Repair Rear End On Left Side - Ar64.20-P-1200LF
Model 217.3, 222
Shown on model 222
| 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 caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel. | No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. Wear protective clothing when handling fuel. |
AS47.00-Z-0001-01A | |
| 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 | 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 | |
| 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 module members, crossmember and straightening 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 lower rear center section (1.1) with rear crossmember (1.2) | AR64.20-P-1060LF | |
| 7 | Remove rear fender (4) | Model 217.3 | AR63.50-P-1400LC |
| Model 222 | AR63.50-P-1400LF | ||
| 8.1 | Remove C-pillar strut (5) from outer C-pillar | Model 217.3 | AR63.20-P-0500LC |
| 8.2 | Remove C-pillar strut (5) from outer C-pillar | Model 222 except code Z07 (B7 armoring on special protection version) | AR63.20-P-0500LF |
| 8.3 | Remove C-pillar strut (5) from outer C-pillar | Model 222 with code Z07 (B7 armoring on special protection version) Body power jigsaw Round wire brush Spot weld milling machine Heat gun Wet/dry vacuum cleaner |
AR63.20-P-0500-07LFS |
| 9 | Remove outer rear wheel well (7) | Model 217.3 Model 222 except code Z07 (B7 armoring on special protection version) |
AR63.10-P-0665LF |
| 10.1 | Remove reinforcement (6) from inner C-pillar side wall | Model 222 except code Z07 (B7 armoring on special protection version) | AR63.10-P-0700LF |
| 10.2 | Remove reinforcement (6) from inner C-pillar side wall | Model 222 with code Z07 (B7 armoring on special protection version) | |
Round wire brush Spot weld milling machine Heat gun Wet/dry vacuum cleaner |
AR63.10-P-0700-06LFS | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 11 | Remove rear longitudinal member (2.1), lower rear longitudinal member (2.3), rear longitudinal member end plate (2.4) and rear rear-end floor (3) | Round wire brush Body power jigsaw Spot weld milling machine Heat gun Wet/dry vacuum cleaner |
AR64.20-P-1260-01LF |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 12 | Prepare ear longitudinal member (2.1), lower rear longitudinal member (2.3), rear longitudinal member end plate (2.4) and rear rear-end floor (3) | Round wire brush |
AR64.20-P-1260-02LF |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 13 | Prepare C-pillar strut (5) on outer C-pillar for installation | Model 222 with code Z07 (B7 armoring on special protection version) Round wire brush |
AR63.20-P-0500-08LFS |
| 14 | Prepare reinforcement (6) on inner C-pillar side wall for installation | Model 222 with code Z07 (B7 armoring on special protection version) | AR63.10-P-0700-07LFS |
Round wire brush |
|||
| 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 | |
| Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes | Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only. | AS00.00-Z-0016-01A | |
| 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 | ||
| 15 | Install rear longitudinal member (2.1), lower rear longitudinal member (2.3), rear longitudinal member end plate (2.4) and rear rear-end floor (3) | ||
| WS60.00-P-0010B | |||
| AR64.20-P-1260-03LF | |||
| 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 Spot welder Wet/dry vacuum cleaner |
WS60.00-P-0023K | |
| Adhesive kit, body, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Blind rivet Y2 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A | ||
| 16 | Install rear outer wheel well (7) | Model 217.3 Model 222 except code Z07 (B7 armoring on special protection version) |
AR63.10-P-0665LF |
| 17.1 | Install reinforcement (6) from inner C-pillar side wall | Model 222 except code Z07 (B7 armoring on special protection version) | AR63.10-P-0700LF |
| 17.2 | Install reinforcement (6) from inner C-pillar side wall | Model 222 with code Z07 (B7 armoring on special protection version) | AR63.10-P-0700-08LFS |
Round wire brush Manual temporary fastener, 6.35 mm Wet/dry vacuum cleaner |
WS60.00-P-0010B | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Blind rivet with polygrip countersunk head 6.4 X14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN) | *BR00.45-Z-1002-13A | ||
| 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 | ||
| 18.1 | Install C-pillar strut (5) on outer C-pillar | Model 217.3 | AR63.20-P-0500LC |
| 18.2 | Install C-pillar strut (5) on outer C-pillar | Model 222 except code Z07 (B7 armoring on special protection version) | AR63.20-P-0500LF |
| 18.3 | Install C-pillar strut (5) on outer C-pillar | Model 222 with code Z07 (B7 armoring on special protection version) | AR63.20-P-0500-09LFS |
Round wire brush Manual temporary fastener, 6.35 mm Spot welder Wet/dry vacuum cleaner |
WS60.00-P-0010B | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Blind rivet with polygrip countersunk head 6.4 X14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN) | *BR00.45-Z-1002-13A | ||
| 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 | ||
| 19 | Install rear fender (4) | Model 217.3 | AR63.50-P-1400LC |
| Model 222 | AR63.50-P-1400LF | ||
| 20 | Install bottom rear center section (1.1) with rear crossmember (1.2) | AR64.20-P-1060LF | |
| 21 | Release vehicle from straightening bench, lift vehicle and remove straightening bench | ||
| 22 | 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-1002-13A | Blind rivet with polygrip countersunk head 6.4X14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN) | A 003 990 86 97 05 |
| 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-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-1092-02A | Adhesive kit, body, 2-component adhesive | A 012 989 17 71 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |