Replace bottom rear center section together with rear crossmember - AR64.20-P-1060V
MODEL 171, 172
Illustrated on model 171
| 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 splatter 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 death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform 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 | |
| Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | ||
| General information on body repair | AH60.00-N-0001-01A | ||
| 1 | Remove detachable parts in area to be repaired | ||
| 2 | Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket | Welding protective blanket |
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| 3 | Equip straightening bench with module members, cross members and straightening tool set. | Straightening bracket set, passenger cars, cross-country vehicles (Celette) Straightening system, passenger cars (Car Bench) |
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| 4 | Place vehicle on straightening bench lift and fasten | Two-column lift 3.0 - -3.5 t electromechanical Two-post lifting platform, 2.5 - 3.5 t electrohydraulic |
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| 5 | Separate rear center section (1) with rear cross member (2) | AR64.20-P-1060-01V | |
| Body jig saw Weld-spot milling machine Round wire brush Wet and dry vacuum cleaner |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 6 | Prepare rear center section (1) with rear cross member (2) | AR64.20-P-1060-05V | |
| Round wire brush |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 7 | Install rear center section (1) with rear cross member (2) and weld in | AR64.20-P-1060-06V | |
| Figure | |||
| Figure | |||
| Model 171 | *BE60.00-P-1003-01L | ||
| Model 172 Straightening bracket set, passenger cars, cross-country vehicles (Celette) Straightening system, passenger cars (Car Bench) Multifunction device (spot welding) MIG-MAG inert gas welder Pneumatic/hydraulic blind rivet tool Vice grip pliers (standard) Wet and dry vacuum cleaner Round wire brush |
*BE60.00-P-1003-01Y | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 8 | Adjust gaps on hoods, doors and lids | AR60.00-P-0700-01V | |
| Figure | |||
| Model 171 | *BE60.00-P-1003-01L | ||
| Model 172 | *BE60.00-P-1003-01Y | ||
| 9 | Release vehicle from straightening bench, lift vehicle and remove straightening bench | Two-column lift 3.0 - -3.5 t electromechanical Two-post lifting platform, 2.5 - 3.5 t electrohydraulic |
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| 10 | Clean weld joints and sheet metal flanges with rotary wire brush | Round wire brush |
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| 11 | Remove welding protection blankets | ||
| 12 | Clean repair area | Wet and dry vacuum cleaner |
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| 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 skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 13 | Prime repair area with primer filler | ||
| 14 | Carry out seam sealing after repairs | Model 171 | AR97.10-P-4000V |
| Model 172 | AR97.10-P-4000W | ||
| 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 skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 15 | Paint repair area adjacent surfaces | ||
| 16 | Apply additional cavity preservation | Model 171 | AR97.20-P-1500V |
| Model 172 | AR97.20-P-1500W | ||
| 17 | Install all removed detachable parts |
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 171 | |||
|---|---|---|---|---|---|
| BE60.00-P-1003-01L | Gap dimension | Trunk lid to rear fender | Dim. "F" | mm | 3.5 (+1.5) |
| Trunk lid to rear lamp unit | Dim. "M" | mm | 4.0 (+1.6/-0.5) | ||
| Trunk lid to bumper | Dim. "V" | mm | 5.0 (+1.5/-1.0) | ||
| Rear fender to rear lamp unit | Dim. "U" | mm | 2.5 (± 0.5) | ||
| Trunk lid tip to rear fender | Dim. "E" | mm | 5, 0 (+1, 5) | ||
| See picture | AR60.00-P-0700-01V | ||||
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 172 | |||
|---|---|---|---|---|---|
| BE60.00-P-1003-01Y | Gap dimension | Trunk lid to rear fender | Dim. "F" | mm | 4.5 (± 1) |
| Trunk lid to rear lamp unit | Dim. "M" | mm | 4.5 (+1.5/-0.5) | ||
| Trunk lid to bumper | Dim. "V" | mm | 6.0 (± 1.5) | ||
| Rear fender to rear lamp unit | Dim. "U" | mm | 1.5 (± 1) | ||
| Trunk lid tip to rear fender | Dim. "E" | mm | 6.5 (+1/-0.5) | ||
| See picture | AR60.00-P-0700-01V | ||||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |