Disassemble/assemble rear-end door (left door wing)

AR72.20-D-2401D

Disassemble/assemble rear-end door (left door wing)

22.12.2016

Model

903.612/613

with code PG3 (Integral box-body with shelving)

Model

903.612/613

with code PG4 (Integral box body without fitted shelving)

Model

903.612/613

with code Z22 (Post freight delivery service)

Model

903.612

with code PG5 (Integral box body UPS)

Model

906.135

with code PZ0 (Package delivery vehicle, integral box body DP DHL)

Modification notes

16.07.2012

Notes on modified locking pin and retrofitting on model 906.135 inserted

Operation step 2

Shown on model 903

1

Rear window (not on model 906.135 with code (PZ0) Package delivery vehicle, integral box body DP DHL)

4

Rear-end door

7

Lock linkage

2

Bracket

5

Lock

8

Rubber stopper

3

Inner actuation

6

Channel

9

Closing wedge

 

Disassemble/assemble

 Danger !

Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.

No parts of the body or limbs should be within the operating area when the components are moving.

AS00.00-Z-0011-01A



General information on riveting

AH60.00-P-0003-01N

1

Remove rear window (1)

Model 903.612/613
with code PG3 (Integral box-body with shelving)
Model 903.612/613
with code PG4 (Integral box body without fitted shelving)
Model 903.612/613
with code Z22 (Post freight delivery service)

AR67.20-D-5145D

 New rear-end door (4) is only delivery with rear window (1) installed.

2

Remove bracket (2)



Lock striker on rear-end door modified

Model 906.135
with code PZ0 (Package delivery vehicle, integral box body DP DHL)

BT72.20-D-1031-01A

 Installation: Insert bolts for bracket mount with thread locking agent.

Thread locking agent, Loctite 243 (10 ml)

*BR00.45-Z-1133-02A

If the locking pin is still the old version, retrofit to new version when installing.





Upgrade lock striker of rear-end door to new version
Model 906.135 up to 7/31/12
with code PZ0 (Package delivery vehicle, integral box body DP DHL)

SM72.20-D-0002A

3

Remove inside door handle (3)

4

Remove rear-end door (4) and left door wing

Model 903.612/613
with code PG3 (Integral box-body with shelving)
Model 903.612/613
with code PG4 (Integral box body without fitted shelving)
Model 903.612/613
with code Z22 (Post freight delivery service)
Model 903.612
with code PG5 (Integral box body UPS)

AR72.20-D-1901D

Model 906.135
with code PZ0 (Package delivery vehicle, integral box body DP DHL)

AR72.20-D-1901G

5

Remove locks (5)

6

Open ducts (6) for lock linkages (7)

7

Remove lock linkages (7)

8

Drill out rivets for ducts (6)

9

Remove ducts (6)

10

Remove stop rubber (8)

 Model 906.135
with code PZ0 (Package delivery vehicle, integral box body DP DHL)Bolt, door catch to rear-end door

*BA72.20-N-1003-01A

11

Remove closing wedge (9)

12

Remove rubber seal at bottom and in center of rear-end door (4)

13

Assemble in the reverse order

 Installation: Blind rivet tool

 Rear-end door

Number

Designation

Model 906.135
with code PZ0 (Package delivery vehicle, integral box body DP DHL)

BA72.20-N-1003-01A

Bolt, door catch to rear-end door

Nm

2

Repair materials

Number

Designation

Order number

BR00.45-Z-1133-02A

Thread locking agent, Loctite 243 (10 ml)

A 613 989 09 71 09