Replace rear wheel well inner section when replacing outer section and rear longitudinal member. - AR63.10-P-0610CW
WARNING: This page is about a different car, the 2011 Mercedes-Benz C300, 2010 Mercedes-Benz C300, 2009 Mercedes-Benz C300, and 2008 Mercedes-Benz C300. However, it is still accessible from the selected car via links, so may be relevant.
MODEL 204
Illustrated on model 204.0
Shown on reinforcements on rear wheel well inner section only on model 204.9
| Removing | ||||
| 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 | ||
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. | AS00.00-Z-0010-01A | ||
| 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 | ||
| 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 explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel | No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel. |
AS47.00-Z-0001-01A | ||
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-N-0005-01A | |||
| General information on repairs to body | AH60.00-N-0001-01A | |||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | |||
| General information on MB materials | AH98.00-P-9409-03A | |||
| General information on riveting | AH60.00-P-0003-01N | |||
| 1 | Prepare required workshop equipment and commercially available tools for repair | |||
| 2 | Remove all detachable body components in area to be repaired. | |||
| 3 | Cover all detachable parts remaining in vehicle with welding protection blanket | |||
| 4 | Equip straightening bench with module members, cross members and straightening bracket set. | |||
| 5 | Lift vehicle with two-post lifting platform | |||
| 6 | Remove rear seat console (9), longitudinal member reinforcement (10), support (11), rear axle mount reinforcement (12), front axle mount reinforcement (13), front rear-axle spacer (14), rear rear-axle spacer (15) and brake line bracket (16) | Model 204.9 only | AR63.10-P-0610-04WX | |
| Spot weld milling cutter | Fig 3 | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | |||
| 7 | Set vehicle onto straightening bench | |||
| 8 | Fasten vehicle to straightening bench | |||
| 9 | Remove rear fender | Model 204.0 | AR63.50-P-1400CW | |
| Model 204.2 | AR63.50-P-1400CX | |||
| Model 204.9 | AR63.50-P-1400WX | |||
| 10.1 | Remove inner C-pillar side wall | Model 204.0 | AR63.10-P-0700CW | |
| 10.2 | Partially remove inner side wall with rear outer wheelhouse | Model 204.2 | AR63.10-P-6050CX | |
| Model 204.9 | AR63.10-P-6050WX | |||
| 11 | Partially remove rear longitudinal member with rear locking lug | Model 204.0/2 | AR64.20-P-1260-01CW | |
| Model 204.9 | AR64.20-P-1260-01WX | |||
| Spot weld milling cutter | Fig 3 | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | |||
| 12 | Remove outer longitudinal member (1), wheel well inner section (2), loading floor crossmember (3), front spare wheel well locking lug (4), upper rear axle crossmember (5), rear axle crossmember (6), front rear axle crossmember (7) and inner longitudinal member (8) | AR63.10-P-0610-01CW | ||
| Spot weld milling cutter | Fig 3 | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | |||
| 13 | Prepare partial rear longitudinal member and rear locking lug for installation | Model 204.0/2 | AR64.20-P-1260-02CW | |
| Model 204.9 | AR64.20-P-1260-02WX | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | |||
| 14 | Prepare outer longitudinal member (1), wheel well inner section (2), loading floor crossmember (3), front spare wheel well locking lug (4), upper rear axle crossmember (5), rear axle crossmember (6), front rear axle crossmember (7) and inner longitudinal member (8) for installation | AR63.10-P-0610-02CW | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | |||
| 15 | Prepare rear seat console (9), longitudinal member reinforcement (10), support (11), rear axle mount reinforcement (12), front axle mount reinforcement (13), front rear-axle spacer (14), rear rear-axle spacer (15) and brake line bracket (16) for installation | Model 204.9 only | AR63.10-P-0610-05WX | |
| Install | ||||
| 16 | Set up side portal frame with welding device | |||
| Fig 4 | ||||
| Figure | ||||
| 17 | Partially Install outer longitudinal member (1), wheel well inner section (2), loading floor crossmember (3), front spare wheel well locking lug (4), upper rear axle crossmember (5), rear axle crossmember (6), front rear axle crossmember (7) and inner longitudinal member (8) with rear longitudinal member and rear locking lug | AR63.10-P-0610-03CW | ||
| Adhesive | *BR00.45-Z-1092-02A | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | |||
| Rivet | *BR00.45-Z-1012-13A | |||
| 18.1 | Install inner C-pillar side wall | Model 204.0 | AR63.10-P-0700CW | |
| 18.2 | Partially install inner side wall with outer rear wheel well | Model 204.2 | AR63.10-P-6050CX | |
| Model 204.9 | AR63.10-P-6050WX | |||
| 19 | Install rear fender | Model 204.0 | AR63.50-P-1400CW | |
| Model 204.2 | AR63.50-P-1400CX | |||
| Model 204.9 | AR63.50-P-1400WX | |||
| 20 | Install rear seat console (9), longitudinal member reinforcement (10), support (11), rear axle mount reinforcement (12), front axle mount reinforcement (13), front rear-axle spacer (14), rear rear-axle spacer (15) and brake line bracket (16) | Model 204.9 only | AR63.10-P-0610-06WX | |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | |||
| Rivet | *BR00.45-Z-1001-13A | |||
| 21 | Unfasten vehicle from straightening bench | |||
| 22 | Lift vehicle with two-post lifting platform | |||
| 23 | Remove straightening bench. | |||
| 24 | Clean weld joints and sheet metal flanges with round wire brush | |||
| 25 | Clean repair areas | |||
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open flames! Use respiratory protection, protective clothing, gloves, safety goggles and skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | ||
| 26 | Prime area to be repaired using primer filler | |||
| Notes on paintwork repairs | AH98.00-P-9408-02A | |||
| 27 | Carry out seam sealing after repairs | AR97.10-P-4000CW | ||
| Sealant | *BR00.45-Z-1003-01A | |||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | |||
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open flames! Use respiratory protection, protective clothing, gloves, safety goggles and skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | ||
| 28 | Paint repair areas and adjacent surfaces | |||
| Notes on paintwork repairs | AH98.00-P-9408-02A | |||
| Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents | Never spray anticorrosion agents on flames or glowing hot objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection. | AS97.00-Z-0001-01A | ||
| 29 | Apply additional cavity preservation | AR97.20-P-1500CW | ||
| Notes on cavity preservation | AH97.20-P-0001-01B | |||
| Preservation agent | *BR00.45-Z-1003-05A | |||
| 30 | Remove welding protection blanket | |||
| 31 | Install all removed detachable body components | |||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | Sealant, white, 310 ml, DB supply specification 6069.20 | A 001 989 63 20 |
| BR00.45-Z-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 20 |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |
| BR00.45-Z-1003-05A | Cavity preservation, solvent-free (1 l container) | 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 | Blind rivet 6.4X14 | A 003 990 35 97 |
| BR00.45-Z-1012-13A | Blind rivet 6.5X12.5 | A 004 990 16 97 |