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Home >> Mercedes Benz >> 2003 >> G500 >> Repair and Diagnosis >> Collision >> General Collision Information >> Rear Wall & Rear End >> Testing & Repair >> Prepare rear portal for installation - AR64.20-P-1001-05A

Prepare rear portal for installation - AR64.20-P-1001-05A

DANGER Risk of death  caused by high voltage used for electric 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 fumes. Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. AS00.00-Z-0007-01A
DANGER 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 non-deburred vehicle parts.
Deburr repair panels.		 AS00.00-Z-0017-01A
NOTES Measures for preventing damage to vehicles or components when performing electric welding work All models AH00.00-N-0005-01A
NOTES General information on repairs to body   AH60.00-N-0001-01A
NOTES Notes on paintwork repairs   AH98.00-P-9408-02A
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
BR00.45-Z-1031-07A Passenger car primer filler 283-150VOC Glasurit GmbH Glasuritstrabe 1
48165 Munster
Germany
Tel.+49 2501 14-0
Fax +49 2501 14 3373
www.glasurit.de
  1. Grind spot weld flange on outer side of rear panel down to bare metal in crosshatched area on both sides.

    Rotary wire brush gotis://K_58.3_06.0 

  2. Coat inside of spot weld flange with zinc dust paint in crosshatched area.
    Fig 1: Identifying Spot Weld Flange Grinding Areas
    G07711189Courtesy of MERCEDES-BENZ USA
  3. Grind spot weld flange on inner side of rear panel down to bare metal in crosshatched area on both sides.

    Rotary wire brush gotis://K_58.3_06.0 

  4. Coat insides of spot weld flange in crosshatched areas with zinc dust paint.
  5. Grind mating surface in area A down to bare metal on one side.

    Rotary wire brush gotis://K_58.3_06.0 

    Fig 2: Identifying Spot Weld Flange Grinding Areas
    G07711190Courtesy of MERCEDES-BENZ USA
  6. Coat upper bracket for splinter guard (1) on inside with 283-150 VOC passenger car primer/filler

    IMPORTANT Only on model 461, 463 with code (ZS4) Special protection version FB4, code (ZS6) Special protection version FB6 and code (ZS7) Special protection version FB7.

    IMPORTANT Later coating is no longer possible.

    Fig 3: Identifying Splinter Guard
    G07711191Courtesy of MERCEDES-BENZ USA
  7. Grind spot welding flange down to bare metal in shaded areas on both sides.

    Rotary wire brush gotis://K_58.3_06.0 

  8. Coat insides of spot weld flange in crosshatched areas with zinc dust paint.
    Fig 4: Identifying Spot Welding Flange Grinding Areas
    G07711192Courtesy of MERCEDES-BENZ USA
    Fig 5: Identifying Rear Portal And Roof Frame Profiles
    G07711193Courtesy of MERCEDES-BENZ USA
  9. Cut out roof frame on new rear portal (2) according to separated old part with new body jig saw.

    Body jig saw gotis://K_58.1_01.0 

    IMPORTANT The separated roof frame profiles (5) are still required for fabrication of reinforcement shoes.

    Fig 6: Identifying Splinter Guard Grinding Areas
    G07711194Courtesy of MERCEDES-BENZ USA
  10. Grind mating surfaces in area of upper bracket for splinter guard (1) down to bare metal on one side.

    IMPORTANT Only on model 461, 463 with code (ZS4) Special protection version FB4, code (ZS6) Special protection version FB6 and code (ZS7) Special protection version FB7.

    round wire brush gotis://K_58.3_06.0 

  11. Fit upper bracket for splinter guard (1) on rear pillar together with rear pillars (2) to be installed vertically.

    IMPORTANT Only on model 461, 463 with code (ZS4) Special protection version FB4, code (ZS6) Special protection version FB6 and code (ZS7) Special protection version FB7.

    IMPORTANT Always observe distance dimension (Y) of 8 mm.

  12. Tack weld upper bracket for splinter guard (1).

    IMPORTANT Only on model 461, 463 with code (ZS4) Special protection version FB4, code (ZS6) Special protection version FB6 and code (ZS7) Special protection version FB7.

