Left side rear end damage - AR64.20-P-1200CW
MODEL 204.0/3. 207.3
Shown on model 204.0
| 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 columns of vehicle lift and position four support plates at vehicle lift support points specified by 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 | |
| General information on body repair | AH60.00-P-0001-01A | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| General information on riveting | AH60.00-P-0003-01 N | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1 | Prepare all workshop equipment and commercially available tools required for repair | ||
| 2 | Remove all detachable parts in area to be repaired | ||
| 3 | Coverall detachable parts remaining in vehicle with fire-resistant welding protection blanket | Welding protective blanket |
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| 4 | Equip straightening bench with module members, cross members and straightening tool set. | Passenger car straightening system (Celette) Passenger car straightening system (Car Bench) Straightening systems for passenger cars (Car-O-Liner) |
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| 5 | Lift vehicle with two-post lifting platform | Two-column lift 2.5 - -3.5 t electromechanical |
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| 6 | Set vehicle onto straightening bench | ||
| 7 | Fasten vehicle to straightening bench | ||
| 8 | Damage area, reshaping | ||
| Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel | No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel. |
AS47.00-Z-0001-01A | |
| 9 | Separate rear fender (1) | ||
| Model 204.0 | AR63.50-P-1400-02CW | ||
| Model 204.3 | AR63.50-P-1400-02CC | ||
| Model 207.3 | AR63.50-P-1400-02EC | ||
| Sheet metal crimping pliers for areas not easily accessible | WF58.50-P-6350-01SC | ||
| Beading pliers Metal needle template Body jig saw Window glazing device, FSC 1.6 Round wire brush Hot-air gun Weld-spot milling machine Wet and dry vacuum cleaner |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 10 | Remove spare tire well (3) | ||
| 11 | Remove rear end (2) | Model 204.0/3 | AR64.20-P-1020-01CW |
| Model 207.3 Round wire brush Wet and dry vacuum cleaner |
AR64.20-P-1020-01EC | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 12 | Remove rear longitudinal member section (5) with rear end part (4) | AR64.20-P-1260-01CW | |
| Round wire brush |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 13 | Prepare rear fender (1) for installation | Model 204.0 | AR63.50-P-1400-03CW |
| Model 204.3 | AR63.50-P-1400-03CC | ||
| Model 207.3 Metal needle template Weld-spot milling machine Round wire brush |
AR63.50-P-1400-03EC | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 14 | Prepare rear end (2) for installation | Model 204.0/3 | AR64.20-P-1020-02CW |
| Model 207.3 Round wire brush |
AR64.20-P-1020-02EC | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 15 | Prepare rear longitudinal member section (5) and rear end part (4). | AR64.20-P-1260-02CW | |
| Round wire brush Wet and dry vacuum cleaner |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 16 | Install rear longitudinal member section (5) with rear end part (4) | AR64.20-P-1260-03CW | |
| Round wire brush Multifunction device (spot welding) Inert gas welder Vice grip pliers (standard) Manual temporary fastener, 4.1 mm Wet and dry vacuum cleaner |
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| Blind rivet 6.5X12.5 | *BR00.45-Z-1012-13A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 17 | Install rear end (2), fit and weld in | Model 204.0 | AR64.20-P-1020-03CW |
| Trunk lid to rear fender, top | *BE60.00-P-1003-01U | ||
| Trunk lid to rear lamp unit | *BE60.00-P-1003-01U | ||
| Rear fender to lamp unit | *BE60.00-P-1003-01U | ||
| Model 204.3, 207.3 | AR64.20-P-1020-03EC | ||
| Trunk lid to rear fender, top | *BE60.00-P-1003-01W | ||
| Taillamp, trunk lid to taillamp | *BE60.00-P-1003-01W | ||
| Rear fender to lamp unit | *BE60.00-P-1003-01W | ||
Multifunction device (spot welding) Vice grip pliers (standard) Hand riveting tool (for blind pop rivets) Round wire brush |
Figure | ||
| Blind rivet 6.4X14 | *BR00.45-Z-1001-13A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 18 | Install spare tire well (3) | ||
| 19 | Install rear fender (1), fit and weld in | Model 204.0 | AR63.50-P-1400-04CW |
| Rear door to side piece, bottom | *BE60.00-P-1002-01U | ||
| Trunk lid to rear fender, top | *BE60.00-P-1003-01U | ||
| Trunk lid to rear lamp unit | *BE60.00-P-1003-01U | ||
| Rear fender to lamp unit | *BE60.00-P-1003-01U | ||
| Fuel filler flap | *BE60.00-P-1004-01U | ||
| Model 204.3 | AR63.50-P-1400-04CC | ||
| Front door to rear fender | *BE60.00-P-1002-01W | ||
| Trunk lid to rear fender, top | *BE60.00-P-1003-01W | ||
| Taillamp, trunk lid to taillamp | *BE60.00-P-1003-01W | ||
