Completely Remove And Install Rear Longitudinal Member - Ar64.20-P-1220LWR
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 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 body repair | AH60.00-P-0001-01KOA | |
| Notice | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | |
| 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 to be repaired | ||
| 2 | Cover all detachable parts remaining on vehicle with spark protection blankets | ||
| 3 | Remove rear end assembly | AR64.20-P-1000LWR | |
| 4 | Remove inner side wall with partial rear outer wheelhouse | AR63.10-P-6051LWR | |
| 5 | B-pillar | AR63.20-P-1350LWR | |
| 6 | Partially remove rear-end floor and rear longitudinal member | 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 | |
| 1K-zinc dust paint | *BR00.45-Z-1056-07A | ||
| 7 | Remove crossmember above rear axle | AR64.20-P-1301LW | |
| 8 | Remove rear longitudinal member (1) with front end plate (11), upper crossmember (2), lower crossmember (3), mounting console (4), center reinforcement (5), center support (6), left tunnel reinforcement (7), right tunnel reinforcement (8), crossmember reinforcement (9), support (10), mounting console (12) and supports (13) | AR64.20-P-1200-22LWR | |
| 000 588 00 84 00 Heat gun | Round wire brush Body power jigsaw 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 | ||
| 9 | Prepare rear longitudinal member (1), front end plate (11), upper crossmember (2), lower crossmember (3), mounting console (4), center reinforcement (5), center support (6), left tunnel reinforcement (7), right tunnel reinforcement (8), crossmember reinforcement (9), support (10), mounting console (12) and supports (13) | Round wire brush Body power jigsaw Wet/dry vacuum cleaner Body and aluminum workplace Aluminum tools |
AR64.20-P-1200-23LWR |
| 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 | ||
| 10 | Install rear longitudinal member (1), front end plate (11), upper crossmember (2), lower crossmember (3), mounting console (4), center reinforcement (5), center support (6), left tunnel reinforcement (7), right tunnel reinforcement (8), crossmember reinforcement (9), support (10), mounting console (12) and supports (13) | AR64.20-P-1200-24LWR | |
| 000 588 01 84 00 Welder | WS60.00-P-0021K | ||
| 000 588 02 84 00 Welder | WS60.00-P-0022K | ||
| 000 588 01 23 00 Body straightening system | Manual temporary fastener 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Hole finder 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 Y2 6.5 x 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A | ||
| Blind rivet Y1 6.4 x 12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1035-13A | ||
| Blind rivet Y3 6.5 x 14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1016-13A | ||
| Blind rivet Y4 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN) | *BR00.45-Z-1032-13A | ||
| Countersunk-head blind rivet Z1 6.4 x 14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1043-13A | ||
| 11 | Install crossmember above rear axle | AR64.20-P-1301LW | |
| 12 | Partially prepare rear-end floor and rear longitudinal member | Round wire brush |
AR64.20-P-1260-02LW |
| 1K-zinc dust paint | *BR00.45-Z-1056-07A | ||
| 13 | Partially install rear-end floor and rear longitudinal member | AR64.20-P-1260-03LW | |
| 000 588 01 23 00 Body straightening system | Manual temporary fastener 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Spot welder Wet/dry vacuum cleaner Body and aluminum workplace Aluminum tools |
WS60.00-P-0023K | |
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Countersunk-head blind rivet Z3 6.4x17.0 (clamping area 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1055-13A | ||
| Blind rivet Y2 6.5 x 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A | ||
| Blind rivet Y3 6.5 x 14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1016-13A | ||
| Blind rivet Y5 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN) | *BR00.45-Z-1034-13A | ||
| Blind rivet Y4 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 B-pillar | AR63.20-P-1350LWR | |
| 15 | Install inner side wall with partial outer rear wheel well | AR63.10-P-6051LWR | |
| 16 | Install rear end assembly | AR64.20-P-1000LWR | |
| 17 | Install detachable parts in area to be repaired |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1012-13A | Blind rivet Y2 6.5 x 12.5 (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 Y3 6.5 x 14.5 (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 Y4 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 Y5 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-1035-13A | Blind rivet Y1 6.4 x 12 (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 | Countersunk-head blind rivet Z1 6.4 x 14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) | A 000 991 82 32 |
| BR00.45-Z-1055-13A | Countersunk-head blind rivet Z3 6.4x17.0 (clamping area 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) | A 000 991 86 32 |
| BR00.45-Z-1056-07A | 1K-zinc dust paint | A 000 986 28 00 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |