Partially Remove Rear Longitudinal Member - Ar64.20-P-1260-01W
| 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-0010-1A | |
| 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. Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | AS00.00-Z-0002-01A | |
| 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-0017-007 | |
| General information on body repair | AH6n.00-p-0001-01KOA | ||
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| Pretreatment of bonding surfaces | AH6n.00-p-0008-nisx | ||
| General information on crack diagnosis of aluminum parts | AH6n.00-p-00i4-niN | ||
| Note on working on aluminum components and vehicles | AH6n.00-p-0034-niLW |
Model 205
Model 238
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-i056-07A | 1K-zinc dust paint | a 000 986 98 00 |
The following steps are shown on the left side of the vehicle and must be performed analogously on the right side in the event of damage.
The following repair materials must be used:
- Zinc dust paint
- Expose spot welds on rear-end floor (1) and cut out (areas A and B).
Cut out spot welds through two sheet metal thicknesses (area B).
- Expose self-piercing riveting on rear-end floor (1) with Ø 6 mm bit (areas C).
- Expose impact spikes on rear-end floor (i) and cut out (area J).
- Expose spot welds on rear-end floor (1) and rear longitudinal member (2) and cut out (areas D).
- Expose self-piercing riveting on rear longitudinal member (2) and drill with Ø 6 mm (area E).
- Expose impact spikes on rear longitudinal member (2) and cut out (area H).
- Heat rear-end floor (1) and rear longitudinal member (2) in cross-hatched areas.
- Remove rear-end floor (1) with rear longitudinal member (2).
- Grind mating surfaces down to bare metal in cross-hatched areas.
Sand down spot weld flanges to bare metal on both sides.
- Remove grinding dust and drill chips.
- Coat insides of spot weld flanges with zinc dust paint.
Do not coat bonding surfaces with zinc dust paint (areas G and F).
Otherwise adhesion problems may occur.