Repair rear end on left side - AR64.20-P-1200LF
MODEL 217.3, 222
Shown on MODEL 222
Fig 1: Bottom Rear Center Section, Rear Floor, Rear Fender, C-Pillar Strut, Reinforcement And Outer Rear Wheel Well - Shown On Model 222
| 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 explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel. | No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. Wear protective clothing when handling fuel. |
AS47.00-Z-0001-01A | |
| 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 | Set up straightening bench with module members, crossmember and straightening set | ||
| 000 588 01 23 00 Body straightening system | WS60.00-P-0023K | ||
| 4 | Place vehicle on straightening bench and fasten | ||
| 5 | Damage area, reshaping | ||
| 6 | Remove lower rear center section (1.1) with rear crossmember (1.2) | AR64.20-P-1060LF | |
| 7 | Remove rear fender (4) | Model 217.3 | AR63.50-P-1400LC |
| Model 222 | AR63.50-P-1400LF | ||
| 8.1 | Remove C-pillar strut (5) from outer C-pillar | Model 217.3 | AR63.20-P-0500LC |
| 8.2 | Remove C-pillar strut (5) from outer C-pillar | Model 222 except code Z07 (Top protection) |
AR63.20-P-0500LF |
| 8.3 | Remove C-pillar strut (5) from outer C-pillar | Model 222 with code Z07 (Top protection) Body power jigsaw Round wire brush Spot weld milling machine Heat gun Wet/dry vacuum cleaner |
AR63.20-P-0500-07LFS |
| 9 | Remove outer rear wheel well (7) | Model 217.3 Model 222 except code Z07 (Top protection) |
AR63.10-P-0665LF |
| 10.1 | Remove reinforcement (6) from inner C-pillar side wall | Model 222 except code Z07 (Top protection) |
AR63.10-P-0700LF |
| 10.2 | Remove reinforcement (6) from inner C-pillar side wall | Model 222 with code Z07 (Top protection) Round wire brush Spot weld milling machine Heat gun Wet/dry vacuum cleaner |
AR63.10-P-0700-06LFS |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 11 | Remove rear longitudinal member (2.1), lower rear longitudinal member (2.3), rear longitudinal member end plate (2.4) and rear rear-end floor (3) | AR64.20-P-1260-01LF | |
Round wire brush Body power jigsaw Spot weld milling machine Heat gun Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding |
*BR00.45-Z-1001-07A | ||
| 12 | Prepare ear longitudinal member (2.1), lower rear longitudinal member (2.3), rear longitudinal member end plate (2.4) and rear rear-end floor (3) | AR64.20-P-1260-02LF | |
Round wire brush Zinc dust paint suitable for spot welding |
*BR00.45-Z-1001-07A | ||
| 13 | Prepare C-pillar strut (5) on outer C-pillar for installation | Model 222 with code Z07 (Top protection) Round wire brush |
AR63.20-P-0500-08LFS |
| 14 | Prepare reinforcement (6) on inner C-pillar side wall for installation | Model 222 with code Z07 (Top protection) Round wire brush |
AR63.10-P-0700-07LFS |
| 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 | ||
| 15 | Install rear longitudinal member (2.1), lower rear longitudinal member (2.3), rear longitudinal member end plate (2.4) and rear rear-end floor (3) | AR64.20-P-1260-03LF | |
| 000 588 02 39 00 Rivet Press Tool | WS60.00-P-0010B | ||
| 000 588 02 84 00 Welder | WS60.00-P-0022K | ||
| 000 588 01 23 00 Body straightening system | WS60.00-P-0023K | ||
Round wire brush Manual temporary fastener, 6.35 mm Spot welder Wet/dry vacuum cleaner Adhesive kit, body, 2-component adhesive |
*BR00.45-Z-1092-02A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Blind rivet 6.5x12.5 | *BR00.45-Z-1012-13A | ||
| 16 | Install rear outer wheel well (7) | Model 217.3 Model 222 except code Z07 (Top protection) |
AR63.10-P-0665LF |
| 17.1 | Install reinforcement (6) from inner C-pillar side wall | Model 222 except code Z07 (Top protection) |
AR63.10-P-0700LF |
| 17.2 | Install reinforcement (6) from inner C-pillar side wall | Model 222 with code Z07 (Top protection) |
|
| AR63.10-P-0700-08LFS | |||
Commercially available devices/tools Round wire brush Manual temporary fastener, 6.35 mm Wet/dry vacuum cleaner |
WS60.00-P-0010B | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Polygrip countersunk-head rivet, 6.4x14 | *BR00.45-Z-1002-13A | ||
| Blind rivet 6.4x12 (clamping range 1 mm to 3.5 mm) | *BR00.45-Z-1035-13A | ||
| 18.1 | Install C-pillar strut (5) on outer C-pillar | Model 217.3 | AR63.20-P-0500LC |
| 18.2 | Install C-pillar strut (5) on outer C-pillar | Model 222 except code Z07 (Top protection) |
AR63.20-P-0500LF |
| 18.3 | Install C-pillar strut (5) on outer C-pillar | Model 222 with code Z07 (Top protection) |
|
| AR63.20-P-0500-09LFS | |||
Round wire brush Manual temporary fastener, 6.35 mm Spot welder Wet/dry vacuum cleaner |
WS60.00-P-0010B | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Polygrip countersunk-head rivet, 6.4x14 | *BR00.45-Z-1002-13A | ||
| Blind rivet 6.4x12 (clamping range 1 mm to 3.5 mm) | *BR00.45-Z-1035-13A | ||
| 19 | Install rear fender (4) | Model 217.3 | AR63.50-P-1400LC |
| Model 222 | AR63.50-P-1400LF | ||
| 20 | Install bottom rear center section (1.1) with rear crossmember (1.2) | AR64.20-P-1060LF | |
| 21 | Release vehicle from straightening bench, lift vehicle and remove straightening bench | ||
| 22 | Install all detachable body components 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-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 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |