Remove/install taillamp reinforcement

AR63.20-L-2011VA

Remove/install taillamp reinforcement

11.6.01



Remove

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

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.

AS00.00-Z-0017-01A



General information on repairs to body

All models

AH60.00-N-0001-01A



Guidelines for removing fuel tank when performing welding work on bodies

All models

AH60.00-P-3000-01Z



General information on riveting

AH60.00-P-0003-01N

1

Remove attached parts in rear area

2

Remove detachable parts in vehicle interior (area to be repaired)

3

Cover all attached parts remaining in vehicle (area to be repaired)

*WH58.30-Z-1001-40A

4

Separate taillamp reinforcement

AR63.20-L-2011-01VA

 Spot weld milling cutter

*201589005100

 Vario Drill WS 91 spot weld removing tool

*WH58.30-Z-1006-01A

 Ball cutter, 12 mm

*WH58.30-Z-1002-01A

 Round wire brush, braided,  70 mm

*WH58.30-Z-1001-03A

 Abrasive disk,  115 mm, 80 m/s (max.

*WH58.30-Z-1024-04A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Tarpaulin (fire-resistant)

*WH58.30-Z-1001-40A

Two-post lift

*WE58.40-Z-1001-05A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

5

Prepare taillamp reinforcement

AR63.20-L-2011-02VA

 Spot weld milling cutter

*201589005100

 Round wire brush, braided,  70 mm

*WH58.30-Z-1001-03A

 Abrasive disk,  115 mm, 80 m/s (max.

*WH58.30-Z-1024-04A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Tarpaulin (fire-resistant)

*WH58.30-Z-1001-40A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

6

Set up Celette or Car-Bench straightening bench with modular and cross members

Observe enclosed setup plans!

7

Set up Celette or Car-Bench straightening set

Observe enclosed setup plans!

8

Set vehicle onto straightening bench using two-column lift and fasten



Install

 Danger!

Risk of death caused by high voltage used for arc welding. Risk of explosion caused by welding in the area of highly inflammable materials. Injury hazard from welding spatter and UV-light while welding. Risk of poisoning caused by inhaling welding vapors.

Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor.

AS00.00-Z-0007-01A

9

Install and weld in taillamp reinforcement

AR63.20-L-2011-03VA

Polygrip aluminum/steel countersunk head rivets

dia. 4  10 mm

 Test and welding jig

*414589032300

 Test and welding device

*414589042300

 Round wire brush, braided,  70 mm

*WH58.30-Z-1001-03A

 Abrasive disk,  115 mm, 80 m/s, (max. 13,250 rpm)

*WH58.30-Z-1024-04A

 Clamps

*WH58.30-Z-1031-02A

 Clamping pliers

*WH58.30-Z-1003-02A

 Pop rivet with locking thread, dia. 4.0 mm - clamping range 0-6 mm, identification color yellow

*WH58.30-Z-1036-02A

 Pop rivet gun, model HN 1

*WH58.30-Z-1001-29A

 Electrode miller

*WH58.30-Z-1003-01A

Celette straightening bench M8S

*WE58.40-Z-1001-01E

Celette straightening unit C8S

*WE58.40-Z-1002-01E

Set of Celette modular members 955.940

*WE58.40-Z-1007-01E

Celette additional member 955.908

*WE58.40-Z-1008-01E

Celette straightening bench MT 10, (without old hole pattern, model 123 cannot be repaired)

*WE58.40-Z-1001-01E

Car-Bench straightening bench BT 17

*WE58.40-Z-1003-01E

Car-Bench alignment and lifting platform CB 41

*WE58.40-Z-1004-01E

Car-Bench straightening unit PT 13

*WE58.40-Z-1005-01E

Car-Bench universal cross member set A 296/15 (all cross members 1500 mm long)

*WE58.40-Z-1011-01E

Car-Bench straightening bracket set 82 423 (for model 168, 414)

*WE58.40-Z-1011-01A

Celette straightening bracket set 7168.300 (for model 168, 414)

*WE58.40-Z-1010-01A

Celette straightening set 7414.300 (for model 414)

