Rear Lamp Reinforcement Installation - Ar63.20-P-2011-04S

	000 588 04 39 00 Rivet press tool		WS60.00-P-0440B
	000 588 03 39 00 Rivet die		WS60.00-P-0386K

Model 223.0/1/9 

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Countersunk-head rivet (Z) 

• Z₁ = countersunk-head rivet 6.4x14.0
• Z₂ = countersunk-head rivet 6.4x15.5
• Z₃ = countersunk-head rivet 6.4x17.0
• Z₄ = countersunk-head rivet 6.4x19.0
• Z₅ = countersunk-head rivet 6.4x21.0

Blind rivet (Y) 

• Y₁ = rivet 6.4x12.0
• Y₂ = rivet 6.5x12.5
• Y₃ = rivet 6.5x14.5
• Y₄ = Rivet 6.4M6
• Y₅ = Rivet 6.4
• Y₆ = rivet 6.5x13.5
• Y₇ = rivet 6.4x14.0
• Y₈ = rivet 6.4x17.0
• Y₉ = rivet 6.4x20

Flow-form rivet with countersunk head (X) 

• X₁ = Flow-form rivet with countersunk head 1.3 mm to 2.5 mm clamping range
• X₂ = Flow-form rivet with countersunk head 2.3 mm to 3.5 mm clamping range
• X₃ = Flow-form rivet with countersunk head 3.35 mm to 4.1 mm clamping range
• X₄ = Flow-form rivet with countersunk head 4 mm to 5.15 mm clamping range
• X₅ = Flow-form rivet with countersunk head 5.0 mm to 6.1 mm clamping range
• X₆ = Flow-form rivet with countersunk head 6.0 mm to 7.2 mm clamping range
• X₇ = Flow-form rivet with countersunk head 7.1 mm to 8.3 mm clamping range

Flow-form rivet (W) 

• W₁ = Flow-form rivet structure with 3.5 mm clamping range
• W₃ = Flow-form rivet structure 3.35 mm up to 4.1 mm clamping range
• W₄ = Flow-form rivet structure 4 mm up to 5.15 mm clamping range
• W₅ = Flow-form rivet structure 5.0 mm up to 6.1 mm clamping range
• W₆ = Flow-form rivet structure 6.0 mm up to 7.2 mm clamping range
• W₇ = Flow-form rivet structure 7.1 mm up to 8.3 mm clamping range

Blind rivet (V) 

• V₁ = rivet 3.2x4.5
• V₂ = rivet 3.2x6.5

Blind rivet (U) 

• U₁ = rivet 3.2x9.5

Blind rivet with countersunk head (T) 

• T₁ = blind rivet with countersunk head 3.0 mm to 5.0 mm clamping range
• T₂ = blind rivet with countersunk head 1.5 mm to 3.0 mm clamping range

The following steps are shown on model 223.1 on the left side of the vehicle and must be similarly performed on the right side of the vehicle in the event of damage.

The superordinate service document as well as the safety information in the service document must be observed.

The graphics show the vehicle from the mechanic's perspective. At the same time, this perspective also specifies the direction in which the rivets must be placed.

1. Install rear lamp reinforcement (1), fit and fix in place.
2. Drill rivet holes in rear lamp reinforcement (1) with Ø 6.7 mm bit (areas A₁ , A₂ , A₄ ).
3. Drill rivet holes in rear lamp reinforcement (1) with Ø 4.1 mm bit (area A₃ ).
4. Countersink rivet holes in rear lamp reinforcement (1) (areas A₁ , A₄ ).
5. Punch rivet holes in rear lamp reinforcement (1) with Ø 6.0 mm bit using a rivet press tool (areas B).
6. Remove rear lamp reinforcement (1).
7. Deburr rivet holes on rear lamp reinforcement (1) and body on both sides.
8. Remove drilling chips.

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9. Apply 2-component adhesive to body in cross-hatched areas.

   Apply 2-component adhesive to inside of body (area C).

   Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

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10. Install rear lamp reinforcement (1) and fix in place.
11. Rivet rear lamp reinforcement (1) with countersunk-head rivets Ø 6.4x14.0 (areas Z₁ ).
12. Rivet rear lamp reinforcement (1) with countersunk-head rivets Ø 6.4x15.5 (areas Z₂ ).
13. Rivet rear lamp reinforcement (1) with countersunk-head rivets Ø 6.4x17.0 (areas Z₃ ).
14. Rivet rear lamp reinforcement (1) with structured flow-form rivets with 3.5 mm clamping range (areas W₁ ).
15. Rivet rear lamp reinforcement (1) with rivets Ø 6.5x13.5 (area Y₆ ).

    Courtesy of MERCEDES-BENZ USA