Body - Casing Bumper Rear, Replacing
Section8
Group
86
No.
0013
Year
03
Month
05
Reference: This edition replaces previous SB 860013 dated september 2002. A clarification has been added in stage 6 regarding treatment using rustproofing agent.
Casing bumper rear, replacing
Background:
New bumper casings will not fit vehicles up to chassis number -244447 unless modification is carried out on the body according to the following method
Affected vehicles
Model Factory Chassis No.
S80 1 - 244447
Materials
Description Quantity Part No.
Bracket (Right) 1 8659497
Bracket (Left) 1 8659496
Screw Torx M5x20 4 969407
Washer MS 4 960138
Joint protection tape 1 9128331
Cavity protection (low viscosity) 1381065
Underbody protection (high viscosity) 1381063
Tools Required
Rivet Gun and MS rivet nuts
Bumper with mounting and damping
Casing bumper rear, replacing
1
Preparation
Remove the bumper see VADIS.
2
Remove the RTI/CD player (if applicable.)
Lift out the rear electrical unit. Start by pressing up on the catch (1).
Angle out the electrical unit and unhook it from the body mountings (2).
Push the electrical unit to one side so that it is free from the body mountings.
Release the clip for the cable harness holder
3
Remove the soundproofing.
Clean the surfaces around the air evacuation hole
4
Modifing the template
Note! The shown illustrations A and B is a reduction in size of aftached templates.
Left Side. The arrow points forward (A).
Make sure the distance (C) measures 134 mm.
Cut according to attached templates A and B.
Right Side. The arrow points forward (B). Make sure the distance (C) measures 134 mm.
5
Making holes
Tape the template for making holes into place by placing it against the air evacuation hole. When taping ensure that the template follows the profile of the panel (1).
Mark the holes using a center punch.
Note! Check that the cable harness have been moved away from the area behind
First drill using 3mm (1/8") drill bit.
Enlarge using 7mm (17/64") drill bit.
Smooth off any sharp edges.
Carefully sand down the inside and outside of the hole.
Rust-proof both the inside and outside of the hole using low viscosity rustproofing agent.
6
Installing brackets
Install the M5 rivet nuts (2 per side) using a rivet gun.
Note! Install the M5 screws in the rivet nuts. Apply low viscosity rustproofing agent to the screws.
Note! Remove the M5 screws.
Install the brackets using screws and washers from the kit.
Tighten the screws to 5 Nm.
Install the joint protection tape on the rivet nut which protrudes under the electrical unit.
7
Finishing
Reinstall:
- the soundproofing
- the electrical unit
- the clip for the cable harness holder
- the RTI/CD player (if applicable).
Install the bumper.
Templates A and B for Service Bulletin 860013
