Remove/install end plate

AR64.20-D-5731F

Remove/install end plate

14.05.2019

Model

909

1

End panel

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



Remove

1

Remove spare tire

2

Remove trailer coupling

Model 909.6
with code QA8 (Trailer hitch for increased towing capacity 2.8 t/3.0 t)

AR31.10-D-8000F

3

Remove rear bumper

AR88.20-D-2200F

4

Remove rear door step

Model 909
with code W73 (Rear door step)

AR88.30-D-8832F

5

Remove cover rail on wooden floor

Model 909.6
with code V43 (Wood flooring)

6

Remove rear wooden floor

Model 909.6
with code V43 (Wood flooring)

7

Remove rear doors

AR72.20-D-1901FA

8

Remove door seal

9

Remove all electrical lines from repair area and cover with spark protection blanket

10

Remove all detachable parts in repair area

11

Cover all detachable parts remaining on vehicle with spark protection blanket

12

Separate end plate (1)

AR64.20-D-5731-01F

Work instructions for cutting

AR64.20-D-0002F

 Spot weld milling cutter

*201589005100



Install

13

Straighten connecting plates, grind down to bare metal and coat with zinc dust paint

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

14

Prepare connection panel (1) for installation

AR64.20-D-5731-02F

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 plate (1)

AR64.20-D-5731-03F

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

Remove spark protection blankets

18

Clean cavities


Thoroughly clean cavities.
Otherwise metal shavings and other metallic grinding dust can cause corrosion damage.

 Danger

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 protective skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

19

Clean areas repaired and priming with MB primer filler

 Use only primer filler approved by Daimler AG:
http://aftersales.mercedes-benz.com

20

Supplement standard seals with MB body sealant

AR97.10-D-4000F

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

21

Supplement standard underfloor protection with MB permanent underbody sealant

 Danger

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 protective skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

22

Paint repair area adjacent surfaces

 Use only paints approved by Daimler AG
http://aftersales.mercedes-benz.com

23

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

AR64.20-D-5731-04F

 Perform step to ensure that no exhaust gases get into the passenger compartment through the openings in the rear panel while driving.

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

*BR00.45-Z-1032-01A

24

Add cavity preserving agent

AR97.20-D-1500F

25

Reinstall all detachable parts removed from repair area

26

Reinstall all electrical lines removed from repair area

27

Install door seal

28

Install rear doors

AR72.20-D-1901FA

29

Install rear wooden floor

Model 909.6
with code V43 (Wood flooring)

30

Install cover rail for wooden floor

Model 909.6
with code V43 (Wood flooring)

31

Install rear door step

Model 909
with code W73 (Rear door step)

AR88.30-D-8832F

32

Install rear bumper

AR88.20-D-2200F

33

Install trailer coupling

Model 909
with code QA8 (Trailer hitch for increased towing capacity 2.8 t/3.0 t)

34

Install spare tire

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)