Completely remove/install rear longitudinal member - AR64.20-P-1220LW
Model 205.0/1/2
Shown on MODEL 205.0
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the 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 | |
| Risk of death when touching components on vehicles with high-voltage on-board electrical system | Do not touch components and open lines of the high-voltage on-board electrical system. Persons who wear electronic implants (e.g. cardiac pacemakers), must not carry out any work on high-voltage on-board electrical systems. | AS54.00-Z-0001-01A | |
| Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust | Wear dust filter mask, safety glasses and protective gloves. Use a suitable, grounded dust extraction system. |
AS60.00-Z-0007-01N | |
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| Note on high-voltage on-board electrical system | AH54.00-P-0010-01A | ||
| Note on high-voltage battery | AH54.10-P-0006-01MEV | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| General information on crack diagnosis of aluminum parts | AH60.00-P-0014-01N | ||
| Evaluation of high-voltage components | AH54.00-P-6500-01SXH | ||
| General information on body repair | AH60.00-P-0001-01A | ||
| Note on working on aluminum components and vehicles | AH60.00-P-0034-01LW | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| Remove | |||
| 1 | Remove detachable parts in area to be repaired | ||
| 2 | Cover all detachable parts remaining on vehicle with spark protection blanket | ||
| 3 | Remove spare wheel well | AR64.20-P-1245LW | |
| 4 | Remove rear end assembly | Model 205.0/1 | AR64.20-P-1020LW |
| Model 205.2 | AR64.20-P-1020LWS | ||
| 5.1 | Remove inner C-pillar side wall | Model 205.0/1 | |
| AR63.10-P-0700LW | |||
| 5.2 | Partially remove inner side wall with rear outer wheelhouse | Model 205.2 | |
| AR63.10-P-6050LWS | |||
| 6 | Remove longitudinal member outer shell | AR63.30-P-1102LW | |
| 7 | Partially remove rear-end door and rear longitudinal member | AR64.20-P-1260-01LW | |
Round wire brush Spot weld milling machine Heat gun Wet/dry vacuum cleaner Body and aluminum workplace Aluminum tools |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 8 | Remove crossmember above rear axle | AR64.20-P-1301LW | |
| 9 | Remove rear longitudinal member(1) with end plate (4), bottom crossmember (2) and top crossmember (3) | AR64.20-P-1200-22LW | |
Round wire brush Body power jigsaw Spot weld milling machine Heat gun Wet/dry vacuum cleaner Body and aluminum workplace Aluminum tools |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 10 | Prepare rear longitudinal member(1), with end plate (4), bottom crossmember (2) and top crossmember (3) | AR64.20-P-1200-23LW | |
Round wire brush Body power jigsaw Body and aluminum workplace Aluminum tools |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases | Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly flammable materials from the hazard area. Use air extraction system. | AS00.00-Z-0007-01A | |
| 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 | |
| Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| 11 | Install rear longitudinal member(1), bottom crossmember (2), top crossmember (3) and end plate (4) | AR64.20-P-1200-24LW | |
| 000 588 02 84 00 Welder | WS60.00-P-0022K | ||
Round wire brush Manual temporary fastener, 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Spot welder Wet/dry vacuum cleaner Body and aluminum workplace Aluminum tools |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Adhesive kit, body, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| Blind rivet 6.5X12.5 | *BR00.45-Z-1012-13A | ||
| Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm) | *BR00.45-Z-1035-13A | ||
| Blind rivet, 6.5 x 14.5 | *BR00.45-Z-1016-13A | ||
| Straightening systems for passenger cars (Celette) Straightening systems for passenger cars (Car Bench) Straightening systems for passenger cars (Car-O-Liner) |
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| 12 | Install crossmember above rear axle | AR64.20-P-1301LW | |
| 13 | Partially prepare rear-end door and rear longitudinal member | AR64.20-P-1260-02LW | |
Round wire brush |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 14 | Install rear-end floor (1) and rear longitudinal member (2) | AR64.20-P-1260-03LW | |
Round wire brush Manual temporary fastener, 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Spot welder Wet/dry vacuum cleaner Body and aluminum workplace Aluminum tools |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Adhesive kit, body, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| Polygrip countersunk-head rivet, 6.4X14 | *BR00.45-Z-1002-13A | ||
| Blind rivet 6.5X12.5 | *BR00.45-Z-1012-13A | ||
| Blind rivet, 6.5 x 14.5 | *BR00.45-Z-1016-13A | ||
| Blind rivet 6.4 Straightening systems for passenger cars (Celette) Straightening systems for passenger cars (Car Bench) Straightening systems for passenger cars (Car-O-Liner) |
*BR00.45-Z-1034-13A | ||
| 15 | Install longitudinal member outer shell | AR63.30-P-1102LW | |
| 16.1 | Install inner C-pillar side wall | Model 205.0/1 | |
| AR63.10-P-0700LW | |||
| 16.2 | Partially install inner side wall with outer rear wheel well | Model 205.2 | |
| AR63.10-P-6050LWS | |||
| 17 | Install rear end assembly | Model 205.0/1 | AR64.20-P-1020LW |
| Model 205.2 | AR64.20-P-1020LWS | ||
| 18 | Install spare wheel well | AR64.20-P-1245LW | |
| 19 | Install detachable parts in area to be repaired |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
| BR00.45-Z-1002-13A | Polygrip countersunk-head rivet, 6.4X14 | A 003 990 86 97 05 |
| BR00.45-Z-1012-13A | Blind rivet 6.5X12.5 | A 004 990 16 97 |
| BR00.45-Z-1016-13A | Blind rivet, 6.5 x 14.5 | A 004 990 17 97 |
| BR00.45-Z-1034-13A | Blind rivet 6.4 | A 003 990 80 97 |
| BR00.45-Z-1035-13A | Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm) | A 000 991 76 32 |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |