Left Side Rear End Damage - AR64.20-P-1200WX
MODEL 204.9
| 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 spatter 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 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 repairs to body | AH60.00-N-0001-01A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1 | Prepare required workshop equipment and commercially available tools for repair | ||
| 2 | Remove all detachable parts in area to be repaired | ||
| 3 | Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket | Welding protective blanket | |
| 4 | Equip straightening bench with module members, cross members and straightening bracket set. | Celette straightening bracket set Car-Bench straightening set |
|
| 5 | Lift vehicle with two-post lifting platform | Two-column lift | |
| 6 | Set vehicle onto straightening bench | ||
| 7 | Fasten vehicle to straightening bench | ||
| 8 | Damage area, reshaping | ||
| 9 | Remove rear fender (1) | AR63.50-P-1400-02WX | |
| Sheet metal crimping pliers for areas not easily accessible | WF58.50-P-6350-01SC | ||
Welding protective blanket Beading pliers Weld-spot milling machine Round wire brush Metal needle template Window glazing device, FSC 1.6 Body jig saw Wet and dry vacuum cleaner |
Figure | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 10 | Remove spare tire well (3) | ||
| 11 | Remove rear end (2) | AR64.20-P-1020-01WX | |
Weld-spot milling machine Round wire brush Wet and dry vacuum cleaner |
Figure | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 12 | Partially remove rear longitudinal member (7) with side rear-end floor (4), side closing panel (5) and rear console (6) | AR64.20-P-1260-01WX | |
Weld-spot milling machine Round wire brush Wet and dry vacuum cleaner |
Figure | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 13 | Prepare rear fender (1) for installation | AR63.50-P-1400-03WX | |
| Metal needle template Body jig saw Round wire brush |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 14 | Prepare rear end (2) for installation | AR64.20-P-1020-02WX | |
Round wire brush |
Figure | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 15 | Partially prepare rear longitudinal member (7), side rear-end floor (4), side closing panel (5) and rear console (6) for installation | AR64.20-P-1260-02WX | |
| Round wire brush | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 16 | Partially install rear longitudinal member (7), side rear-end floor (4), side closing panel (5) and rear console (6), fit and weld in | AR64.20-P-1260-03WX | |
| General information on riveting | AH60.00-P-0003-01N | ||
| Vice grip pliers (standard) Manual temporary fastener, 6.35 mm Round wire brush Wet and dry vacuum cleaner |
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| Rivet | *BR00.45-Z-1012-13A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 17 | Install rear end (2), fit and weld in | AR64.20-P-1020-03WX | |
| General information on riveting | AH60.00-P-0003-01N | ||
| *BE60.00-P-1005-01U | |||
Vice grip pliers (standard) Manual temporary fastener, 6.35 mm Round wire brush Wet and dry vacuum cleaner |
Figure | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Rivet | *BR00.45-Z-1001-13A | ||
| Rivet | *BR00.45-Z-1012-13A | ||
| 18 | Install spare tire well (3) | ||
| 19 | Install rear fender (1), fit and weld in | AR63.50-P-1400-04WX | |
| *BE60.00-P-1002-01U | |||
| *BE60.00-P-1003-01U | |||
| *BE60.00-P-1004-01U | |||
| *BE60.00-P-1005-01U | |||
Vice grip pliers (standard) Manual temporary fastener, 6.35 mm Round wire brush Wet and dry vacuum cleaner |
Figure | ||
| Sealant | *BR00.45-Z-1003-01A | ||
| Adhesive | *BR00.45-Z-1092-02A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Polygrip countersunk head rivet, 6.4X14 | *BR00.45-Z-1002-13A | ||
| 20 | Set gap dimensions | AR60.00-P-0700-01WX | |
| *BE60.00-P-1002-01U | |||
| *BE60.00-P-1003-01U | |||
| *BE60.00-P-1004-01U | |||
| *BE60.00-P-1005-01U | |||
| Figure | |||
| 21 | Unfasten vehicle from straightening bench | ||
| 22 | Lift vehicle with two-post lifting platform | Two-column lift | |
| 23 | Remove straightening bench. | ||
| 24 | Clean weld joints and sheet metal flanges with round wire brush | Round wire brush | |
| 25 | Clean area to be repaired | Wet and dry vacuum cleaner | |
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open flames! Use respiratory protection, protective clothing, gloves, safety goggles and skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 26 | Prime area to be repaired with primer filler | Passenger car primer filler 283-150 VOC | *BR00.45-Z-1031-07A |
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 27 | Carry out seam sealing after repairs | AR97.10-P-4000CW | |
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open flames! Use respiratory protection, protective clothing, gloves, safety goggles and skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 28 | Paint area repaired and adjacent surfaces | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 29 | Apply additional cavity preservation | AR97.20-P-1500CW | |
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Cavity preservation gun | |||
| Preservation agent | *BR00.45-Z-1003-05A | ||
| 30 | Remove welding protection blanket | ||
| 31 | Install all removed detachable body components |
CHECK VALUES FOR GAPS
| Number | Designation | Model 204.9 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01U | Gap dimension | Front door to fender | Dimension "G" | mm | 4.5 (±1) |
| Front door to rear door | Dimension "H" | mm | 4.5 (±1) | ||
| Front door to roof frame | Dimension "I" | mm | 10 (+2/-1) | ||
| Rear door to roof frame | Dimension "J" | mm | 9.5 (+2/-1) | ||
| Rear door to side section, bottom | Dimension "K" | mm | 4 (±1) | ||
| Driver door cover to rear door cover | Dimension "W" | mm | 4 (+1.5/-0.5) | ||
| See picture | AR60.00-P-0700-01WX | ||||
| BE60.00-P-1003-01U | Gap dimension | Trunk lid to rear fender, top | Dimension "L" | mm | - |
| Trunk lid to rear lamp unit | Dimension "M" | mm | - | ||
| Trunk lid to bumper | Dimension "N" | mm | - | ||
| Rear fender to rear lamp unit | Dimension "O" | mm | 2 (±1) | ||
| Taillamp to bumper | Dimension "P" | mm | 2 (±1) | ||
| Taillamp, trunk lid to taillamp | Dimension "M1" | mm | - | ||
| See picture | AR60.00-P-0700-01WX | ||||
| BE60.00-P-1004-01U | Gap dimension | Fuel filler flap (around) | Dimension "Q" | mm | 3, 0 (±1) |
| See picture | AR60.00-P-0700-01WX | ||||
| BE60.00-P-1005-01U | Gap dimension | Liftgate to roof | Dimension "R" | mm | - |
| Liftgate to roof (spoiler removed) | Dimension "R1" | mm | 8 (±1.5) | ||
| Spoiler to roof | Dimension "R2" | mm | 5.5 (±1.5) | ||
| Liftgate to rear fender | Dimension "S" | mm | 4 (±1) | ||
| Liftgate to taillamp | Dimension "T" | mm | 4 (±1) | ||
| Liftgate to bumper | Dimension "U" | mm | 5.5 (±1.5) | ||
| Liftgate to D-pillar | Dimension "V" | mm | - | ||
| Rear window and D-pillar | Dimension "X" | mm | 4 (±1) | ||
| Top sliding roof to roof | Dimension "Y" | mm | 5 (±1.5) | ||
| Rear window to liftgate, bottom | Dimension "Z" | mm | 3.5 (±1.5) | ||
| - | AR60.00-P-0700-01WX | ||||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | Sealant, white, 310 ml, DB supply specification 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 preservation, 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-1031-07A | Passenger car primer filler 283-150 VOC | Glasurit GmbH Glasuritstrase 1 48165 Munster Germany Tel.+49 2501 14-0 Fax +49 2501 14 3373 www.glasurit.de |
| BR00.45-Z-1001-13A | Blind rivet 6.4X14 | A 003 990 35 97 |
| 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 |