Rear Longitudinal Member Completely Removal And Installation - Ar64.20-P-1220S
Model 223.0/1/9
MODIFICATION NOTES
| 29.11.2021 | Method extended. | Operation steps 6, 18 |
| 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-0017-01A | |
| 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-0001-01S | |
| Notice | Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | |
| Note on working on aluminum components and vehicles | AH60.00-P-0034-01RG | ||
| 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 | Set up straightening bench with straightening bench support members and straightening set. | ||
| 000 588 01 23 00 Body straightening system | WS60.00-P-0023K | ||
| 4 | Place vehicle on straightening bench and fasten. | ||
| 5 | Remove lower rear-end center section with rear crossmember. | AR64.20-P-1060S | |
| 6 | Remove reinforcements on rear longitudinal member (1). | Model 223.0/1 with code Z07 (B7 armoring on special protection version) |
AR64.20-P-1220-28SG |
| 7 | Remove crossmember under rear-end floor. | AR64.20-P-1145S | |
| 8 | Remove crossmember at lower front rear-end floor. | AR64.20-P-1140S | |
| 9 | Remove crossmember under the rear seat. | AR63.40-P-1194S | |
| 10 | Remove rear longitudinal member (1). | AR64.20-P-1200-22S | |
| 000 588 02 39 00 Rivet press tool | WS60.00-P-0010B | ||
| 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-0003-01S | ||
| General notes on welding | AH60.00-P-0005-01N | ||
| 11 | Prepare rear longitudinal member (1). | AR64.20-P-1200-23S | |
| 12 | Install rear longitudinal member (1). | AR64.20-P-1200-24S | |
| 000 588 02 39 00 Rivet press tool | WS60.00-P-0010B | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A | ||
| Blind rivet Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1016-13A | ||
| Flow-form rivet structure W5 5.0 mm up to 6.1 mm clamping range (S4) | *BR00.45-Z-1029-13A | ||
| Flow-form rivet structure W7 7.1 mm up to 8.3 mm clamping range (S6) | *BR00.45-Z-1031-13A | ||
| 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 | ||
| Blind rivet Y1 6.4x12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1035-13A | ||
| Hexalobular bolt M6x16 | *BR00.45-Z-1041-13A | ||
| Nut M6 | *BR00.45-Z-1042-13A | ||
| Blind rivet Y9 6.4x20 (clamping range 7 mm to 10.5 mm, draw-off strength min. 15.4 kN) Screw M6x20-10.9 |
*BR00.45-Z-1047-13A *BR00.45-Z-1080-13A | ||
| 13 | Release vehicle from straightening bench, lift and remove straightening bench. | ||
| 14 | Clean sheet metal flanges. | ||
| 15 | Install crossmember under the rear seat. | AR63.40-P-1194S | |
| 16 | Install crossmember on lower front rear-end floor. | AR64.20-P-1140S | |
| 17 | Install crossmember under rear-end floor. | AR64.20-P-1145S | |
| 18 | Install reinforcements on rear longitudinal member (1). | Model 223.0/1 with code Z07 (B7 armoring on special protection version) |
AR64.20-P-1220-29SG |
| 000 588 02 39 00 Rivet press tool | WS60.00-P-0010B | ||
| 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 | ||
| 19 | Install lower rear-end center section with rear crossmember. | AR64.20-P-1060S | |
| 20 | Remove spark protection blankets. | ||
| 21 | Reinstall detachable parts in area of repair point. |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1012-13A | Blind rivet Y2 6.5x12.5 (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 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | A 004 990 17 97 |
| BR00.45-Z-1029-13A | Flow-form rivet structure W5 5.0 mm up to 6.1 mm clamping range (S4) | A 000 991 19 33 |
| BR00.45-Z-1031-13A | Flow-form rivet structure W7 7.1 mm up to 8.3 mm clamping range (S6) | A 000 991 21 33 |
| 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 6.4x12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | A 000 991 76 32 |
| BR00.45-Z-1041-13A | Hexalobular bolt M6x16 | N 910143 006001 |
| BR00.45-Z-1042-13A | Nut M6 | N 910112 006003 |
| BR00.45-Z-1047-13A | Blind rivet Y9 6.4x20 (clamping range 7 mm to 10.5 mm, draw-off strength min. 15.4 kN) | A 000 991 54 32 |
| BR00.45-Z-1080-13A | Screw M6x20-10.9 | N 000000 003765 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |