Replace Complete Bottom Rear Center Section - Ar64.20-P-1000LWA
Model 238.4
| 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 | |
| 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 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 | Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | |
| Notice | Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | |
| Notice | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | |
| Notice | General information on body repair | AH60.00-P-0001-01KOA | |
| Notice | Notes on paintwork repairs | AH98.00-P-9408-02A | |
| General information on operation items and work procedures for painting | AH98.00-P-0003-01A | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| 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 center section (1). | Round wire brush Spot weld milling machine Wet/dry vacuum cleaner |
AR64.20-P-1000-02LWA |
| 1K-zinc dust paint | *BR00.45-Z-1056-07A | ||
| Fig 4 | |||
| Preparation | |||
| 4 | Prepare rear-end center section (1) for installation. | Round wire brush |
AR64.20-P-1000-07LWA |
| 1K-zinc dust paint | *BR00.45-Z-1056-07A | ||
| Install | |||
| 5 | Install rear-end center section (1). | AR64.20-P-1000-08LWA | |
| Gap dimensions on hoods, doors and lids Round wire brush Manual temporary fastener 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Wet/dry vacuum cleaner |
AR60.00-P-0700-01LWO | ||
| Trunk lid to fender at rear, top | *BE60.00-P-1009-01HA | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| 1K-zinc dust paint | *BR00.45-Z-1056-07A | ||
| 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 | ||
| 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 | ||
| Fig 3 | |||
| Fig 2 | |||
| Clean | |||
| 6 | Clean weld joints and sheet metal flanges. | Round wire brush |
|
| 7 | Remove spark protection blankets. | ||
| 8 | Clean repair area. | Wet/dry vacuum cleaner |
|
| Paint | |||
| 9 | Prime repair areas with primer filler. | ||
| 10 | Realize seam seal after repair work. | AR97.10-P-4000LWO | |
| 11 | Paint repair areas and adjacent surfaces. | ||
| 12 | Supplement cavity preservation. | AR97.20-P-1500LWO | |
| Assemble | |||
| 13 | Install all detachable parts in area of repair point. |
CHECK VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 238.4 | ||
|---|---|---|---|---|
| BE60.00-P-1009-01HA | Trunk lid to fender at rear, top | Dimension "K" | mm | 3 (± 0, 5) |
| Dimension "K1" | mm | - | ||
| For picture, see | AR60.00-P-0700-01LWO | |||
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-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-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 |