Replace bottom rear end center assembly complete - AR64.20-P-1000T: Notes
MODEL 211.0
| 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 | |
| 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 | |
| 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 | Cut off rear end center assembly | AR64.20-P-1000-02T | |
| 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 | ||
| Body saw (electric/pneumatic) | *WE58.40-Z-1004-03A | ||
| Wet/dry vacuum cleaner | *WE58.40-Z-1005-03A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 4 | Prepare bottom rear center section for installation | AR64.20-P-1000-07T | |
| *WH58.30-Z-1001-03A | |||
| Drill (electric/pneumatic) | *WE58.40-Z-1001-03A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 5 | Install bottom rear center section and weld in | AR64.20-P-1000-08T | |
| Figure | |||
| *WH58.30-Z-1001-03A | |||
| *WH58.30-Z-1003-01A | |||
| *WH58.30-Z-1003-02A | |||
| General notes on riveting | AH60.00-P-0003-01N | ||
| *WH58.30-Z-1003-29A | |||
| Blind rivet tool PowerBird | *WE58.40-Z-1003-14A | ||
| *WH58.30-Z-1038-02A | |||
| Rivet | *BR00.45-Z-1001-13A | ||
| Inert gas welder | *WE58.40-Z-1001-02A | ||
| Drill (electric/pneumatic) | *WE58.40-Z-1001-03A | ||
| Spot welder | *WE58.40-Z-1002-02A | ||
| Wet/dry vacuum cleaner | *WE58.40-Z-1005-03A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| MB body sealant for sealing seams (suitable for painting/310ml cartridge) | *BR00.45-Z-1003-01A | ||
| MB preservative | *BR00.45-Z-1003-05A | ||
| 6 | Adjust gap dimensions on hoods, doors and covers | AR60.00-P-0700-01T | |
| Rear fender to taillamp | *BE60.00-P-1003-01F | ||
| Trunk lid to upper rear fender | *BE60.00-P-1003-01F | ||
| Trunk lid cover to taillamp | *BE60.00-P-1003-01F | ||
| Rear door to upper side section | *BE60.00-P-1002-01F | ||
| Rear door to bottom side section | *BE60.00-P-1002-01F | ||
| Fuel filler flap | *BE60.00-P-1004-01F | ||
| 7 | Clean weld joints and metal flanges with wire brush | ||
| 8 | Clean areas to be repaired and prime with primer/filler | ||
| 9 | Seam sealing following repair | AR97.10-P-4000T | |
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 10 | Paint areas to be repaired and adjacent surfaces | ||
| 11 | Hollow cavity preservation following repair work | ||
| Notes on hollow cavity preservation | Models 124, 126, 129, 140, 170, 201, 202, 203, 208, 210, 211, 215, 220, 463, 671 | AH97.20-P-0001-01B | |
| 12 | Install all removed detachable body components |
TEST VALUES FOR GAPS ON HOODS, DOORS AND LIDS
| Number | Designation | Model 211.0 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01F | Gap dimensions | Front door to A-pillar | Dimension "D" | mm | 4.5 (± 0.5) |
| Front door to fender | Dimension "E" | mm | 4 (± 0.5) | ||
| Front door to rear door | Dimension "F" | mm | 4 (+1) | ||
| Front door to roof | Dimension "G" | mm | 4.5 (± 0.5) | ||
| Rear door to upper side section | Dimension "H" | mm | 4.5 (± 0.5) | ||
| Rear door to lower side section | Dimension "I" | mm | 3.5 (± 0.5) | ||
| Fig., see | AR60.00-P-0700-01T | ||||
| BE60.00-P-1003-01F | Gap dimensions | Trunk lid to top of rear fender | Dimension "J" | mm | 3.5 (+1) |
| Trunk lid to taillamp | Dimension "K" | mm | 3.9 (+1) | ||
| Trunk lid to bumper | Dimension "L" | mm | 6.5 (-0.5/+1) | ||
| Rear fender to taillamp | Dimension "M" | mm | 2.5 (± 0.5) | ||
| Trunk lid cover to taillamp | Dimension "N" | mm | 4.3 (+1) | ||
| Fig., see | AR60.00-P-0700-01T | ||||
| BE60.00-P-1004-01F | Gap dimensions | Fuel filler flap | Dimension "O" | mm | 3.5 (± 0.5) |
| Fig., see | AR60.00-P-0700-01T | ||||
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-1038-02A | Manual temporary fastener, dia.6.4 mm - clamping range 0 -15 mm, identification color silver Firma Hausmann GmbH D-34346 Hann. Munden, Germany |
| 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-1003-29A | Hand riveter |
| WH58.30-Z-1001-40A | Tarp (fire-resistant) |
WORKSHOP EQUIPMENT
| WE58.40-Z-1001-02A | Inert gas welder |
| 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-1004-03A | Body saw (electric/pneumatic) |
| WE58.40-Z-1005-03A | Wet/dry vacuum cleaner |
| WE58.40-Z-1003-14A | Blind rivet tool |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | Sealant | A 001 989 63 20 |
| BR00.45-Z-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 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 |
| BR00.45-Z-1001-13A | Rivet | A 003 990 35 97 |