*WE58.40-Z-1043-01A

Celette 7414.309 supplementary straightening set for Celette straightening bracket set 7168.300 (for model 414)

*WE58.40-Z-1043-01A

Car-Bench 82444 supplementary straightening set for Car-Bench straightening bracket set 82 423 (for model 414)

*WE58.40-Z-1043-01A

Spot welder

*WE58.40-Z-1002-02A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Inert gas welder

*WE58.40-Z-1001-02A

Tarpaulin (fire-resistant)

*WH58.30-Z-1001-40A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

Two-post lift

*WE58.40-Z-1001-05A



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

All models

AH00.00-N-0005-01A

10

Detach vehicle from straightening bench and lift with two column lift. Remove straightening bench.

11

Adjust gap dimensions on hoods, doors and lids

AR60.00-L-0700-01VA

 Feeler gauge

*129589032100

12

Clean welds and metal flanges with wire brush. Clean repair areas

13

Prime repaired area with MB-2K priming filler



Notes on paintwork repairs

Model 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463

AH98.00-P-9408-02A

14

Supplement standard seals with MB body sealant

Seam sealing after repairs

AR97.10-L-4000VA



General information on MB materials

All models

AH98.00-P-9409-03A

15

Supplement standard underbody protection with MB permanent underbody sealant

Permanent underfloor protection

AR97.20-P-0500-03A



General information on MB materials

All models

AH98.00-P-9409-03A

16

Paint taillamp reinforcement and adjacent surfaces



Notes on paintwork repairs

Model 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463

AH98.00-P-9408-02A

17

Apply additional cavity preservation



Preservation

AP97.20-P-0640A

18

Reinstall all removed assembly parts

 Seal body joints with aluminum adhesive tape TYPE 3M no. 425 in area of the rear portal seal.

Number

Designation

WH58.30-Z-1002-01A

Ball cutter, dia. 12 mm

WH58.30-Z-1003-01A

Electrode miller

WH58.30-Z-1006-01A

Vario Drill WS 91 spot weld removing tool

WH58.30-Z-1003-02A

Clamping pliers

WH58.30-Z-1031-02A

C-clamp

WH58.30-Z-1036-02A

Manual temporary fastener, 4.0 mm - span range 0...6mm, identification color yellow,

Firma Hausmann GmbH D-34346 Hann. Münden, Germany

WH58.30-Z-1001-03A

Round wire brush, braided, dia. 70 mm

WH58.30-Z-1024-04A

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

WH58.30-Z-1001-29A

Lever riveting device

WH58.30-Z-1001-40A

Tarp (fire-resistant)

WE58.40-Z-1010-01A

Celette straightening bracket set 7168.300 (model 168, model 414)

WE58.40-Z-1011-01A

Car-Bench straightening bracket set 82 423 (model 168, model 414)

WE58.40-Z-1040-01A

Celette 7414.309 supplementary straightening set for Celette straightening bracket set 7168.300 (model 414)

WE58.40-Z-1043-01A

Celette straightening set 7414.300 (model 414)

WE58.40-Z-1044-01A

Car-Bench 82444 supplementary straightening set for Car Bench straightening bracket set 82 423 (model 414)

WE58.40-Z-1001-01E

Celette straightening bench

WE58.40-Z-1002-01E

Celette straightening unit

WE58.40-Z-1003-01E

Car-Bench straightening bench

WE58.40-Z-1004-01E

Car-Bench straightening lifting platform

WE58.40-Z-1005-01E

Car-Bench straightening equipment

WE58.40-Z-1007-01E

Celette module crossmember set 955.940

WE58.40-Z-1008-01E

Celette additional member 955.908

WE58.40-Z-1011-01E

Car-Bench Universal crossmember set A 296/15 (all crossmembers 1500 mm long)

WE58.40-Z-1001-02A

Inert gas welder

WE58.40-Z-1002-02A

Spot welder

WE58.40-Z-1001-03A

Drill (electric/pneumatic)

WE58.40-Z-1005-03A

Wet/dry vacuum cleaner

WE58.40-Z-1001-05A

Two-post lifting platform

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42