Remove/install end plate

AR64.20-D-5731A

Remove/install end plate

14.05.2019

Model

690.63/64

Model

901.06/36/37/46/66/67, 902.06/07/36/37/46/47/66/67, 903.06/07/36/37/46/47/66/67, 904.06/36/46/66

1

End piece



Remove

 Warning

Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units.

Store airbag units with deployment side facing up; do not expose to temperatures greater than 100 °C. When working on these units, disconnect the power supply.

AS91.00-Z-0001-01D

Topical note

Notes on performing repair, body work and welding on vehicles with airbags and RTE units

AH91.00-P-0002-01M

Topical note

General information on body repair

AH60.00-N-0001-01A

1

Remove trailer coupling

Only for vehicles with trailer coupling.

2

Remove spare tire

3

Remove rear bumper

AR88.20-D-2200A

4

Remove rear door step

AR88.30-D-8832A

 Only with code W73, rear-end door step

5

Remove cover rail on wooden floor

6

Remove rear wooden floor

7

Remove rear doors

AR72.20-D-1901A

8

Remove door seal

9

Remove electric lines from the repair area and cover

10

Remove other detachable parts in repair area

11

Cover all detachable body components that remain in the area to be repaired

12

Cut off end piece (1)

AR64.20-D-5731-01A

AR64.20-D-0002A

 Cut spot welds.

 Spot weld milling cutter

*201589005100



Install

13

Align, grind off connecting plates and coat with zinc dust paint

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

14

Prepare end piece (1) for installation

AR64.20-D-5731-02A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

 Danger

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

15

Weld in end piece (1)

AR64.20-D-5731-03A

Topical note

Measures for preventing damage to vehicles or components when performing electric welding work

AH00.00-N-0005-01A

General notes on welding

AH60.00-N-0005-01A

16

Grind off any residue welding material

17

Vacuum out hollow cavities


Metal shavings and/or metallic grinding dust in cavities
can lead to corrosion damage.

18

Clean areas repaired and priming with MB primer filler

19

Supplement standard seals with MB body sealant

AR97.10-D-4000A

 Seam seals after repairs

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

20

Supplement standard underfloor protection with MB permanent underbody sealant

21

Paint repair area adjacent surfaces

22

Seal right and left hollow cavities in the end piece (1) with assembly foam

AR64.20-D-5731-04A

 Perform operation step to ensure that, exhaust can get into the vehicle interior via the openings in the rear panel during operating status.

Installation foam, e.g.: Ceresit TS31 500 ml

*BR00.45-Z-1032-01A

23

Add cavity preserving agent

24

Install rear doors

AR72.20-D-1901A

25

Install rear wooden floor

26

Install door seal

27

Install cover rail for wooden floor

28

Tie electric lines to the body

29

Install rear door step

AR88.30-D-8832A

 Only with code W73, rear-end door step.

30

Install rear bumper

AR88.20-D-2200A

31

Install trailer coupling

Only for vehicles with trailer coupling.

32

Install spare tire

33

Reinstall other detachable parts

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-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1032-01A

Installation foam, e.g.: Ceresit TS31 500 ml

Freely available
(Manufacturer Henkel)