Replace complete rear end - AR64.20-P-1020EC
MODEL 207.3
| Removing | |||
| 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 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 spatter 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 | |
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-N-0005-01A | ||
| General information on repairs to body | AH60.00-N-0001-01A | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1 | Prepare required workshop equipment and commercially available tools for repair | ||
| 2 | Remove detachable parts in area to be repaired | ||
| 3 | Coverall detachable parts remaining in vehicle with welding protection blanket | Welding protective blanket | |
| 4 | Separate rear end (1) | AR64.20-P-1020-01EC | |
Hot-air gun Round wire brush Wet and dry vacuum cleaner |
Figure | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 5 | Prepare rear end (1) for installation | AR64.20-P-1020-02EC | |
| Round wire brush | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 6 | Install rear end (1) and weld in | AR64.20-P-1020-03EC | |
| General information on riveting | AH60.00-P-0003-01N | ||
Multifunction device (spot welding) Vice grip pliers (standard) Hand riveting tool (for blind pop rivets) Round wire brush Wet and dry vacuum cleaner |
Figure | ||
| Adhesive | *BR00.45-Z-1092-02A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Rivet | *BR00.45-Z-1001-13A | ||
| 7 | Adjust gaps on hoods, doors and lids | ||
| Trunk lid to rear fender, top | *BE60.00-P-1003-01W | ||
| Trunk lid to bumper | *BE60.00-P-1003-01W | ||
| Rear fender to rear lamp unit | *BE60.00-P-1003-01W | ||
| Taillamp to bumper | *BE60.00-P-1003-01W | ||
| Taillamp, trunk lid to taillamp | *BE60.00-P-1003-01W | ||
| Figure | |||
| 8 | Clean repair areas | Wet and dry vacuum cleaner | |
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open flames! Use respiratory protection, protective clothing, gloves, safety goggles and skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 9 | Prime area to be repaired with primer filler | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 10 | Seam sealing following repair | AR97.10-P-4000EC | |
| Sealant | *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 flames! Use respiratory protection, protective clothing, gloves, safety goggles and skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 11 | Paint area repaired and adjacent surfaces | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 12 | Apply additional cavity preservation | AR97.20-P-1500EC | |
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Preservation agent | *BR00.45-Z-1003-05A | ||
| 13 | Remove welding protection blanket | ||
| 14 | Install all removed assembly parts |
CHECK VALUES FOR GAPS
| Number | Designation | Model 207.3 | |||
|---|---|---|---|---|---|
| BE60.00-P-1003-01W | Gap dimension | Trunk lid to rear fender, top | Dimension "H" | mm | 4(±1) |
| Trunk lid to bumper | Dimension "I" | mm | 5, 5 (±2) | ||
| Rear fender to rear lamp unit | Dimension "J" | mm | 2 (+1.5/-1) | ||
| Taillamp to bumper | Dimension "K" | mm | 2 (±1) | ||
| Taillamp, trunk lid to taillamp | Dimension "L" | mm | 4 (±1) | ||
| AR60.00-P-0700-01EC | |||||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | Sealant, white, 310 ml, DB supply specification 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 preservation, 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 |