Completely Remove And Install Rear Longitudinal Member - Ar64.20-P-1220LW
Model 205.0/1/2/3
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 | Remove rear end assembly | Model 205.0/1 | AR64.20-P-1020LW |
| Model 205.2 | AR64.20-P-1020LWS | ||
| Model 205.3 | AR64.20-P-1020CLW | ||
| 4.1 | Remove inner C-pillar side wall | Model 205.0/1 | AR63.10-P-0700LW |
| 4.2 | Remove inner side wall with partial rear outer wheelhouse | Model 205.2/3 Model 205.2 |
AR63.10-P-6050LWS |
| Model 205.3 | AR63.10-P-6050CLW | ||
| 5 | Remove longitudinal member outer shell | Model 205.0/1/2 | AR63.30-P-1102LW |
| Model 205.3 |
AR63.30-P-1102CLW | ||
| 6 | Remove rear-end door and partial rear longitudinal member | Round wire brush Spot weld milling machine Heat gun Wet/dry vacuum cleaner Body and aluminum workplace Aluminum tools |
AR64.20-P-1260-01LW |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 7 | Remove crossmember above rear axle | AR64.20-P-1301LW | |
| 8 | Remove rear longitudinal member (1) with end plate (4), bottom crossmember (2) and top crossmember (3) | Round wire brush Body power jigsaw Spot weld milling machine Heat gun Wet/dry vacuum cleaner Body and aluminum workplace Aluminum tools |
AR64.20-P-1200-22LW |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 9 | Prepare rear longitudinal member (1), bottom crossmember (2), top crossmember (3) and end plate (4) | Round wire brush Body power jigsaw Body and aluminum workplace Aluminum tools |
AR64.20-P-1200-23LW |
| 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 | ||
| 10 | Install rear longitudinal member (1), bottom crossmember (2), top crossmember (3) and end plate (4) | AR64.20-P-1200-24LW | |
| 000 588 02 84 00 Welder | WS60.00-P-0022K | ||
| 000 588 01 23 00 Body straightening system | Round wire brush Manual temporary fastener 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Spot welder Hole finder Wet/dry vacuum cleaner Body and aluminum workplace Aluminum tools |
WS60.00-P-0023K | |
| 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 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 | ||
| 11 | Install crossmember above rear axle | AR64.20-P-1301LW | |
| 12 | Prepare rear-end door and partial rear longitudinal member | Round wire brush |
AR64.20-P-1260-02LW |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 13 | Install rear-end floor and partial rear longitudinal member | AR64.20-P-1260-03LW | |
| 000 588 01 23 00 Body straightening system | Round wire brush 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 | |
| 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 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 longitudinal member outer shell | Model 205.0/1/2 | AR63.30-P-1102LW |
| Model 205.3 |
AR63.30-P-1102CLW | ||
| 15.1 | Install inner C-pillar side wall | Model 205.0/1 | AR63.10-P-0700LW |
| 15.2 | Install inner side wall with partial outer rear wheel well | Model 205.2/3 Model 205.2 |
AR63.10-P-6050LWS |
| Model 205.3 | AR63.10-P-6050CLW | ||
| 16 | Install rear end assembly | Model 205.0/1 | AR64.20-P-1020LW |
| Model 205.2 | AR64.20-P-1020LWS | ||
| Model 205.3 | AR64.20-P-1020CLW | ||
| 17 | Install detachable parts 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-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-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 |