Replace rear wheel well inner section when replacing outer section and rear longitudinal member - AR63.10-P-0610SX
MODEL 216
MODEL 221 except CODE (Z07) Top protection
Shown on 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 | |
| Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust | Wear protective respiratory mask, protective gloves and safety glasses. Use suitable, grounded vacuum cleaner |
AS60.00-Z-0007-01N | |
| 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 MB materials | AH98.00-P-9409-03A | ||
| Notes on various body materials | AH60.00-P-0011-01SX | ||
| General information on dent removal and straightening aluminum parts | AH60.00-P-0012-01N | ||
| General information on body connection techniques | AH60.00-P-0015-01SX | ||
| 1 | Remove rear suspension strut | ||
| Model 221.0/1 (except 221.08/18) except code 487 Active Body Control (ABC) Model 221.0/1 (except 221.08/18) except code 979 Special protection version Model 221.0/1 (except 221.08/18) except code Z07 Top protection |
AR32.25-P-1016SX | ||
| Model 221.0/1 with code 487 Active Body Control (ABC) | AR32.25-P-1016SY | ||
| 2 | Remove rear shelf paneling | Model 216 | AR68.30-P-4580SC |
| Model 221 | AR68.30-P-4580SX | ||
| 3 | Cover all detachable parts remaining in vehicle | Tarp (fire-resistant) | |
| 4 | Remove rear fender | Model 216 | AR63.50-P-1400SC |
| Model 221 | AR63.50-P-1400SX | ||
| 5 | Remove inner C-pillar side wall | Model 216 | AR63.10-P-0700SC |
| Model 221 | AR63.10-P-0700SX | ||
| 6 | Equip straightening bench with module members, cross members and straightening tool set. | Passenger car straightening system (Celette) Accessories for straightening systems (Celette) Straightening systems for passenger cars (Car Bench) Straightening system accessories (Car Bench) |
|
| 7 | Lift vehicle using two-column lifter | Two-post lifting platform 3.0-3.5 t, electromechanical | |
| 8 | Set vehicle onto straightening bench | ||
| 9 | Fasten vehicle to straightening bench | ||
| 10 | Separate inner rear wheel well (1) | AR63.10-P-0670-01SX | |
| Fig 2 | |||
Ball cutter, dia. 12 mm Vario Drill WS 91 spot weld removing tool |
Fig 3 | ||
| Round wire brush, braided, dia. 70 mm | Round wire brush 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 Aluminum workshop vehicle Drill Straight grinder Angle grinder Body jig saw Wet/dry vacuum cleaner |
||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 11 | Prepare rear inner wheel well (1) for installation | AR63.10-P-0610-02SX | |
| Round wire brush, braided, dia. 70 mm | Round wire brush Drill |
||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 12 | Install and weld in inner rear wheel well (1) | AR63.10-P-0610-03SX | |
| General information on riveting | AH60.00-P-0003-01N | ||
| 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 | Round wire brush Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Aluminum workshop vehicle Blind rivet/punch riveting method MIG MAG gas welder (steel, brazing, aluminum) Inverter spot welder Drill Angle grinder Wet/dry vacuum cleaner |
||
| 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 inner C-pillar side wall | Model 216 | AR63.10-P-0700SC |
| Model 221 | AR63.10-P-0700SX | ||
| 14 | Install rear fender | Model 216 | AR63.50-P-1400SC |
| Model 221 | AR63.50-P-1400SX | ||
| 15 | Unfasten vehicle from straightening bench | ||
| 16 | Lift vehicle with two-post lifting platform | Two-post lifting platform 3.0-3.5 t, electromechanical | |
| 17 | Remove straightening bench. | ||
| 18 | Clean weld joints and sheet metal flange with round wire brush | ||
| Round wire brush, braided, dia. 70 mm | Round wire brush | ||
| 19 | Clean repair areas | ||
| 20 | Prime repair area using primer filler | ||
| 21 | 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 | ||
| 22 | Paint repair areas and adjacent surfaces | ||
| 23 | Glue in insulating cover on rear shelf | ||
| 24 | Apply additional cavity preservation | Model 216 | AR97.20-P-1500SC |
| Model 221 | AR97.20-P-1500SX | ||
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Combination pressure spray gun (corrosion protection) | |||
| Preservation agent | *BR00.45-Z-1003-05A | ||
| 25 | Remove tarp | ||
| 26 | Install rear shelf panel | Model 216 | AR68.30-P-4580SC |
| Model 221 | AR68.30-P-4580SX | ||
| 27 | Install rear spring strut | ||
| Model 221.0/1 (except 221.08/18) except code 487 Active Body Control (ABC) Model 221.0/1 (except 221.08/18) except code 979 Special protection version Model 221.0/1 (except 221.08/18) except code Z07 Top protection |
AR32.25-P-1016SX | ||
| Model 221.0/1 with code 487 Active Body Control (ABC) | AR32.25-P-1016SY |
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 6.4 X 14 | A 003 990 35 97 |