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Home >> Mercedes Benz >> 2002 >> C230 Standard >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Rear Wall & Rear End >> Testing & Repair >> Left side rear end damage - AR64.20-P-1200PA

Left side rear end damage - AR64.20-P-1200PA

MODEL 203.2 

Fig 1: Identifying Left Side Rear End Damage Components (Model 203.2)
G04735241
REMOVING 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 vehicle slipping or toppling off of the lifting platform. Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
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 spatter 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
DANGER Risk of explosion  as fuel vapors can ignite. Risk of poisoning  from inhaling fuel vapors and exposed handling of fuel. Risk of injury  if fuel splashes hit the eyes. No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.
Wear protective clothing when handling fuel.		 AS47.00-Z-0001-01A
NOTES General information on repairs to body All models AH60.00-N-0001-01A
NOTES Measures for preventing damage to vehicles or components when performing electric welding work All models AH00.00-N-0005-01A
NOTES Guidelines for removing fuel tank when performing welding on bodies   AH60.00-P-3000-01Z
IMPORTANT Notes on paintwork repairs   AH98.00-P-9408-02A
IMPORTANT General information on MB materials   AH98.00-P-9409-03A
1.1 Install filler neck covering When replacing right rear fender. AR63.50-P-1400-01P
2 Remove detachable parts in repair point    
3 Cover all detachable parts remaining in vehicle (repair area) Tarp (fire-resistant)  
4 Equip straightening bench with module members or crossmembers and straightening bracket set IMPORTANT Observe assembly plans provided
Celette straightening benchM8S,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Celette straightening bench Sevenne,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Set of Celette module members 955.940,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Celette auxiliary member 955.908,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Celette straightening bracket set 7203.300 (for model 203),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Car-Bench straightening bench BT 17,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Car-Bench straightening bench BT 43/1,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Celette straightening bracket set 7203.309 (for model 203), as supplement to 7203.300,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Celette straightening bracket set 7203.310 (for model 203), only for new orders includes supplement 7203.309,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Celette 7203.308 supplementary straightening set for Celette straightening bracket set 7203.310 (for model 203 4MATIC),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Car-Bench universal crossmember set
A 296,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Car-Bench straightening bracket set 82434 (for model 203),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Car-Bench 82445 supplementary straightening set for Car-Bench straightening bracket set 82434 (for model 203 4MATIC),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Multi-Z straightening set system MZ 450.000,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
5 Set vehicle onto straightening bench using two post lift and fasten Two-post lift,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
6 Remove rear fender   AR63.50-P-1400PA
7 Remove rear end assembly   AR64.20-P-1020PA 
8 Remove spare tire well Except CODE (550) Trailer hitch AR88.30-P-1000P
    With CODE (550) Trailer hitch AR88.30-P-1000PP
9 Remove longitudinal member at rear   AR64.20-P-1200-22P 
    SPECIAL TOOL Spot weld milling cutter Figure
    Ball cutter, ø 12 mm
Vario Drill WS 91 spot weld removing tool
Round wire brush, braided, ø 70 mm
Abrasive disk, ø 115 mm, 80 m/s (max. 13,250 rpm)
Cutting disk, ø 65 mm, 80 m/s (max. 23.500 rpm)
Drill (electric/pneumatic),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Straight grinder (electric/pneumatic),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Angle grinder (electric/pneumatic),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Wet/dry vacuum cleaner,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
10 Separate D-pillar side wall   AR63.10-P-0800-07PA
    SPECIAL TOOL Spot weld milling cutter Figure
    Vario Drill WS 91 spot weld removing tool Round wire brush, braided, ø 70 mm
Abrasive disk, ø 115 mm, 80 m/s (max. 13,250 rpm)
Drill (electric/pneumatic),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Body saw (electric/pneumatic),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Wet/dry vacuum cleaner,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Angle grinder (electric/pneumatic),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
11 Prepare D-pillar side wall for installation   AR63.10-P-0800-08PA
    Round wire brush, braided, ø 70 mm,
Drill (electric/pneumatic),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Body saw (electric/pneumatic),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
12 Prepare rear longitudinal member for installation   AR64.20-P-1200-23P 
    Round wire brush, braided, ø 70 mm
Drill (electric/pneumatic),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install     
13 Install rear longitudinal member   AR64.20-P-1200-24P 
    Electrode miller
Round wire brush, braided, ø 70 mm
Abrasive disk, ø 115 mm, 80 m/s (max. 13,250 rpm)
Clamping pliers
Insert gas welder,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Spot welder,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Drill (electric/pneumatic),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Angle grinder (electric/pneumatic),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Wet/dry vacuum cleaner,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
14 Install D-pillar side wall   AR63.10-P-0800-05PA
    SPECIAL TOOL Feeler gauge Figure
    Electrode miller
Round wire brush, braided, ø 70 mm
Abrasive disk, ø 115 mm, 80 m/s (max. 13,250 rpm)
Clamping pliers
Insert gas welder,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Spot welder,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Drill (electric/pneumatic),
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Angle grinder (electric/pneumatic), refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
    Wet/dry vacuum cleaner,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
15 Adjust gap dimensions on hoods, doors and lids   AR60.00-P-0700-01PA
    Rear door to side piece, bottom *BE60.00-P-1002-01E 
    Rear fender to taillamp *BE60.00-P-1003-01E 
    Rear-end door to rear fender *BE60.00-P-1004-01E 
    SPECIAL TOOL Feeler gauge Figure
16 Install rear end assembly   AR64.20-P-1020PA 
17 Install rear fender   AR63.50-P-1400PA
18 Detach vehicle from straightening bench and lift using two-column lift, remove straightening bench. Two-post lift,
refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
19 Clean weld joints and metal flanges using wire brush    
20 Clean repair areas and prime using primer filler    
21 Supplement standard sealant using MB body sealant MB body sealant for seam sealant (paintable/310 ml cartridge) *BR00.45-Z-1003-01A 
22 Supplement standard underfloor protection with MB permanent underbody sealant    
23 Paint repair areas and adjacent surfaces    
24 Install spare tire well Except CODE (550) Trailer hitch AR88.30-P-1000P
    With CODE (550) Trailer hitch AR88.30-P-1000PP
25 Apply additional cavity preservation    
NOTES Notes on cavity preservation   AH97.20-P-0001-01B
REFER TO MAINTENANCE Processing instructions for cavity preservation   AP97.20-P-0640-01A
26 Install all removed assembly parts    
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number Designation Model 203.204/206/207/208/216/218/220/235/240/242/243/245/246/252/254/256/261/264/265/281/284/287/292
BE60.00-P-1002-01E Gap dimension Front door to A-pillar Dimension "B" mm 6.5 (+1)
Front door to fender Dimension "H" mm 3.5 (-0.5/+1)
Front door to rear door Dimension "I" mm 4 (-0.5/+1)
Front door to roof Dimension "C" mm 6.5 (+1)
Rear door to C-pillar Dimension "T" mm 6 (+1)
Rear door to side piece, bottom Dimension "J" mm 3.5 (+1)
Front door to rear fender Dimension "P" mm -
See picture   AR60.00-P-0700-01PA
BE60.00-P-1003-01E Gap dimension Trunk lid to rear fender, top Dimension "F" mm -
Trunk lid to taillamp Dimension "M" mm -
Rear fender to taillamp Dimension "U" mm 2 (0.5)
See picture   AR60.00-P-0700-01PA
BE60.00-P-1004-01E Gap dimension Rear-end door to roof Dimension "E" mm 6.5 (±1)
Rear-end door to rear fender Dimension "M" mm 3.5
Rear-end door to taillamp Dimension "L" mm 4
Rear-end door to bumper Dimension "S" mm 5.5
Rear-end door to D-pillar Dimension "Q" mm -
See picture   AR60.00-P-0700-01PA
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G04735242
Fig 3: Identifying Feeler Gauge (129 589 03 21 00)
G04735243
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1003-01A Sealant A 001 989 63 20
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
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