Replace complete rear end - AR64.20-P-1020LW
Model 205.0/1
MODIFICATION NOTES
| 29.8.14 | Trunk lid to rear fender, top | TYPE 205.0/1 | BE60.00-P-1012-01BB |
| 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 | |
| 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 | ||
| Evaluation of high-voltage components | AH54.00-P-6500-01SXH | ||
| General information on body repair | AH60.00-P-0001-01A | ||
| 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 | Separate rear end (1) | AR64.20-P-1020-01LW | |
Round wire brush Spot weld milling machine Heat gun Wet/dry vacuum cleaner Glass removal |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 4 | Prepare rear end (1) for installation | AR64.20-P-1020-05LW | |
Round wire brush |
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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 | ||
| 5 | Install rear end (1) | AR64.20-P-1020-06LW | |
| Gap dimensions on hoods, doors and lids Round wire brush Manual temporary fastener, 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Spot welder Inert gas welder Wet/dry vacuum cleaner |
AR60.00-P-0700-01LW | ||
| Trunk lid to fender at rear, top | *BE60.00-P-1012-01BB | ||
| Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm) | *BR00.45-Z-1035-13A | ||
| Blind rivet 6.5X12.5 | *BR00.45-Z-1012-13A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Glazing repair kit, 2-component adhesive | *BR00.45-Z-1049-02A | ||
| Adhesive kit, body, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| Fig 2 | |||
| 6 | Clean welds and sheet metal flange | ||
| 7 | Remove spark protection blankets | ||
| 8 | Clean repair area | ||
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 9 | Prime repair area using primer filler | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 10 | Carry out seam sealing after repairs | AR97.10-P-4000LW | |
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 11 | Paint repair areas and adjacent surfaces | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 12 | Apply additional cavity preservation | AR97.20-P-1500LW | |
| 13 | Install all detachable body components in area to be repaired |
CHECK VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 205.0/1 | ||
|---|---|---|---|---|
| BE60.00-P-1012-01BB | Trunk lid to fender at rear, top | Dimension "K" | mm | 3, 5 (+0, 5/-1) |
| For picture, see | AR60.00-P-0700-01LW | |||
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-1012-13A | Blind rivet 6.5X12.5 | A 004 990 16 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-1049-02A | Glazing repair kit, 2-component adhesive | A 168 670 00 93 |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |