Repair Rear End On Left Side - Ar64.20-P-1200LWR
Model 205.4
| 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 . | |
| 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 . | |
| Topical note | General information on body repair | AH60.00-N-0001-01A . | |
| Topical note | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A . | |
| Topical note | Pretreatment of bonding surfaces | AH60.00-P-0008-01SX . | |
| Topical note | 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 to be repaired | ||
| 2 | Cover all detachable parts remaining on vehicle with spark protection blankets | ||
| 3 | Set up straightening bench with straightening bench crossmembers 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 | Damage area, reshaping | ||
| 6 | Remove spare wheel well (5) | AR64.20-P-1245LWR . | |
| 7 | Remove rear fender (3) | AR63.50-P-1401LWR . | |
| 8 | Remove rear-end center section (6) | AR64.20-P-1000LWR . | |
| 9 | Remove side wall reinforcement (4) | AR63.20-P-0861-01LWR . | |
| 10 | Remove rear-end floor (1) and rear longitudinal member (2) | AR64.20-P-1260-01LW . | |
| 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 . | |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A . | ||
| 11 | Prepare rear-end floor (1) and rear longitudinal member (2) | Round wire brush |
AR64.20-P-1260-02LW . |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A . | ||
| 12 | Prepare side wall reinforcement (4) | Round wire brush |
AR63.20-P-0861-03LWR . |
| 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 . | |
| Topical note | 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 . | ||
| 13 | Install rear-end floor (1) and rear longitudinal member (2) | AR64.20-P-1260-03LW . | |
| 000 588 01 23 00 Body straightening system | WS60.00-P-0023K . | ||
| 000 588 01 84 00 Welder | 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-0021K . | |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A . | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A . | ||
| Blind rivet with countersunk head 6.4x17.0 (clamping range 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1055-13A . | ||
| 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 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN) | *BR00.45-Z-1032-13A . | ||
| 14 | Install side wall reinforcement (4) | AR63.20-P-0861-04LWR . | |
| 000 588 02 84 00 Welder | WS60.00-P-0022K . | ||
| 15 | Release vehicle from straightening bench, lift vehicle and remove straightening bench | ||
| 16 | Install rear-end center section (6) | AR64.20-P-1000LWR . | |
| 17 | Install rear fender (3) | AR63.50-P-1401LWR . | |
| 18 | Install spare wheel well (5) | AR64.20-P-1245LWR . | |
| 19 | Install all detachable body components in area to be repaired |
REAR END REPAIR MATERIALS (LEFT SIDE) (Model 205.4)
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
| 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-1032-13A | Blind rivet 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN) | A 003 990 81 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-1055-13A | Blind rivet with countersunk head 6.4x17.0 (clamping range 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) | A 000 991 86 32 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |