Replace complete rear end assembly - AR64.20-P-1020PA
MODEL 203.2
| 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 | AH98.00-P-9408-02A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1 | Remove detachable parts in repair area | ||
| 2 | Cover all detachable parts remaining in vehicle (repair area) | Tarp (fire-resistant) | |
| 3 | Equip straightening bench with modular or crossmembers and straightening tools | Celette straightening bench M8S refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Celette straightening bench Sevenne, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Set of Celette module members 955.940, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Celette auxiliary member 955.908, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Celette straightening bracket set 7203.300 (for model 203), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Car-Bench straightening bench BT 17, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Car-Bench straightening bench BT 43/1, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Celette straightening bracket set 7203.309 (for model 203), as supplement to 7203.300, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Celette straightening bracket set 7203.310 (for model 203), only for new orders includes supplement 7203.309, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Celette 7203.308 supplementary straightening set for Celette straightening bracket set 7203.310 (for model 203 4MATIC), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Car-Bench universal crossmember set A 296, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Car-Bench straightening bracket set 82434 (for model 203), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Car-Bench 82445 supplementary straightening set for Car-Bench straightening bracket set 82434 (for model 203 4MATIC), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Multi-Z straightening set system MZ 450.000, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| 4 | Set vehicle onto straightening bench using two-post lift and fasten | Two-post lift, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| 5 | Detach rear end | AR64.20-P-1020-01PA | |
| Figure | |||
| 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 | ||
| 6 | Prepare rear end for installation | AR64.20-P-1020-02PA | |
| Round wire brush, braided, ø 70 mm Hole punching pliers, ø 7 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 rear end assembly | AR64.20-P-1020-03PA | |
| Figure | |||
| Electrode miller Round wire brush, braided, ø 70 mm Abrasive disk, ø 115 mm, 80 m/s (max. 13,250 rpm) Clamping pliers 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 gaps on hoods, doors and lids | AR60.00-P-0700-01PA | |
| Rear door to side piece, bottom | *BE60.00-P-1002-01E | ||
| Rear fender to taillamp | *BE60.00-P-1003-01E | ||
| Rear-end door to rear fender | *BE60.00-P-1004-01E | ||
| Figure | |||
| 9 | Clean weld joints and metal flanges using wire brush | ||
| 10 | Release vehicle from straightening bench and lift with two-column lift, remove straightening bench | Two-post lift, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| 11 | Clean repair areas and prime using primer filler | ||
| 12 | Seam seal following repair | AR97.10-P-4000P | |
| MB body sealant for seam sealant (paintable/310 ml cartridge) | *BR00.45-Z-1003-01A | ||
| 13 | Paint repair areas and adjacent surfaces | ||
| 14 | Apply additional cavity preservation | ||
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Processing instructions for cavity preservation | AP97.20-P-0640-01A | ||
| 15 | Install all removed assembly parts |
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 | Model 203.204/206/207/208/216/218/220/235/240/242/243/245/246/252/254/256/261/264/265/281/284/287/292 | |||
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| BE60.00-P-1002-01E | Gap dimension | Front door to A-pillar | Dimension "B" | mm | 6.5 (+1) | 6.5 (+1) |
| Front door to fender | Dimension "H" | mm | 3.5 (-0.5/+1) | 3.5 (-0.5/+1) | ||
| Front door to rear door | Dimension "I" | mm | 4 (-0.5/+1) | 4 (-0.5/+1) | ||
| Front door to roof | Dimension "C" | mm | 6.5 (+1) | 6.5 (+1) | ||
| Rear door to C-pillar | Dimension "T" | mm | - | 6 (+1) | ||
| Rear door to side piece, bottom | Dimension "J" | mm | 3.5 (+1) | 3.5 (+1) | ||
| Front door to rear fender | Dimension "P" | mm | - | - | ||
| See picture | AR60.00-P-0700-01P | AR60.00-P-0700-01PA | ||||
| 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 | - | 2 (0.5) | ||
| See picture | AR60.00-P-0700-01P | AR60.00-P-0700-01PA | ||||
| BE60.00-P-1004-01E | Gap dimension | Rear-end door to roof | Dimension "E" | mm | - | 6.5 (±1) |
| Rear-end door to rear fender | Dimension "M" | mm | - | 3.5 | ||
| Rear-end door to taillamp | Dimension "L" | mm | - | 4 | ||
| Rear-end door to bumper | Dimension "S" | mm | - | 5.5 | ||
| Rear-end door to D-pillar | Dimension "Q" | mm | - | - | ||
| See picture | - | AR60.00-P-0700-01PA | ||||
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 |