Replace Complete Rear End - AR64.20-P-1020WX
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 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 | |
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-N-0005-01A | ||
| General information on repairs to body | AH60.00-N-0001-01A | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| 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 vehicle with fireproof tarpaulin | ||
| 4 | Remove rear end (1) | Weld-spot milling machine | AR64.20-P-1020-01WX |
| Round wire brush Wet and dry vacuum cleaner |
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| Fig 3 | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 5 | Prepare rear end (1) for installation | AR64.20-P-1020-02WX | |
| Round wire brush | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 6 | Install rear end (1), fit and weld in | AR64.20-P-1020-03WX | |
| Fig 2 | |||
| Vise grip pliers Manual temporary fastener Wet and dry vacuum cleaner |
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| *BE60.00-P-1005-01U | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Rivet | *BR00.45-Z-1001-13A | ||
| Rivet | *BR00.45-Z-1012-13A | ||
| 7 | Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01WX | |
| Fig 2 | |||
| *BE60.00-P-1005-01U | |||
| 8 | Clean weld joints and sheet metal flanges with round wire brush | Round wire brush | |
| 9 | Clean repair areas | ||
| 10 | Prime area to be repaired using primer filler | ||
| 11 | 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 | ||
| 12 | Paint repair areas and adjacent surfaces | ||
| 13 | Apply additional cavity preservation | AR97.20-P-1500CW | |
| Cavity preservation gun | |||
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Preservation agent | *BR00.45-Z-1003-05A | ||
| 14 | Remove tarp | ||
| 15 | Install all removed detachable body components |
CHECK VALUES FOR GAPS
| Number | Designation | Model 204.9 | |||
|---|---|---|---|---|---|
| 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) | ||
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-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-1001-13A | Blind rivet 6.4X14 | A 003 990 35 97 |
| BR00.45-Z-1012-13A | Blind rivet 6.5X12.5 | A 004 990 16 97 |