Replace Complete Bottom Rear Center Section - Ar64.20-P-1000LWR
Model 205.4
| 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. | See 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. | See AS00.00-Z-0017-01A . | |
| General information on body repair | See AH60.00-N-0001-01A . | ||
| Information on preventing damage to electronic components due to electrostatic discharge | See AH54.00-P-0001-01A . | ||
| Pretreatment of bonding surfaces | See AH60.00-P-0008-01SX . | ||
| General information on MB materials | See 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 blankets | ||
| 3 | Separate rear center section (1) | See AR64.20-P-1000-02LWR . | |
| 000 588 00 84 00 Heat gun | Round wire brush Body power jigsaw Spot weld milling machine Wet/dry vacuum cleaner |
See WS54.00-P-0049B . | |
| Zinc dust paint suitable for spot welding | See *BR00.45-Z-1001-07A . | ||
| 4 | Prepare rear center section (1) for installation | Round wire brush Body power jigsaw |
See AR64.20-P-1000-07LWR . |
| Zinc dust paint suitable for spot welding | See *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 inflammable materials from the hazard area. Use air extraction system. | See AS00.00-Z-0007-01A . | |
| Measures for preventing damage to components when performing electric welding and soldering work | See AH60.00-P-0001-02A . | ||
| General information on riveting | See AH60.00-P-0003-01N . | ||
| 5 | Install rear end center assembly (1) | See AR64.20-P-1000-08LWR . | |
| 000 588 01 84 00 Welder | See WS60.00-P-0021K . | ||
| 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) Wet/dry vacuum cleaner |
See AR60.00-P-0700-01LW . | ||
| Trunk lid to fender at rear, top | See *BE60.00-P-1012-01BB . | ||
| Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | See *BR00.45-Z-1035-13A . | ||
| Blind rivet with countersunk head 6.4 X 15.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) | See *BR00.45-Z-1044-13A . | ||
| Blind rivet with countersunk head 6.4 X 14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) | See *BR00.45-Z-1043-13A . | ||
| Blind rivet 6.5 X 14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | See *BR00.45-Z-1016-13A . | ||
| Zinc dust paint suitable for spot welding | See *BR00.45-Z-1001-07A . | ||
| Parts kit for 2-component adhesive for body | See *BR00.45-Z-1162-02A . | ||
| 6 | Clean welds and sheet metal flanges | Round wire brush |
|
| 7 | Remove spark protection blankets | ||
| 8 | Clean repair area | Wet/dry vacuum cleaner |
|
| 9 | Prime repair area using primer filler Notes on paintwork repairs |
See AH98.00-P-9408-02A . | |
| 10 | Seal seam following repairs | See AR97.10-P-4000LW . | |
| 11 | Paint repair areas and adjacent surfaces Notes on paintwork repairs |
See AH98.00-P-9408-02A . | |
| 12 | Add cavity preserving agent | AR97.20-P-1500LW | |
| 13 | Install all detachable body components in area to be repaired |
CHECK VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 205.4 | ||
|---|---|---|---|---|
| BE60.00-P-1012-01BB | Trunk lid to fender at rear, top | Dimension "K" | mm | 3, 5 (+ 0, 5) |
| Dimension "K1" | mm | - | ||
| 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-1016-13A | Blind rivet 6.5X 14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | A 004 990 17 97 |
| BR00.45-Z-1035-13A | Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | A 000 991 76 32 |
| BR00.45-Z-1043-13A | Blind rivet with countersunk head 6.4X14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) | A 000 991 82 32 |
| BR00.45-Z-1044-13A | Blind rivet with countersunk head 6.4X15.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) | A 000 991 83 32 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012989 17 71 |