Remove Longitudinal Member At Rear - Ar64.20-P-1200-22LW

Model 205.0/1/2/3 

The following operation steps are shown on the left side of the vehicle on MODEL 205.0 and must be performed analogously on the right side in the event of damage.

Fig 1: Rear Longitudinal Member Locations (Model 205.0/1/2/3)

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1. Expose spot welds on upper crossmember (3) and cut out (areas A).
2. Expose impact spikes on upper crossmember (3) and cut out (areas B).

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3. Heat upper crossmember (3) in crosshatched areas.

   Crosshatched areas are bonded with adhesive.

4. Remove upper crossmember (3).
5. Mark separating point on lower crossmember (2) and cut (area C).

   Do not cut too deeply.

   Otherwise the components below can be damaged and weakened.

6. Expose spot welds on lower crossmember (2) and cut out (areas D).
7. Expose self-piercing riveting on lower crossmember (2) and drill with Ø 6 mm bit (areas E).
   Fig 2: Lower Crossmember Location (Model 205.0/1/2/3)

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8. Heat lower crossmember (2) in crosshatched areas.

   Crosshatched areas are bonded with adhesive.

9. Remove lower crossmember (2).

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   Fig 3: Front Striking Plate Location (Model 205.0/1/2/3)

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10. Expose spot welds on front striking plate (4) and cut out (area D₁ ).
11. Expose spot welds on front striking plate (1) and cut out (area D₂ ).
12. Expose spot welds on rear longitudinal member (1) and drill with Ø 6.5 mm bit (area E₁ ).
    Fig 4: Rear Longitudinal Member Removal Locations (Model 205.0/1/2/3) (1 Of 3)

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13. Mark separating point on rear longitudinal member (1) and cut (area F).

    Do not cut too deeply.

    Otherwise the components below can be damaged and weakened.

14. Expose concealed spot welds below cutout and drill with Ø 6.5 mm.
15. Expose spot welds on rear longitudinal member (1) and cut out (areas G and H).

    Cut out spot welds through two panel thicknesses (areas H).

16. Expose spot welds on rear longitudinal member (1) and drill with Ø 6.5 mm (areas I).
    Fig 5: Rear Longitudinal Member Removal Locations (Model 205.0/1/2/3) (2 Of 3)

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17. Model 205.0/1/3

    Expose impact spikes in rear longitudinal member (1) and cut out (area J).

    Fig 6: Rear Longitudinal Member Removal Locations (Model 205.0/1/2/3) (3 Of 3)

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18. Mark separating point on rear longitudinal member (1) and cut (area K).

    Do not cut too deeply.

    Otherwise the components below can be damaged and weakened.

    Dimensions: 

    k = approx. 20 mm

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19. Model 205.0/1/3

    Heat rear longitudinal member (1) in crosshatched areas.

    Crosshatched areas are bonded with adhesive.

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20. Heat rear longitudinal member (1) in crosshatched areas.

    Crosshatched areas are bonded with adhesive.

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21. Heat rear longitudinal member (1) in crosshatched areas.

    Crosshatched areas are bonded with adhesive.

22. Remove rear longitudinal member (1).

    Helper required.

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23. Sand down mating surfaces to bare metal in crosshatched areas.

    Grind mating surfaces down to bare metal on inside (area N).

    Sand down spot weld flanges to bare metal on both sides.

24. Remove grinding dust and drill chips.
25. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas M and N).

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

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26. Model 205.0/1/3

    Grind mating surfaces down to bare metal in crosshatched areas (areas P and Q).

27. Sand down mating surfaces to bare metal in crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

28. Remove grinding dust and drill chips.
29. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas O and P).

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.