Repair rear end on left side - AR64.20-P-1200LW
Model 205.0/1
| 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 | Equip straightening bench with module members, cross members and straightening tool set | Straightening systems for passenger cars (Celette) Straightening systems for passenger cars (Car Bench) Straightening systems for passenger cars (Car-O-Liner) |
|
| 4 | Place vehicle on straightening bench and fasten | ||
| 5 | Damage area, reshaping | ||
| 6 | Remove spare wheel well (7) | AR64.20-P-1245LW | |
| 7 | Remove rear center section (6) | AR64.20-P-1020LW | |
| 8 | Remove rear fender (3) | AR63.50-P-1400LW | |
| 9 | Remove strut (4) from C-pillar | AR63.20-P-0500LW | |
| 10 | Remove reinforcement (5) from C-pillar side wall | AR63.10-P-0700LW | |
| 11 | Remove rear-end floor (1) and rear longitudinal member (2) | AR64.20-P-1260-01LW | |
Round wire brush Spot weld milling machine Heat gun Wet/dry vacuum cleaner Body and aluminum workplace Aluminum tools |
|||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 12 | Prepare rear-end floor (1) and rear longitudinal member (2) | AR64.20-P-1260-02LW | |
Round wire brush |
|||
| 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 | ||
| 13 | 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 |
|||
| 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 | ||
| 14 | Install reinforcement (5) on C-pillar side wall | AR63.10-P-0700LW | |
| 15 | Install strut (4) on C-pillar | AR63.20-P-0500LW | |
| 16 | Release vehicle from straightening bench, lift vehicle and remove straightening bench | ||
| 17 | Install rear fender (3) | AR63.50-P-1400LW | |
| 18 | Install rear end center assembly (6) | AR64.20-P-1020LW | |
| 19 | Install spare wheel well (7) | AR64.20-P-1245LW |
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-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |