Replace Complete Rear End - Ar64.20-P-1020CLW
Model 205.3
REAR END REPLACEMENT MODIFICATION NOTES (Model 205.3)
| 26.05.2021 | Repair materials reference BR00.45-Z-1049-02A replaced by BR00.45-Z-1104-02A and BR00.45-Z-1180-02A. | Step 5 | |
| 26.05.2021 | WS document reference added | Operation steps 3, 5 |
| 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 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-N-0001-01A . | |
| Notice | Pretreatment of bonding surfaces | AH60.00-P-0008-01SX . | |
| 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 | Cut off rear end assembly (1). | AR64.20-P-1020-01CLW . | |
| 000 588 00 84 00 Heat gun | WS54.00-P-0049B . | ||
Round wire brush Body power jigsaw Spot weld milling machine Wet/dry vacuum cleaner Glass removal 1K-zinc dust paint |
*BR00.45-Z-1056-07A . | ||
| 4 | Prepare rear end assembly (1) for installation. | Round wire brush Body power jigsaw |
AR64.20-P-1020-05CLW . |
| 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 . | ||
| 5 | Install rear end assembly (1). | AR64.20-P-1020-06CLW . | |
| Gap dimensions on hoods, doors and lids | AR60.00-P-0700-01LW . | ||
| 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 |
WS60.00-P-0021K . | |
| Trunk lid to fender at rear, top | *BE60.00-P-1012-01BB . | ||
| Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1035-13A . | ||
| Blind rivet with countersunk head 6.4X14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1043-13A . | ||
| 1K-zinc dust paint | *BR00.45-Z-1056-07A . | ||
| Repair kit for installing windshields, 1-component adhesive | *BR00.45-Z-1180-02A . | ||
| SIKA primer 209, 250 ml | *BR00.45-Z-1104-02A . | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A . | ||
| 6 | Clean weld joints and sheet metal flange. | Round wire brush |
|
| 7 | Remove spark protection blankets. | ||
| 8 | Clean repair area. | Wet/dry vacuum cleaner |
|
| 9 | Treat repair areas with primer filler. | ||
| Notice | Notes on paintwork repairs | AH98.00-P-9408-02A . | |
| 10 | Seal seam after repair. | AR97.10-P-4000LW . | |
| 11 | Paint repair areas and adjacent surfaces. | ||
| Notice | Notes on paintwork repairs | AH98.00-P-9408-02A . | |
| 12 | Supplement cavity preservation. | AR97.20-P-1500LW | |
| 13 | Install all detachable parts in area of repair point. |
CHECK VALUES FOR GAP DIMENSIONS (Model 205.3) (Trunk Lid To Fender)
| Number | Designation | Model 205.3 | ||
|---|---|---|---|---|
| BE60.00-P-1012-01BB | Trunk lid to fender at rear, top | Dimension "K" | mm | 3, 5 (±1) |
| Dimension "K1" | mm | 4 (+1.5/-1) | ||
| For picture, see | AR60.00-P-0700-01LW . | |||
REAR BODY PANEL REPAIR MATERIALS (Model 205.3)
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1035-13A | Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | A 000 991 76 32 |
| BR00.45-Z-1043-13A | Blind rivet with countersunk head 6.4X14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) | A 000 991 82 32 |
| BR00.45-Z-1056-07A | 1K-zinc dust paint | A 000 986 28 00 |
| BR00.45-Z-1104-02A | SIKA primer 209, 250 ml | A 009 989 75 71 09 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |
| BR00.45-Z-1180-02A | Repair kit for installing windshields, 1-component adhesive | A 000 989 49 05 |