Repair Rear End On Left Side - Ar64.20-P-1200LWG
Model 253
Model 293
Fig 1: Quarter Panel, D-Pillar, Spare Wheel Well And Rear Side Member Component Locations (Model 253)
| 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 death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC) | Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines. | AS00.00-Z-0035-01A . | |
| Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust | Wear dust filter mask, safety glasses, and protective gloves. Use a suitable, grounded dust extraction system. |
AS60.00-Z-0007-01N . | |
| 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 . | |
| Notice | General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment | AH00.00-Z-0300-01A . | |
| Notice | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A . | |
| Notice | Notes on battery | AH54.10-P-0001-01A . | |
| Notice | General information on body repair | AH60.00-P-0001-01KOA . | |
| Notice | Pretreatment of bonding surfaces | AH60.00-P-0008-01SX . | |
| Notice | General information on crack diagnosis of aluminum parts | AH60.00-P-0014-01N . | |
| Note on working on aluminum components and vehicles | AH60.00-P-0034-01LW . | ||
| General information on MB materials | AH98.00-P-9409-03A . | ||
| Remove | |||
| 1 | Remove detachable parts in area of repair point. | ||
| 2 | Cover all detachable parts remaining in vehicle with spark protection blankets. | ||
| 3 | Set up straightening bench with straightening bench crossmembers and straightening set. | ||
| 000 588 01 23 00 Body straightening system | WS60.00-P-0023K . | ||
| 4 | Place vehicle on straightening bench and fasten. | ||
| 5 | Reshape damage area. | ||
| 6 | Remove spare wheel well (1). | AR64.20-P-1245LWG . | |
| 7 | Remove rear fender (3). | Model 253.3 | AR63.50-P-1401LWX . |
| Model 253.9 Model 293 |
AR63.50-P-1400LWS . | ||
| 8 | Remove rear-end center section (2). | Model 253.3 Model 293 |
AR64.20-P-1000LWX . |
| Model 253.9 | AR64.20-P-1020LWG . | ||
| 9 | Remove D-pillar (4). | Model 253.3 | AR63.20-P-2000LWX . |
| Model 253.9 Model 293 |
AR63.20-P-2000LWG . | ||
| 10 | Remove rear-end floor (5) and rear longitudinal member (6). | AR64.20-P-1260-01LWG . | |
| 000 588 00 84 00 Heat gun | Round wire brush Spot weld milling machine Wet/dry vacuum cleaner Body and aluminum workplace Aluminum tools |
WS54.00-P-0049B . | |
| 1K-zinc dust paint | *BR00.45-Z-1056-07A . | ||
| 11 | Prepare rear-end floor (5) and rear longitudinal member (6). | Round wire brush |
AR64.20-P-1260-02LWG . |
| 1K-zinc dust paint | *BR00.45-Z-1056-07A . | ||
| Install | |||
| 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 . | |
| Notice | Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A . | |
| General information on riveting | AH60.00-P-0003-01N . | ||
| 12 | Install rear-end floor (5) and rear longitudinal member (6). | AR64.20-P-1260-03LWG . | |
| 000 588 01 84 00 Welder | WS60.00-P-0021K . | ||
| 000 588 01 23 00 Body straightening system | Round wire brush Manual temporary fastener 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Wet/dry vacuum cleaner Body and aluminum workplace Aluminum tools |
WS60.00-P-0023K . | |
| 1K-zinc dust paint | *BR00.45-Z-1056-07A . | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A . | ||
| Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A . | ||
| Blind rivet 6.5X14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1016-13A . | ||
| Blind rivet 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN) | *BR00.45-Z-1034-13A . | ||
| Blind rivet with countersunk head 6.4x19.0 (clamping range 6 mm to 8 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1056-13A . | ||
| 13 | Release vehicle from straightening bench, lift and remove straightening bench. | ||
| 14 | Install D-pillar (4). | Model 253.3 | AR63.20-P-2000LWX . |
| Model 253.9 Model 293 |
AR63.20-P-2000LWG . | ||
| 15 | Install rear-end center section (2). | Model 253.3 Model 293 |
AR64.20-P-1000LWX . |
| Model 253.9 | AR64.20-P-1020LWG . | ||
| 16 | Install rear fender (3). | Model 253.3 | AR63.50-P-1401LWX . |
| Model 253.9 Model 293 |
AR63.50-P-1400LWS . | ||
| 17 | Install spare wheel well (1). | AR64.20-P-1245LWG . | |
| 18 | Install detachable parts in the area of the repair point. |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1012-13A | Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | A 004 990 16 97 |
| BR00.45-Z-1016-13A | Blind rivet 6.5X14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | A 004 990 17 97 |
| BR00.45-Z-1034-13A | Blind rivet 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN) | A 003 990 80 97 |
| BR00.45-Z-1056-07A | 1K-zinc dust paint | A 000 986 28 00 |
| BR00.45-Z-1056-13A | Blind rivet with countersunk head 6.4x19.0 (clamping range 6 mm to 8 mm, draw-off strength min. 15.5 kN) | A 000 991 87 32 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |