Replace complete rear end - AR64.20-P-1020NKB
MODEL 242, 246
| 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 | |
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| 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-1020-01NKB | |
Round brush Spot weld milling machine Body jig saw Heat gun Wet and dry vacuum cleaner |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 4 | Prepare rear end (1) for welding in | AR64.20-P-1020-02NKB | |
Round brush Hole punching pliers (Ø 6 mm) Wet and dry vacuum cleaner |
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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) and weld in | AR64.20-P-1020-03NKB | |
| 000 588 02 39 00 Rivet press tool | WS60.00-P-0010B | ||
| 000 588 02 84 00 Welder | WS60.00-P-0022K | ||
Round brush Spot welder Manual temporary fastener, 6.35 mm Wet and dry vacuum cleaner |
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| Gap dimension | *BE60.00-P-1003-01AA | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Adhesive kit, body, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| Blind rivet 6.5 X 12.5 | *BR00.45-Z-1012-13A | ||
| Fig 2 | |||
| For measuring points of gap dimensions on body see: ↓ | |||
| Gap dimensions on hoods, doors and lids | AR60.00-P-0700-01NKB | ||
| 6 | Clean weld joints and sheet metal flanges with rotary wire brush | ||
| 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-4000NKB | |
| 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-1500NKB | |
| 13 | Install all detachable body components in area to be repaired |
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS
| Number | Designation | MODEL 242, MODEL 246 up to model year 2015 | Model 246 as of model year 2015 | |||
|---|---|---|---|---|---|---|
| BE60.00-P-1003-01AA | Gap dimension | Liftgate to roof (rear spoiler removed) | Dimension "N" | mm | - | - |
| Liftgate to rear fender | Dimension "O" | mm | 5, 0 (±1) | 4, 5 (±1, 5) | ||
| Rear spoiler to roof | Dimension "P" | mm | 6, 5 (±1) | 6, 6 (±1, 0) | ||
| Liftgate to bumper | Dimension "Q" | mm | 5, 5 (±1, 5) | 5, 4 (±1, 5) | ||
| Liftgate to taillamp | Dimension "R" | mm | 4, 0 (±1) | 0, 9 (±0, 7) | ||
| Taillamp to bumper | Dimension "S" | mm | 2, 0 (±1) | 1, 5 (±1, 0) | ||
| Taillamp to fender | Dimension "T" | mm | 2, 0 (±1) | 1, 4 (±0, 7) | ||
| Liftgate taillamp to taillamp | Dimension "U" | mm | 4, 0 (±1) | 4, 0 (±1, 0) | ||
| Picture | AR60.00-P-0700-01NKB | AR60.00-P-0700-01NKB | ||||
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 6.5 X 12.5 | A 004 990 16 97 |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |