Replace complete rear end assembly - AR64.20-P-1020P
MODEL 203.0
| Removing | |||
| Risk of fatal injury due to vehicle slipping off or tilting on the hoist | Align vehicle between lifting platform columns and place the four lifting plates in the lifting platform lifting points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Measures for preventing damage to vehicles or components when performing electric welding work | All models | AH00.00-N-0005-01A | |
| General information on repairs to body | All models | AH60.00-N-0001-01A | |
| 1 | Remove attached parts on the outside of the rear end assembly. | ||
| 2 | Remove attached parts in the trunk, in the area of the rear end assembly and the left and right rear fenders. | ||
| 3 | Cover detachable parts which remain in vehicle (repair area) | Tarp (fire-resistant) | |
| 4 | Detach rear end assembly | AR64.20-P-1020-01P | |
| Ball cutter, ø 12 mm Round wire brush, braided, ø 70 mm Vario Drill WS 91 spot weld removing tool Abrasive disk, ø 115 mm, 80 m/s, (max. 13,250 rpm) |
Figure | ||
| 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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| Body saw (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 | ||
| 5 | Prepare rear end assembly | AR64.20-P-1020-02P | |
| Round wire brush, braided, ø 70 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 | |||
| 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 | |
| 6 | Install and weld in rear end assembly | AR64.20-P-1020-03P | |
| Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01P | ||
| Gap dimensions | *BE60.00-P-1003-01E | ||
Round wire brush, braided, ø 70 mm Electrode miller Clamping pliers Abrasive disk, ø 115 mm, 80 m/s, (max. 13,250 rpm) Insert gas welder, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
Figure | ||
| Spot welder, 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 | ||
| 7 | Clean weld joints and metal flanges using wire brush. Clean repair areas | ||
| 8 | |||
| 9 | Seam seal following repair | AR97.10-P-4000P | |
| Sealant | *BR00.45-Z-1003-01A | ||
| 10 | Paint rear end assembly and adjacent surfaces | ||
| Notes on repair painting | Model 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 210, 215, 220, 463 | ||
| General information on MB materials | Model 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 210, 215, 220, 463 | AH98.00-P-9409-03A | |
| 11 | 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 |
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS
| Number | Designation | Model 203.004/006/007/008/016/018/020/035/040/042/043/045/046/052/056/061/064/065/081/084/087 | |||
|---|---|---|---|---|---|
| BE60.00-P-1003-01E | Gap dimension | Trunk lid to rear fender, top | Dimension "F" | mm | 3.5 (±1) |
| Trunk lid to taillamp | Dimension "M" | mm | 4 (±1) | ||
| Rear fender to taillamp | Dimension "U" | mm | - | ||
| See picture | AR60.00-P-0700-01P | ||||
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 |