Repair rear end on left side - AR64.20-P-1200RK
MODEL 231
Fig 1: Battery Carrier, Rear Lamp Carrier, Rear Floor Assembly, Spare Wheel Well And Left Rear Longitudinal Frame Member
| 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 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 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 | |
| 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 from aluminum grinding dust, risk of injury to respiratory system from inhaling dust | Wear dust filter mask, safety glasses and protective gloves. Use a suitable, grounded dust extraction system. |
AS60.00-Z-0007-01N | |
| General information on body repair | AH60.00-P-0001-01A | ||
| Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| General information on crack diagnosis of aluminum parts | AH60.00-P-0014-01N | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| General notes on welding | AH60.00-P-0005-01N | ||
| Note on working on aluminum components and vehicles | AH60.00-P-0034-01SL | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| Remove | |||
| 1 | Remove all detachable parts in area to be repaired | ||
| 2 | Cover all detachable parts remaining in vehicle with welding protection blankets | ||
| 3 | Completely remove rear fender | AR63.50-P-1400RK | |
| 4 | Remove rear outer wheel well | ||
| 5 | Remove bottom rear center section with rear crossmember | AR64.20-P-1060RK | |
| 6 | Separate deformed rear area | AR64.20-P-1200-11RK | |
| 000 588 02 39 00 Rivet press tool | Rotary wire brush Vacuum unit suitable for aluminum dusts |
WS60.00-P-0010B | |
| 7 | Prepare new parts, left side rear damage | Rotary wire brush Vacuum unit suitable for aluminum dusts |
AR64.20-P-1200-99RK |
| Install | |||
| 8 | Install new parts, left side rear damage | AR64.20-P-1200-33RK | |
| 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 | Rotary wire brush Vice grip pliers (standard) Vacuum unit suitable for aluminum dusts |
WS60.00-P-0023K | |
| Blind rivet 6.5 x 12.5 | *BR00.45-Z-1012-13A | ||
| Blind rivet, 6.5 x 14.5 | *BR00.45-Z-1016-13A | ||
| Blind rivet 6.4 | *BR00.45-Z-1034-13A | ||
| Adhesive kit, body, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| 9 | Install bottom rear center section with rear crossmember | AR64.20-P-1060RK | |
| 10 | Install outer rear wheel well | ||
| 11 | Install complete rear fender | AR63.50-P-1400RK | |
| 12 | Clean weld joints and sheet metal flanges with rotary wire brush | Rotary wire brush |
|
| 13 | Remove welding protection blankets | ||
14 |
Risk of explosion
caused by paint vapors igniting. Risk of poisoning
caused by inhaling paint vapors. Clean repair area |
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 |
| 15 |
Prime repair area using primer filler Notes on paintwork repairs |
AH98.00-P-9408-02A | |
| 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 | |
| 16 | Carry out seam sealing after repairs | AR97.10-P-4000RK | |
| White sealing compound, 310 ml, DBL 6069.20 | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 17 |
Paint repair areas and adjacent surfaces Notes on paintwork repairs |
AH98.00-P-9408-02A | |
| 18 | Apply additional cavity preservation | AR97.20-P-1500RK | |
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Cavity preservation, solvent-free (1 l container) | *BR00.45-Z-1003-05A | ||
| 19 | Install all detachable body components in area to be repaired |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | White sealing compound, 310 ml, DBL 6069.20 | A 001 989 63 20 |
| BR00.45-Z-1003-05A | Cavity preservation, solvent-free (1 l container) | A 000 986 72 70 05 |
| BR00.45-Z-1012-13A | Blind rivet 6.5 12.5 | A 004 990 16 97 |
| BR00.45-Z-1016-13A | Blind rivet, 6.5 x 14.5 | A 004 990 17 97 |
| BR00.45-Z-1034-13A | Blind rivet 6.4 | A 003 990 80 97 |
| 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 |