Remove/install outer rear wheel well - AR63.10-P-0665SX
MODEL 221
| 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 splatter 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 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 | |
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-N-0005-01A | ||
| General information on body repair | AH60.00-N-0001-01A | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1.1 | Remove fuel tank | AR47.10-P-4100SX | |
| 2 | Remove rear fender | AR63.50-P-1400SX | |
| 3 | Cover all detachable parts remaining in vehicle | Tarp (fire-resistant) | |
| 4 | Separate outer rear wheel well (1) | AR63.10-P-0660-01SX | |
Vario Drill WS 91 spot weld removing tool Round wire brush, braided, dia. 70 mm Hot air gun - 3000 W Drill Body jig saw Wet/dry vacuum cleaner |
Figure | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 5 | Prepare outer rear wheel well (1) for installation | AR63.10-P-0670-05SX | |
| Round wire brush, braided, dia. 70 mm Drill Body jig saw |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 6 | Install rear outer wheel well (1) | AR63.10-P-0670-06SX | |
| General information on riveting | AH60.00-P-0003-01N | ||
Electrode miller Clamping pliers Manual temporary fastener, dia. 6.4 mm - clamping range 0 to 15 mm, identification color silver Round wire brush, braided, dia. 70 mm |
Fig 3 | ||
| Taurus 3 blind rivet tool with 100 mm extension unit | Blind rivet/punch riveting method MIG MAG gas welder (steel, brazing, aluminum) Inverter spot welder Drill Wet/dry vacuum cleaner |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Polygrip flat round head rivet, 6.4X14 | *BR00.45-Z-1001-13A | ||
| Adhesive | *BR00.45-Z-1092-02A | ||
| Rear door to side piece, bottom | *BE60.00-P-1002-01R | ||
| Trunk lid to rear lamp unit | *BE60.00-P-1003-01R | ||
| Rear fender to lamp unit | *BE60.00-P-1003-01R | ||
| Trunk lid license plate panel to rear lamp unit | *BE60.00-P-1003-01R | ||
| 7 | Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01SX | |
| Fig 3 | |||
| Rear door to side piece, bottom | *BE60.00-P-1002-01R | ||
| Trunk lid to rear lamp unit | *BE60.00-P-1003-01R | ||
| Rear fender to lamp unit | *BE60.00-P-1003-01R | ||
| Trunk lid license plate panel to rear lamp unit | *BE60.00-P-1003-01R | ||
| 8.1 | Install fuel tank | AR47.10-P-4100SX | |
| 9 | Install rear fender | AR63.50-P-1400SX | |
| 10 | Clean weld joints and sheet metal flange with round wire brush | Round wire brush, braided, dia. 70 mm Drill |
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| 11 | Clean repair areas | ||
| 12 | Prime repair area using primer filler | ||
| 13 | Carry out seam sealing after repairs | AR97.10-P-4000SX | |
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 14 | Paint repair areas and adjacent surfaces | ||
| 15 | Apply additional cavity preservation | AR97.20-P-1500SX | |
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Combination pressure spray gun (corrosion protection) |
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| Preservation agent | *BR00.45-Z-1003-05A | ||
| 16 | Remove tarp |
CHECK VALUES FOR GAPS
| Number | Designation | Model 221 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01R | Gap dimension | 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 | 4.5 (±0.5) | ||
| Trim strip at front door to roof frame | Dimension "G" | mm | 4.5 (±0.5) | ||
| Trim strip at rear door to roof frame | Dimension "H" | mm | 4.5 (±0.5) | ||
| Rear door to side piece, bottom | Dimension "I" | mm | 4.5 (±0.5) | ||
| Front door cover to rear door cover | Dimension "S" | mm | 4.5 (±0.5) | ||
| See picture | |||||
| AR60.00-P-0700-01SX | |||||
| BE60.00-P-1003-01R | Gap dimension | Trunk lid to rear fender, top | Dimension "J" | mm | 4 (±0.5) |
| Trunk lid to rear lamp unit | Dimension "K" | mm | 4 (±0.5) | ||
| Trunk lid to bumper | Dimension "L" | mm | 5.5 (±1.5) | ||
| Rear fender to lamp unit | Dimension "M" | mm | 2.5 (±0.5) | ||
| Trunk lid license plate panel to rear lamp unit | Dimension "N" | mm | 4 (±0.5) | ||
| See picture | |||||
| AR60.00-P-0700-01SX | |||||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | White sealing compound, 310 ml, DBL 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 sealant, 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 |