Replace complete rear end assembly - AR64.20-P-1020PB
MODEL 203.7
| Removing | |||
| 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 | |
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| 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 | |
| General information on repairs to body | All models | AH60.00-N-0001-01A | |
| Measures for preventing damage to vehicles or components when performing electric 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 parts in repair area | ||
| 2 | Cover all detachable parts that remain in the repair area | Tarp (fire-resistant) | |
| 3 | Detach rear end assembly | AR64.20-P-1020-01PB | |
| Figure | |||
| Ball cutter, ø 12 mm Electrode miller Vario Drill WS 91 spot weld removing tool Round wire brush, braided, ø 70 mm Abrasive disk, ø 115 mm, 80 m/s (max. 13,250 rpm) Drill (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Straight grinder (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Angle grinder (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Wet/dry vacuum cleaner, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 4 | Prepare rear end assembly | AR64.20-P-1020-02PB | |
| Round wire brush, braided, ø 70 mm Hole punching pliers, ø 6 mm Drill (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 7 | Install and weld in rear end assembly | AR64.20-P-1020-03PB | |
| Figure | |||
| Electrode miller Round wire brush, braided, ø 70 mm Abrasive disk, ø 115 mm, 80 m/s (max. 13,250 rpm) Clamping pliers Hand riveter Insert gas welder, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Spot welder, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Drill (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Angle grinder (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| 8 | Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01PB | |
| Rear fender to taillamp | *BE60.00-P-1003-01E | ||
| Rear-end door to rear fender | *BE60.00-P-1004-01E | ||
| Rear-end door to bumper | *BE60.00-P-1004-01E | ||
| Figure | |||
| 9 | Clean repair areas and prime using primer filler | ||
| 10 | Seam seal following repair | AR97.10-P-4000P | |
| MB body sealant for seam sealant (paintable/310 ml cartridge) | *BR00.45-Z-1003-01A | ||
| 11 | Paint repair areas and adjacent surfaces | ||
| 12 | Apply additional cavity preservation | AP97.20-P-0640-01A | |
| Notes on cavity preservation | Model 124, 126, 129, 140, 170, 201, 202, 203, 208, 210, 215, 220, 463, 671 | AH97.20-P-0001-01B | |
| 13 | Install all removed assembly parts |
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS
| Number | Designation | Model 203.706/707/708/718/730/735/740/742/743/745/746/747/752/756/764 | |||
|---|---|---|---|---|---|
| BE60.00-P-1003-01E | Gap dimension | Trunk lid to rear fender, top | Dimension "F" | mm | - |
| Trunk lid to taillamp | Dimension "M" | mm | - | ||
| Rear fender to taillamp | Dimension "U" | mm | 2.5 (±0.5) | ||
| See picture | AR60.00-P-0700-01PB | ||||
| BE60.00-P-1004-01E | Gap dimension | Rear-end door to roof | Dimension "E" | mm | 8.5 (+1) |
| Rear-end door to rear fender | Dimension "M" | mm | 3.5 (±1) | ||
| Rear-end door to taillamp | Dimension "L" | mm | 4 (±1) | ||
| Rear-end door to bumper | Dimension "S" | mm | 6.5 (-1.5) | ||
| Rear-end door to D-pillar | Dimension "Q" | mm | - | ||
| See picture | AR60.00-P-0700-01PB | ||||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | Sealant | A 001 989 63 20 |
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |