Partially replace rear outer wheelhouse - AR63.10-P-0660QA: Notes
MODEL 209.4
| 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 untrimmed vehicle parts. Deburr metal repairs. | AS00.00-Z-0017-01A | |
| Risk of death. Death may result if vehicle slips or topples from the lifting platform. | Align vehicle between columns of lifting platform and position the four support plates below support points specified by vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of death caused by high voltage used for arc welding. Risk of explosion caused by welding in the area of high combustible 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 danger zone. Use air extractor. | AS00.00-Z-0007-01A | |
| Risk of explosion as fuel vapors can ignite. Risk of poisoning from inhaling fuel vapors and exposed handling of fuel. Risk of injury if fuel splashes hit the eyes. | No fire, sparks, naked 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 repairs to body | All models | AH60.00-N-0001-01A | |
| Measures for preventing damage to vehicles or components when performing arc welding work | All models | AH00.00-N-0005-01A | |
| Notes on paintwork repairs | All models | AH98.00-P-9408-02A | |
| General information on MB materials | All models | AH98.00-P-9409-03A | |
| 1 | Remove detachable body components in area to be repaired | ||
| 2 | Cover all detachable body components remaining in vehicle (area to be repaired) | Tarp (fire-resistant) | *WH58.30-Z-1001-40A |
| 3 | Remove rear fender | AR63.50-P-1400QA | |
| 4 | Remove rear outer wheelhouse | AR63.10-P-0660-01QA | |
| Figure | |||
| *WH58.30-Z-1002-01A | |||
| *WH58.30-Z-1001-03A | |||
| *WH58.30-Z-1006-01A | |||
| *WH58.30-Z-1024-04A | |||
| *WH58.30-Z-1021-04A | |||
| 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 | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 5 | Prepare rear outer wheelhouse for installation | AR63.10-P-0670-05QA | |
| *WH58.30-Z-1001-03A | |||
| *WH58.30-Z-1024-04A | |||
| Drill (electric/pneumatic) | *WE58.40-Z-1001-03A | ||
| Angular grinder (electric/pneumatic) | *WE58.40-Z-1003-03A | ||
| Body saw (electric/pneumatic) | *WE58.40-Z-1004-03A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 6 | Install rear outer wheelhouse | AR63.10-P-0670-06QA | |
| General notes on riveting | AH60.00-P-0003-01N | ||
| Fig 4 | |||
| Fig 3 | |||
| *WH58.30-Z-1001-03A | |||
| *WH58.30-Z-1003-01A | |||
| *WH58.30-Z-1003-02A | |||
| *WH58.30-Z-1003-29A | |||
| *WE58.40-Z-1003-14A | |||
| *WH58.30-Z-1038-02A | |||
| Inert gas welder | *WE58.40-Z-1001-02A | ||
| Drill (electric/pneumatic) | *WE58.40-Z-1001-03A | ||
| Spot welder | *WE58.40-Z-1002-02A | ||
| Wet/dry vacuum cleaner | *WE58.40-Z-1005-03A | ||
| Rivet | *BR00.45-Z-1001-13A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 7 | Adjust gap dimensions on hoods, doors and covers | ||
| Rear fender to taillamp | *BE60.00-P-1003-01G | ||
| Trunk lid to top of rear fender | *BE60.00-P-1003-01G | ||
| Trunk lid cover to taillamp | *BE60.00-P-1003-01G | ||
| Front door to rear fender | *BE60.00-P-1002-01G | ||
| Fuel filler flap | *BE60.00-P-1004-01G | ||
| 8 | Install rear fender | AR63.50-P-1400QA | |
| 9 | Clean weld joints and metal flanges with wire brush | ||
| 10 | Clean areas to be repaired and prime with primer / filler | ||
| 11 | Seam sealing following repair | ||
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 12 | Paint areas to be repaired and adjacent surfaces | ||
| 13 | Hollow cavity preservation following repair work | ||
| Notes on hollow cavity preservation | Model 209 | AH97.20-P-0001-01B | |
| 14 | Install all removed parts |
TEST AND ADJUSTMENT VALUES FOR GAPS
| Number | Designation | Model 209.4 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01G | Gap dimensions | Front door to A-pillar | Dimension << D>> | mm | 1 |
| Front door to fender | Dimension << E>> | mm | 3.5 (-0.5/+1) | ||
| Front door to rear fender | Dimension << F>> | mm | 3.5 (-0.5/+1) | ||
| Fig., see | AR60.00-P-0700-01QA | ||||
| BE60.00-P-1003-01G | Gap dimensions | Trunk lid to top of rear fender | Dimension << G>> | mm | 3.5 (± 1) |
| Trunk lid to taillamp | Dimension << H>> | mm | 3.5 (± 0.5/+1) | ||
| Trunk lid to bumper | Dimension | mm | 6.5 (+1) | ||
| Rear fender to taillamp | Dimension << J>> | mm | 3 (± 1) | ||
| Trunk lid cover to taillamp | Dimension << K>> | mm | 2.5 (± 0.5) | ||
| Fig., see | AR60.00-P-0700-01QA | ||||
| BE60.00-P-1004-01G | Gap dimensions | Fuel filler flap | Dimension << L>> | mm | 3.2 (+0.5) |
| Fig., see | AR60.00-P-0700-01QA | ||||
| BE60.00-P-1007-01G | Gap dimensions | Soft top compartment cover to rear fender | Dimension << O>> | mm | 3 (± 0.5) |
| Soft top compartment cover to trunk lid | Dimension << P >> | mm | 4.5 (± 1) | ||
| Fig., see | AR60.00-P-0700-01QA | ||||
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 Firma Hausmann GmbH D-34346 Hann. Munden, Germany |
| WH58.30-Z-1001-03A | Round wire brush, braided, dia. 70 mm |
| WH58.30-Z-1021-04A | Cutting disk, dia. 65 mm, 80 m/s (max. 23, 500 RPM) |
| WH58.30-Z-1024-04A | Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM) |
| WH58.30-Z-1003-29A | Hand riveter |
| WH58.30-Z-1001-40A | Tarp (fire-resistant) |
WORKSHOP EQUIPMENT
| 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-1003-14A | Blind rivet tool |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | Sealant | A 001 989 63 20 |
| BR00.45-Z-1041-01A | Seam sealant, sprayable | 310 ml A 002 989 84 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 |