Repair Rear End On Left Side - Ar64.20-P-1200LW
Model 205.0/1/3
Fig 1: Quarter Panel, Trunk Floor, Rear Side Member And Adjacent Component Locations (Left Side Repair) (Model 205.0/1/3)
Shown on model 205.0
| 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 to be repaired | ||
| 2 | Cover all detachable parts remaining on vehicle with spark protection blanket | ||
| 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 (7) | AR64.20-P-1245LW | |
| 7 | Remove rear-end center section (6) | Model 205.0/1 | AR64.20-P-1020LW |
| Model 205.3 | AR64.20-P-1020CLW | ||
| 8 | Remove rear fender (3) | Model 205.0/1 | AR63.50-P-1400LW |
| Model 205.3 | AR63.50-P-1400CLW | ||
| 9 | Remove strut (4) from C-pillar | Model 205.0/1 | AR63.20-P-0500LW |
| Model 205.3 | AR63.20-P-0500CLW | ||
| 10 | Remove reinforcement (5) from C-pillar side wall | Model 205.0/1 | AR63.10-P-0700LW |
| Model 205.3 | AR63.10-P-6050CLW | ||
| 11 | 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 | ||
| 12 | 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 | ||
| 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 | ||
| 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 | ||
| 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 Y4 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN) | *BR00.45-Z-1032-13A | ||
| 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 | ||
| 14 | Install reinforcement (5) on C-pillar side wall | Model 205.0/1 | AR63.10-P-0700LW |
| Model 205.3 | AR63.10-P-6050CLW | ||
| 15 | Install strut (4) on C-pillar | Model 205.0/1 | AR63.20-P-0500LW |
| Model 205.3 | AR63.20-P-0500CLW | ||
| 16 | Release vehicle from straightening bench, lift vehicle and remove straightening bench | ||
| 17 | Install rear fender (3) | Model 205.0/1 | AR63.50-P-1400LW |
| Model 205.3 | AR63.50-P-1400CLW | ||
| 18 | Install rear-end center section (6) | Model 205.0/1 | AR64.20-P-1020LW |
| Model 205.3 | AR64.20-P-1020CLW | ||
| 19 | Install spare wheel well (7) | AR64.20-P-1245LW | |
| 20 | Install all detachable body components in area to be repaired |
REPAIR MATERIALS
| 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 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-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-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |