Remove/install outer part of rear center section - AR64.20-P-1010TA
MODEL 211.2
| 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
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) | Tarpaulin (fireproof) | *WH58.30-Z-1001-40A |
| 3 | Separate outer part of rear center section | AR64.20-P-1000-01TA | |
| Figure | |||
| *WH58.30-Z-1002-01A | |||
| *WH58.30-Z-1001-03A | |||
| *WH58.30-Z-1006-01A | |||
| *WH58.30-Z-1024-04A | |||
| 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 | ||
| Wet/dry vacuum cleaner | *WE58.40-Z-1005-03A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 4 | Prepare outer part of rear center section | AR64.20-P-1000-09TA | |
| *WH58.30-Z-1001-03A | |||
| *WH58.30-Z-1024-04A | |||
| *WH58.30-Z-1002-01A | |||
| *WH58.30-Z-1006-01A | |||
| Straight grinder (electric/pneumatic) | *WE58.40-Z-1002-03A | ||
| Angular grinder (electric/pneumatic) | *WE58.40-Z-1003-03A | ||
| Drill (electric/pneumatic) | *WE58.40-Z-1001-03A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 5 | Install outer part of rear center section and weld in | AR64.20-P-1000-10TA | |
| Figure | |||
| Figure | |||
| *WH58.30-Z-1003-01A | |||
| *WH58.30-Z-1003-02A | |||
| Spot welder | *WE58.40-Z-1001-03A | ||
| Hollow cavity preservation gun Sata HRS no. 11072 | *WE58.40-Z-1006-08A | ||
| MB preservative | *BR00.45-Z-1003-05A | ||
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 6 | Adjust gaps on hoods, doors and covers | AR60.00-P-0700-01TA | |
| Rear fender to taillamp | *BE60.00-P-1003-01F | ||
| Trunk lid to top of rear fender | *BE60.00-P-1003-01F | ||
| Trunk lid to taillamp | *BE60.00-P-1003-01F | ||
| Trunk lid cover to taillamp | *BE60.00-P-1003-01F | ||
| Figure | |||
| 7 | Clean areas to be repaired and prime with primer/filler | ||
| 8 | Seam sealing following repair | AR97.10-P-4000T | |
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 9 | Paint areas to be repaired and adjacent surfaces | ||
| 10 | Hollow cavity preservation following repair work | AR97.20-P-1500T | |
| Notes on hollow cavity preservation | Model 211 | AH97.20-P-0001-01B | |
| 11 | Install all removed detachable body components |
TEST VALUES FOR GAPS ON HOODS, DOORS AND LIDS
| Number | Designation | Model 211.2 | |||
|---|---|---|---|---|---|
| BE60.00-P-1003-01F | Gap dimensions | Rear fender to taillamp | Dimension "M" | mm | 2.5 (±1) |
| Fig., see | AR60.00-P-0700-01TA | ||||
| BE60.00-P-1005-01F | Gap dimensions | Tailgate to rear fender | Dimension "Q" | mm | 4.5 (± 1) |
| Taillamp in rear door to taillamp | Dimension "R" | mm | 5 (±1) | ||
| Rear window to D-pillar | Dimension "T" | mm | 4.5 (±1) | ||
| Fig., see | AR60.00-P-0700-01TA | ||||
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-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-1001-40A | Tarp (fire-resistant) |
WORKSHOP EQUIPMENT
| 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-1005-03A | Wet/dry vacuum cleaner |
| WE58.40-Z-1006-08A | Cavity preservation gun |
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 |