Replace top rear center section

AR64.20-P-1040QA

Replace top rear center section

21.10.11



Removing

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.

Deburr repair panels.

AS00.00-Z-0017-01A

 Danger!

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



General information on body repair

All models

AH60.00-N-0001-01A



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

All models

AH00.00-N-0005-01A



Notes on paintwork repairs

All models

AH98.00-P-9408-02A



General information on MB materials

All models

AH98.00-P-9409-03A

1

Remove detachable parts in area to be repaired

2

Cover all detachable body components remaining in vehicle (area to be repaired)

Tarp (fire-resistant)

3

Equip straightening bench with modular or crossmembers and straightening tools

 Observe set-up plans enclosed!

Straightening systems for passenger cars (Celette)
gotis://K_60-65_02.0

Straightening systems for passenger cars (Car Bench)
gotis://K_60-65_03.0

4

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

Two-post lifting platform 3.0-3.5 t, electromechanical
gotis://H_00.1_01.0

5

Set up rear portal frame with welding devices

 Observe set-up plans enclosed!

 Portal frame

*129589032300

 Multi-Z element MZ 260

*140589262300

 When mounting rear portal frame, use additional set of Multi-Z elements MZ 260.

 Welding devices

*209589052300

6

Remove top rear center section

AR64.20-P-1060-09QA

 Welding spot miller cutter

*201589005100

Ball cutter, 12 mm dia.

Hard metal ball cutter
gotis://K_58.3_07.0

Round wire brush, braided, dia. 70 mm

Vario Drill WS 91 spot weld removing tool

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

Drill
gotis://K_58.1_04.0

Straight grinder
gotis://K_58.0_03.0

Angle grinder
gotis://K_58.1_07.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

7

Prepare upper rear center section for installation

AR64.20-P-1000-06QA

Round wire brush, braided, dia. 70 mm

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

Drill
gotis://K_58.1_04.0

Angle grinder
gotis://K_58.1_07.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

8

Install upper rear center section

AR64.20-P-1060-08QA

 Portal frame

*129589032300

 Welding devices

*209589052300

Electrode miller

Clamping pliers

Blind rivet nut hand tool

Blind rivet/punch riveting method
gotis://K_68-80_06.0

Inert gas welder (steel, brazing, aluminum)
gotis://K_60-65_17

Spot welder

Inverter spot welder
gotis://K_60-65_16.0

Drill
gotis://K_58.1_04.0

Cavity preservation gun Sata HRS no. 11072

Combination pressure spray gun (corrosion protection)
gotis://K_91-97_01.0

Sealant

*BR00.45-Z-1003-01A

MB preservative

*BR00.45-Z-1003-05A

9

Clean repair areas and prime using primer filler

10

Seam sealing following repair

 Supplement standard sealant using MB preservative.

Sealant

*BR00.45-Z-1003-01A

11

Paint repair areas and adjacent surfaces

12

Release vehicle from straightening bench and lift with two-column lift, remove straightening bench

Two-post lifting platform 3.0-3.5 t, electromechanical
gotis://H_00.1_01.0

13

Cavity preservation following repair work



Notes on cavity preservation

Model 209

AH97.20-P-0001-01B

14

Install all removed detachable parts

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-1003-05A

Cavity sealant, solvent-free (1 l container)

A 000 986 72 70 05

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42