Completely remove/install rear longitudinal member - AR64.20-P-1220SX
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 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 | |
| General information on repair of vehicles with ultra-strength steels. | Failure to observe instructions when straightening/repairing, separating, preparing adhesive points, joining/connecting, resistance spot welding, MIG welding, MIG brazing can lead to considerable damage to ultra-strength steels and their joints. | AH60.00-P-0024-01N | |
| 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 riveting | AH60.00-P-0003-01N | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1.1 | Remove rear axle. | Except special protection version code 979, Except top protection, code Z07 |
AR35.10-P-0010SX |
| 2 | Cover all detachable parts remaining in vehicle | Tarp (fire-resistant) | |
| 3 | Remove bottom rear center section with rear crossmember | AR64.20-P-1060SX | |
| 4 | Remove rear wheel well inner section | AR63.10-P-0610SX | |
| 5 | Equip straightening bench with module members, cross members and straightening tool set. | Straightening systems for passenger cars (Car Bench) Passenger car straightening system (Celette) |
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| 6 | Lift vehicle with two-post lift | Two-post lifting platform, 2.5 - 3.5 t electrohydraulic | |
| 7 | Set vehicle onto straightening bench | ||
| 8 | Fasten vehicle to straightening bench | ||
| 9 | Remove rear longitudinal member (1) | AR64.20-P-1200-22SX | |
| Figure | |||
Ball cutter, dia. 12 mm Vario Drill WS 91 spot weld removing tool BTR Usibor milling cutter, dia. 8X44 mm BTR Usibor drill bit, dia. 6.7 mm BTR Usibor milling cutter, dia. 8 mm BTR Usibor center punch, dia. 8X80 mm Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Cutting disk, Ø 65 mm, 80 m/s (max. 23, 500 rpm) Hot air gun - 3000 W drill Straight grinder Angle grinder Body jig saw Wet and dry vacuum cleaner |
Fig 4 | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 10 | Prepare rear longitudinal member (1), rear locking lug (4) and locking lug above rear axle (5) for installation | AR64.20-P-1200-23SX | |
| Round wire brush, braided, dia. 70 mm drill |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 11 | Prepare inner rear side longitudinal member (2) and outer rear side longitudinal member (3) for installation | AR63.30-P-0865-02SX | |
Vario Drill WS 91 spot weld removing tool BTR Usibor milling cutter, dia. 8X44 mm BTR Usibor milling cutter, dia. 8 mm Round wire brush, braided, dia. 70 mm Hot air gun - 3000 W drill Straight grinder Angle grinder Body jig saw |
Figure | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 12 | Install rear longitudinal member (1) and locking lug above rear axle (5) | AR64.20-P-1200-24SX | |
| Electrode miller Clamping pliers Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Blind rivet/punch riveting tool Inert gas welder Inverter spot welder drill Angle grinder Wet and dry vacuum cleaner |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Rivet | *BR00.45-Z-1001-13A | ||
| Adhesive | *BR00.45-Z-1092-02A | ||
| 13 | Install rear locking lug (4) | AR64.20-P-1240-03SX | |
| Electrode miller Clamping pliers Inverter spot welder drill Wet and dry vacuum cleaner |
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| 14 | Install inner rear side longitudinal member (2) and outer rear side longitudinal member (3) | AR63.30-P-0865-03SX | |
| Electrode miller BTR Usibor drill bit, dia. 6.7 mm Clamping pliers Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Blind rivet/punch riveting tool Inert gas welder Inverter spot welder drill Angle grinder Wet and dry vacuum cleaner |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Rivet | *BR00.45-Z-1001-13A | ||
| Rivet | *BR00.45-Z-1012-13A | ||
| Adhesive | *BR00.45-Z-1092-02A | ||
| 15 | Install rear wheel well inner section | AR63.10-P-0610SX | |
| 16 | Install bottom rear center section with rear crossmember | AR64.20-P-1060SX | |
| 17 | Unfasten vehicle from straightening bench | ||
| 18 | Lift vehicle with two-post lift | Two-post lifting platform, 2.5 - 3.5 t electrohydraulic | |
| 19 | Remove straightening bench. | ||
| 20 | Clean weld joints and sheet metal flange with round wire brush | Round wire brush, braided, dia. 70 mm | |
| 21 | Clean repair areas | ||
| 22 | Prime repair area using primer filler | ||
| 23 | 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 | ||
| 24 | Paint repair areas and adjacent surfaces | ||
| 25 | Apply additional cavity preservation | AR97.20-P-1500SX | |
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Cavity preservation gun | |||
| Preservation agent | *BR00.45-Z-1003-05A | ||
| 26 | Remove tarp | ||
| 27.1 | Install rear axle | Except special protection version code 979, Except top protection, code Z07 | AR35.10-P-0010SX |
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 |
| BR00.45-Z-1012-13A | Blind rivet 6.5X12.5 | A 004 990 16 97 |