drive belt over the generator pulley and
check that it is correctly located on the other pulleys.
Release the tensioner slowly and remove the
spanner. Check the alignment of the belt.
9. Fit the supercharger drive belt tensioner; refer to operation
18.50.24.
10. Fit the supercharger drive belt ; refer to operation 18.50.08.
11. Refit the fan and motor asse mbly; refer to Operation
26.25.12.
12. Refit the air cleaner assembly; refer to Operation 19.10.05.
13. Reconnect the battery ground cable and fit the battery cover.
Reset the radio inform ation and the clock.
Audio Unit - Capacitor
Removal and Installation
Removal
Installation
1. Disconnect the batt ery ground cable.
Remove the battery cover.
2. Raise the vehicle on a ramp.
3. Remove the suppr ession module.
1. Disconnect the multi-plug from the mounting bracket clip.
2. Disconnect the multi-plug.
3. Remove the bolts which secure the suppression module to the mounting bracket.
4. Remove the su ppression module.
1. Installation is th e reverse of the re moval procedure.
2. Reconnect the battery ground cable and fit the battery cover.
Reset the radio inform ation and the clock.
The body is pre-treated to ensure high resistance to corrosion and stone chip dama ge. Prior to the first major pre-treatment process, the body shell is high-pressure washed to remove any metal dust and residual oil.
The first major pre-treatment process consists of phosphate and electro-paint deposition, which together with zinc coating,
forms the basis of the corrosion protection. This process includes high pressure knock-off, alkali de-greasing, zinc phosphate
conversion of body steel (dissolving iron and coating with zinc phosphate crystals), trivalent chrome rinsing and
demineralized water rinsing, seal ing all chemicals and impurities.
Both dip and spray techniques are employed and the bodies are submerged to the waistline during the first and third rinses
of the main phosphate clean. Chemical strengths and soluti on temperatures are continuously monitored and accurately
controlled throughout the process.
An 80% water primer is then cathodic elec tro-deposition applied to the thoroughly cleansed bodies in a uniform 'sag-free'
film 18 to 32 micron thick. Optimum durabi lity of the electroprimer is achieved by finally curing in a stoving oven at 165 °C
for a period of 20 minutes.
All underbody seams of the fully primed bo dies are then manually sealed, to prevent water and dust ingress into the vehicle
and to enhance corrosion protection.
An 800 to 1000 g/m2 PVC coating is semi-automatic airless sp ray applied to the underside of the main floor panels, trunk
floor and rear wheel arches (ref. illustration above).
The upper panels of primed and external ly sealed bodyshells are next lightly scuffed to remove imperfections and a PVC
coating is applied to all internal seams by an airless spray technique. A PVC bead seal is also applied to the doors, hood and
trunk clinch joints.
Following anti-corrosion, sealing and primin g treatment, the bodies enter the first stage of 'cosmetic' painting. This consists
of the application of two coats of a highly chip resistant po lyester surfacer, employing high voltage electrostatic 'spinning
bells', to achieve a final film thickness of 35 to 50 micron. Between surfacer coats, a polyurethane coat is automatically
applied to the sills to impart even greater resistance to stone chipping.
All interior panels are then painted us ing a color keyed sealer, wet-on-wet wi th a surfacer material, after which the
bodyshells are stoved at 160 °C for a period of 20 minutes. Further protection agai nst corrosion is provided by a medium
solids black pigmented wax which is airless spray applied to vehicle undersides.
Wax Injected Box Sections
Critical body box-sections are si milarly protected by spray injecting a high solids wax. This is then re-flowed at 70 to 90 °C
to achieve optimum seam/joint penetratio n and form a resilient and durable internal coating (ref. illustration above).
After full wet sanding, rinsing and drying to provide a good su bstrate, a color-keyed semi-matt sealer co at is applied using
electrostatic bells to achieve a film build of 25 to 35 micron . The bodies are then stoved for a further 20 minutes at a
temperature of 145 °C and subjected to a local 'seek-and-find' de -nib operation prior to the final two coat process. The final
top coat finish is achieved by using poly ester base coat colors and an acrylic sag resistant clear coat. This clear over base
(COB) process produces a high gloss, durabl e paint finish with a film thickness of 50 to 65 micron, which is finally cured at a
temperature of 135°C for 20 minutes.
The Munsell three dimensional system of color management is em ployed to achieve highly accurate control of vehicle colors.
This system ensures that paint pigmentations are accurately maintained and facilitates vigorous final checking of finished
vehicles for color match. The hu e of individual panels such as trunk lids, doors and hoods is in some instances adjusted to
offset the effects of differing light angles. Where applicable, coachlines are manually applied and radiant heat cured on the
completed and valeted vehicle prior to hand spray applic ation of a protective wax coat.
Introduction
All repairs, whether structural or cosmetic must return the vehicle to the original manufactured condition with regard to
occupant safety, dimensional accuracy, fi nish and corrosion protection, and ensure continuation of the Paint Surface and
Corrosion warranty where applicable.
Similarly, repaired vehicles must be fu lly checked, and where appropriate reset, with regard to steering, suspension,
braking, and occupant restraint systems.
Replacement bumper cover assemblies includer side armatures, which should be removed from discarded bumper
assemblies and rout ed for recycling.
BODY SIDE MOULDINGS
Description
Two types of moulding are fitted to the standard wheelbase sedan. The lower mouldings are positioned on the body / door
lower feature lines. Where applicable, the upper mouldings are positioned using the lower mouldings as data. Replacement
lower mouldings are supplied in a primed condition and must be finished as detailed in this section.
Side Moulding Positions
Body Closures
Clearances and Alignments
When any panel, closure or body component is renewed, refitted or reset, the specified clearances and alignments must be
restored. This ensures that vehicle appearance and operation fully satisfy design intent and the customer.
Clearances
Gaps should be uniform around body panel contours and must be parallel to within 1mm in a 400mm linear measurement.
LocationFinishApplicationFixing method
UpperPolished stainless steelDaimler / VDPSelf adhesive
LowerBody colorAll modelsSelf adhesive
1Adhesive tape
2Moulding, Daimler/VDP
3Moulding all models
