Rear End Installation - Ar64.20-P-1020-06RG

	000 588 04 39 00 Rivet press tool		WS60.00-P-0440B
	000 588 12 84 00 Welder		WS00.00-P-0318K

Model 190 

Fig 1: Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

Further information can be found in the superordinate service document. Comply with safety information in superordinate customer service document.

Replace self-pierce rivets installed in vehicle by high-strength rivets according to clamping range.

1. Install rear end assembly (1) and fit.

   First, insert rear end (1) below the fenders at top and then fold it in at the bottom against the longitudinal members.

2. Install and align both rear fender end plates, lock wedge, rear lamp units, rear bumper and seal.
3. Check gaps using feeler gauge and adjust.
4. Check weld seam gaps.

   Check all weld seam gaps before start of welding. The individual weld seam gap may not be greater than 1 mm, where required use a body weld.

5. Fix rear end assembly (1) in place.
6. Remove seal, rear bumper, both rear fender end plates, lock wedge and rear lamp units.

   Courtesy of MERCEDES-BENZ USA

   Shown on model 190.3 

7. Drill rivet holes in the rear end assembly (1) with drill bit ø 6, 7 mm (areas B3, B4 and C2).

   Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt these and prepare together.

8. Prepare the rear end assembly (1) with the rivet press tool (areas A3 and A4).

   Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt these and prepare together.

9. Remove rear end (1).

   Swing rear end (1) out at the bottom from the longitudinal members and then guide it out at the top.

10. Deburr rivet holes on rear end (1) and on body on both sides (cross-hatched areas).

    Observe pretreatment of bonding surfaces.

11. Remove shavings using wet/dry vacuum cleaner.

    Courtesy of MERCEDES-BENZ USA

    Shown on model 190.3 

12. On body apply the 2-component adhesive (cross-hatched areas).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

13. Install rear end (1), fit and fix in place.

    First, insert rear end (1) below the fenders at top and then fold it in at the bottom against the longitudinal members.

14. Rivet the rear end assembly (1) with the rivet press tool and Rivet the flow-form rivets (areas A5 and A6).

    Use flow-form rivet structure 4 mm up to 5.15 mm clamping range (S38).

15. Rivet the rear end assembly (1) with the rivet press tool and blind rivets or Riveting the blind rivets (areas B5, B6 and C3).

    Use blind rivet 6.5x12.5 (Klemmbereich 2 mm up to 5 mm, draw-off strength min. 19 kN) or blind rivet 6.5x14.5 (Klemmbereich 4 mm up to 7 mm, draw-off strength min. 19 kN).

    Courtesy of MERCEDES-BENZ USA

    Shown on model 190.3 

16. Tack rear end (1) with welder ( ) (areas D and E).

    When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Weld seams must  be tack welded at start, end and every approx. 4 cm.

17. Check weld seam gaps.

    Check all weld seam gaps before start of welding. The weld seam gap may not be greater than 1 mm, where required use a body weld.

18. Weld rear end (1) with welder ( ) (areas D and E).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

19. Level welds on rear end (1) and restore surface (areas D and E).
20. Remove shavings using wet/dry vacuum cleaner.