Partially replace outer rear wheel well - AR63.10-P-0660QBS (Black Series): Notes
MODEL 209.3 with CODE P98 Black Series
| 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 | ||
| The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly flammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases. | Use insulating mats. Wear protective clothing when handling fuel. Remove highly flammable materials from the hazard area. Use air extraction system. | AS47.00-Z-0007-01A | ||
| Measures for preventing damage to vehicles or components when performing arc welding work | All models | AH00.00-N-0005-01A | ||
| General information on repairs to body | All models | AH60.00-N-0001-01A | ||
| General information on MB materials | All models | AH98.00-P-9409-03A | ||
| 1 | Prepare all workshop equipment and commercially available tools required for repair | |||
| 2 | Remove detachable body components in area to be repaired | |||
| 3 | Cover all detachable body components remaining in vehicle (area to be repaired) with fire-resistant tarp | |||
| 4 | Remove rear fender | AR63.50-P-1400Q | ||
| 5 | Partially remove outer rear wheel well (1) | AR63.10-P-0660-02QBS | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | |||
| Fig 2 | ||||
| 6 | Partially prepare outer rear wheel well (1) for installation | AR63.10-P-0660-03QBS | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | |||
| Install | ||||
| Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes. | Wear respiratory protection, protective gloves, and safety glasses. Pour adhesive into suitable and appropriately marked containers only. | AS00.00-Z-0016-01A | ||
| 7 | Partially install outer rear wheel well (1) | AR63.10-P-0660-04QBS | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | |||
| Adhesive kit, body, 2-component adhesive | *BR00.45-Z-1092-02A | |||
| 8 | Adjust gap dimensions on hoods, doors, and covers | Gap dimension | *BE60.00-P-1002-01G | |
| Gap dimension | *BE60.00-P-1003-01G | |||
| Gap dimension | *BE60.00-P-1004-01G | |||
| Fig 3 | ||||
| 9 | Install rear fender | AR63.50-P-1400Q | ||
| 10 | Clean weld joints and metal flanges with wire brush | |||
| 11 | Clean repair area with wet/dry vacuum cleaner | |||
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses, and skin cream. Ensure that the area is well ventilated. | |||
| 12 | Prime repair area with primer filler | |||
| Notes on paintwork repairs | AH98.00-P-9408-02A | |||
| 13 | Carry out seam sealing after repairs | AR97.10-P-4000Q | ||
| Sealing compound | *BR00.45-Z-1003-01A | |||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | |||
| 14 | Paint repair area adjacent surfaces | |||
| Notes on paintwork repairs | AH98.00-P-9408-02A | |||
| 15 | Apply additional cavity preservation | AR97.20-P-1500Q | ||
| Notes on hollow cavity preservation | Solvent-free cavity preservation | *BR00.45-Z-1003-05A | ||
| 16 | Remove welding protection blankets from covered parts on vehicle | |||
| 17 | Install all removed detachable parts | |||
TEST AND ADJUSTMENT VALUES FOR GAPS
| Number | Designation | Model 209.3 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01G | Gap dimensions | Front door to A-pillar | Dimension "D" | mm | - |
| 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) | ||
| See illustration in: | AR60.00-P-0700-01Q | ||||
| BE60.00-P-1003-01G | Gap dimensions | Trunk lid to top of rear fender | Dimension "G" | mm | 3.5 (± 0.5) |
| Trunk lid to rear lamp unit | Dimension "H" | mm | 3.5 (± 0.5) | ||
| Trunk lid to bumper | Dimension "I" | mm | 5 (- 1) | ||
| Rear fender to lamp unit | Dimension "J" | mm | 2 (± 0.5) | ||
| Trunk lid license plate panel to rear lamp unit | Dimension "K" | mm | - | ||
| See illustration in: | AR60.00-P-0700-01Q | ||||
| BE60.00-P-1004-01G | Gap dimensions | Fuel filler flap | Dimension "L" | mm | 3.5 (± 0.5) |
| See illustration in: | AR60.00-P-0700-01Q | ||||
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-1003-01A | White sealing compound, 310 ml, DBL 6069.20 | A 001 989 63 20 |
| BR00.45-Z-1003-05A | Solvent-free cavity preservation (1 L container) | A 000 986 72 70 05 |
| BR00.45-Z-1041-01A | Seam sealant, sprayale 310 ml | A 002 989 84 20 |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |