Completely Remove/Install Rear Longitudinal Member - Ar64.20-P-1220GQX

Model 166

Shown on model 166.8

Courtesy of MERCEDES-BENZ USA

	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.	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 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 .
Topical note	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A .
Topical note	General information on body repair		AH60.00-N-0001-01A
	General information on MB materials		AH98.00-P-9409-03A .
	Remove
1	Remove detachable parts in area to be repaired
2	Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket
3	Equip straightening bench with module members, cross members and straightening tool set
	000 588 01 23 00 Body straightening system		WS60.00-P-0023K .
4	Place vehicle on straightening bench and fasten
5	Remove fender	Model 166.8	AR63.50-P-1400GQX .
		Model 166.0	AR63.50-P-1400GQ
6	Remove rear outer wheel well	Model 166.8	AR63.10-P-0665GQX .
		Model 166.0	AR63.10-P-0665GQ
7	Remove rear center section		AR64.20-P-1000GQ .
8	Remove rear crossmember		AR64.20-P-1100-01GQ .
		Commercially available devices/tools Round wire brush Spot weld milling machine Wet and dry vacuum cleaner
9	Remove spare wheel well		AR64.20-P-1245GQ .
10	Remove complete rear longitudinal member		AR64.20-P-1200-22GQX .
		Commercially available devices/tools Round wire brush Spot weld milling machine Body jig saw Heat gun Wet and dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A .
11	Prepare rear longitudinal member for installation		AR64.20-P-1200-23GQX .
		Commercially available devices/tools Spot weld milling machine Round wire brush
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A .
12	Prepare rear crossmember for installation		AR64.20-P-1100-02GQ .
	Install
13	Completely install rear longitudinal member		AR64.20-P-1200-24GQX .
	000 588 02 84 00 Welder		WS60.00-P-0022K .
		Commercially available devices/tools Spot welder Round wire brush Manual temporary fastener 6.35 mm Wet and dry vacuum cleaner Multifunction unit (spot welding)
		White sealing compound, 310 ml, DBL 6069.20	*BR00.45-Z-1003-01A .
14	Install spare wheel well		AR64.20-P-1245GQ .
15	Install rear crossmember		AR64.20-P-1100-05GQ .
		Commercially available devices/tools Blind rivet tool Spot welder Round wire brush Manual temporary fastener 6.35 mm Wet and dry vacuum cleaner
16	Completely install lower rear center section		AR64.20-P-1000GQ .
17	Install outer rear wheel well	Model 166.8	AR63.10-P-0665GQX .
		Model 166.0	AR63.10-P-0665GQ
18	Install fender	Model 166.8	AR63.50-P-1400GQX .
		Model 166.0	AR63.50-P-1400GQ
19	Release vehicle from straightening bench, lift vehicle and remove straightening bench
20	Clean repair area
21	Remove welding protection blankets
	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 .
22	Prime repair area with primer filler	Use only primer filler approved by Daimler AG.
23	Seal seam following repairs	Supplement standard seam seal.	AR97.10-P-4000GQ .
	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 . ↓
24	Paint repair area adjacent surfaces	Use only paints approved by Daimler AG. ↓
25	Add cavity preserving agent		AR97.20-P-1500GQ .
26	Install all removed detachable parts

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-1003-01A	White sealing compound, 310 ml, DBL 6069.20	A 001 989 63 20