| Rear fender to lamp unit | *BE60.00-P-1003-01W | ||
| Fuel filler flap | *BE60.00-P-1004-01W | ||
| Model 207.3 | AR63.50-P-1400-04EC | ||
| Front door to rear fender | *BE60.00-P-1002-01W | ||
| Trunk lid to rear fender, top | *BE60.00-P-1003-01W | ||
| Taillamp, trunk lid to taillamp | *BE60.00-P-1003-01W | ||
| Rear fender to lamp unit | *BE60.00-P-1003-01W | ||
| Fuel filler flap | *BE60.00-P-1004-01W | ||
Multifunction device (spot welding) Vice grip pliers (standard) Hand riveting tool (for blind pop rivets) Round wire brush |
Figure | ||
| White sealing compound, 310 ml, DBL 6069.20 | *BR00.45-Z-1003-01A | ||
| 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 6.4X14 | *BR00.45-Z-1001-13A | ||
| Polygrip countersunk-head rivet, 6.4X14 | *BR00.45-Z-1002-13A | ||
| 20 | Unfasten vehicle from straightening bench | ||
| 21 | Lift vehicle with two-post lifting platform | Two-post lifting platform, 3.0 - 3.5 t electromechanical |
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| 22 | Remove straightening bench. | ||
| 23 | Clean weld joints and sheet metal flange with round wire brush | Round wire brush |
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| 24 | Clean repair areas | 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 | |
| 25 | Prime repair area with primer filler | ↓ |
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| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 26 | Carry out seam sealing after repairs | ||
| Model 204.0/3 | AR97.10-P-4000CW | ||
| Model 207 | AR97.10-P-4000EC | ||
| White sealing compound, 310 ml, DBL 6069.20 | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 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 | |
| 27 | Paint repair areas and adjacent surfaces | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| Risk of explosion and poisoning caused by solvent vapors and gases. Risk of injury to skin and eyes when working with anticorrosion agents | Never spray anticorrosion agents on flames or glowing hot objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection. | AS97.00-Z-0001-01A | |
| 28 | Apply additional cavity preservation | Model 204 | AR97.20-P-1500CW |
| Model 207 | AR97.20-P-1500EC | ||
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Cavity sealant, solvent-free (1 I container) | *BR00.45-Z-1003-05A | ||
| 29 | Remove welding protection blankets | ||
| 30 | Install all removed detachable parts |
CHECK VALUES FOR GAPS
| Number | Designation | Model 204.0 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01U | Gap dimension | Front door to fender | Dim. "G" | mm | 4(+1/-0.5) |
| Front door to rear door | Dim. "H" | mm | 4(+1/-0.5) | ||
| Front door to roof frame | Dim. "I" | mm | 15 (+0.5/-1) | ||
| Rear door to roof frame | Dim. "J" | mm | 15.5 (+1/-0.5) | ||
| Rear door to side piece, bottom | Dim. "K" | mm | 4 (+1/-0.5) | ||
| Driver door cover to rear door cover | Dim. "W" | mm | 4 (+1.5) | ||
| AR60.00-P-0700-01CW | |||||
| BE60.00-P-1003-01U | Gap dimension | Trunk lid to rear fender, top | Dim. "L" | mm | 4 (±1) |
| Trunk lid to rear lamp unit | Dim. "M" | mm | 4 (±1) | ||
| Trunk lid to bumper | Dim. "N" | mm | 5.5 (±1) | ||
| Rear fender to lamp unit | Dim. "O" | mm | 1 (±1) | ||
| Taillamp to bumper | Dim. "P" | mm | 2 (±1) | ||
| Taillamp, trunk lid to taillamp | Dim. "M1" | mm | - | ||
| AR60.00-P-0700-01CW | |||||
| BE60.00-P-1004-01U | Gap dimension | Fuel filler flap (around) | Dim. "Q" | mm | 3.0 (±0.5) |
| AR60.00-P-0700-01CW | |||||
CHECK VALUES FOR GAPS
| Number | Designation | Model 204.3 | Model 207.3 | |||
|---|---|---|---|---|---|---|
| BE60.00-P-1002-01W | Gap dimension | Front door to fender | Dim. "F" | mm | 4 (+1.5/-0.5) | 4 (+1.5/-0.5) |
| Front door to rear fender | Dim. "G" | mm | 4 (+1/-0.5) | 4 (+1/-0.5) | ||
| AR60.00-P-0700-01CW | AR60.00-P-0700-01EC | |||||
| BE60.00-P-1003-01W | Gap dimension | Trunk lid to rear fender, top | Dim. "H" | mm | 4 (±1) | 4 (±1) |
| Trunk lid to bumper | Dim. "I" | mm | 5.5 (±2) | 5.5 (±2) | ||
| Rear fender to lamp unit | Dim. "J" | mm | 2 (+1.5/-1) | 2 (+1.5/-1) | ||
| Taillamp to bumper | Dim. "K" | mm | 2 (±1) | 2 (±1) | ||
| Taillamp, trunk lid to taillamp | Dim. "L" | mm | 4 (±1) | 4 (±1) | ||
| AR60.00-P-0700-01CW | AR60.00-P-0700-01EC | |||||
| BE60.00-P-1004-01W | Gap dimension | Fuel filler flap (around) | Dim. "M" | mm | 3 (+1/-0.5) | 3 (+1/-0.5) |
| AR60.00-P-0700-01CW | AR60.00-P-0700-01EC | |||||
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-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 |
| BR00.45-Z-1003-05A | Cavity sealant, solvent-free (1 I container) | A 000 986 72 70 05 |
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
| BR00.45-Z-1001-13A | Blind rivet 6.4X14 | A 003 990 35 97 |
| BR00.45-Z-1012-13A | Blind rivet 6.5X12.5 | A 004 990 16 97 |
| BR00.45-Z-1002-13A | Polygrip countersunk-head rivet, 6.4X14 | A 003 990 86 97 05 |