Partially replace rear fender - AR63.50-P-1450RK
MODEL 231
| Removing | |||
| Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding splatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. | Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. | AS00.00-Z-0007-01A | |
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. | AS00.00-Z-0010-01A | |
| 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 | |
| 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 | |
| Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust | Wear protective respiratory mask, protective gloves and safety glasses. Use suitable, grounded vacuum cleaner |
AS60.00-Z-0007-01N | |
| Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | ||
| General information on body repair | AH60.00-P-0001-01A | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| General information on crack diagnosis of aluminum parts | AH60.00-P-0014-01N | ||
| General notes on welding | AH60.00-P-0005-01N | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| Note for working on aluminum components and vehicles | Body and aluminum workplace | AH60.00-P-0034-01SL | |
| 1 | Remove detachable parts in area to be repaired | ||
| 2 | Cover all detachable parts remaining on vehicle with spark protection blanket | ||
| 3 | Partially remove rear fender (1) | Hot air gun Safety vacuum cleaner, dust class B1 Riveter for self-piercing and flow-form rivets |
AR63.50-P-1450-01RK |
| Recycle aluminum parts | OS60.00-P-0001-01N | ||
| 4 | Prepare partial rear fender (1) | Hot air gun Safety vacuum cleaner, dust class B1 |
AR63.50-P-1450-02RK |
| Install | |||
| 5 | Install partial rear fender (1) | AR63.50-P-1450-03RK | |
| Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01RK | ||
| Front door to longitudinal member panel | *BE60.00-P-1011-01AB | ||
| Front door to rear fender | *BE60.00-P-1013-01AB | ||
| Trunk lid to fender | *BE60.00-P-1018-01AB | ||
| Taillamp to fender | *BE60.00-P-1021-01AB | ||
| Figure | |||
Stainless steel round brush Riveter for self-piercing and flow-form rivets Blind rivet holes with draw-off strength of 19 kN MIG/MAG aluminum welder Safety vacuum cleaner, dust class B1 |
Figure | ||
| White sealing compound, 310 ml, DBL 6069.20 | *BR00.45-Z-1003-01A | ||
| Adhesive kit, body, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| Blind rivet 6.4 14 | *BR00.45-Z-1001-13A | ||
| Blind rivet 4.8X8 | *BR00.45-Z-1008-13A | ||
| Flow-form rivet 3.35 mm up to 4.1 mm clamping range (A2) | *BR00.45-Z-1024-13A | ||
| 6 | Adjust gap dimensions on front door, trunk lid and taillamp | AR60.00-P-0700-01RK | |
| Front door to longitudinal member panel | *BE60.00-P-1011-01AB | ||
| Front door to rear fender | *BE60.00-P-1013-01AB | ||
| Trunk lid to fender | *BE60.00-P-1018-01AB | ||
| Taillamp to fender | *BE60.00-P-1021-01AB | ||
| Figure | |||
| 7 | Clean weld joints and sheet metal flanges with rotary wire brush | ||
| 8 | Remove spark protection blankets | ||
| 9 | Clean repair area | Safety vacuum cleaner, dust class B1 | |
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 10 | Prime repair area using primer filler | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 11 | Carry out seam sealing after repairs | AR97.10-P-4000RK | |
| White sealing compound, 310 ml, DBL 6069.20 | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 12 | Paint repair areas and adjacent surfaces | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 13 | Apply additional cavity preservation | AR97.20-P-1500RK | |
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Preservation agent for cavities and engine compartment 1 l | *BR00.45-Z-1003-05A | ||
| 14 | Install all detachable body components in area to be repaired |
TEST AND ADJUSTMENT VALUES
| Number | Designation | Model 231 | |||
|---|---|---|---|---|---|
| BE60.00-P-1011-01AB | Gap dimension | Front door to longitudinal member panel | Dimension "K" | mm | 5.0 (±1) |
| BE60.00-P-1013-01AB | Gap dimension | Front door to fender at the rear | Dimension "M" | mm | 4.0 (±0.5) |
| BE60.00-P-1018-01AB | Gap dimension | Trunk lid to fender | Dimension "R" | mm | 4.5 (±1) |
| BE60.00-P-1021-01AB | Gap dimension | Taillamp to fender | Dimension "U" | mm | 1.5 (±0.5) |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | White sealing compound, 310 ml, DBL 6069.20 | A 001 989 63 20 |
| BR00.45-Z-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 20 |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |
| BR00.45-Z-1003-05A | Cavity sealant, solvent-free (1 l container) | A 000 986 72 70 05 |
| BR00.45-Z-1001-13A | Blind rivet 6.4 14 | A 003 990 35 97 |
| BR00.45-Z-1008-13A | Blind rivet, power window at left door 4.8X8 | A 003 990 24 97 |
| BR00.45-Z-1024-13A | Flow-form rivet 3.35 mm up to 4.1 mm clamping range (A2) | A 000 991 08 33 |