  13. Upper bracket for splinter guard (1) in area H and area of arrows MHIELDED GAS SEAM WELD INTERRUPTED .

    IMPORTANT Only on model 461, 463 with code (ZS4) Special protection version FB4, code (ZS6) Special protection version FB6 and code (ZS7) Special protection version FB7.

  14. Punch holes in areas F and K with hole punching pliers.
  15. Grind mating surfaces down to bare metal in areas F and K on both sides.

    Rotary wire brush gotis://K_58.3_06.0 

  16. Grind spot welding flange down to bare metal in shaded areas on both sides.

    Rotary wire brush gotis://K_58.3_06.0 

  17. Coat insides of spot weld flange in crosshatched areas with zinc dust paint.
  18. Grind rear portal (2) down to bare metal in areas B, C, D, E, L, M, N and O on one side.

    Rotary wire brush gotis://K_58.3_06.0 

  19. Punch holes in areas P and Q with hole punching pliers.

    Hole punching pliers gotis://K_58.3_04.0 

  20. Grind mating surfaces down to bare metal in areas P and Q on both sides.

    Rotary wire brush gotis://K_58.3_06.0 

  21. Grind spot welding flange down to bare metal in crosshatched area on both sides.

    Rotary wire brush gotis://K_58.3_06.0 

  22. Coat insides of spot welding flange with zinc dust paint.
    Fig 7: Identifying Spot Welding Flange Grinding Areas
    G07711195Courtesy of MERCEDES-BENZ USA
  23. Grind lower reinforcement (4) for rear portal (2) down to bare metal in areas R to Z on both sides.

    IMPORTANT Only on model 461, 463 with code (ZS4) Special protection version FB4, Code (ZS6) Special protection version FB6 and code (ZS7) Special protection version FB7.

    round wire brush gotis://K_58.3_06.0 

    Fig 8: Identifying Lower Reinforcement Grinding Areas
    G07711196Courtesy of MERCEDES-BENZ USA
  24. Grind spot welding flange down to bare metal in crosshatched area on both sides.

    Rotary wire brush gotis://K_58.3_06.0 

  25. Coat spot weld flange in crosshatched area with zinc dust paint on both sides.

    IMPORTANT Later coating is no longer possible.

  26. Punch holes in areas AA, AC and AD using hole punching pliers.

    Hole punching pliers gotis://K_58.3_04.0 

    Fig 9: Locating Punch Holes & Mating Surfaces
    G07711197Courtesy of MERCEDES-BENZ USA
  27. Grind mating surfaces down to bare metal in areas AA, AC and AD on both sides.

    Rotary wire brush gotis://K_58.3_06.0 

  28. Grind mating surface down to bare metal in area AB on one side.

    Rotary wire brush gotis://K_58.3_06.0 

  29. Grind mating surfaces down to bare metal in areas AF and AG on one side.

    Rotary wire brush gotis://K_58.3_06.0 

    Fig 10: Identifying Mating Surfaces
    G07711198Courtesy of MERCEDES-BENZ USA
  30. Punch holes in areas AH, AJ, AK and AL using hole punching pliers.

    Hole punching pliers gotis://K_58.3_04.0 

  31. Grind mating surfaces down to bare metal in areas AH, AJ, AK and AL on both sides.

    Rotary wire brush gotis://K_58.3_06.0 

    Fig 11: Identifying Punched Holes & Mating Surfaces
    G07711199Courtesy of MERCEDES-BENZ USA
  32. Cut roof frame profiles (5) to fabricate reinforcement shoes (6).
  33. Reshape reinforcement shoes (6).

    IMPORTANT According to course of left and right roof frame.

  34. Grind connection points on reinforcement shoes (6) down to bare metal on one side.

    Rotary wire brush gotis://K_58.3_06.0 

    Fig 12: Identifying Roof Frame Profiles And Reinforcement Shoes
    G07711200Courtesy of MERCEDES-BENZ USA
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