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Home >> Mercedes Benz >> 2005 >> E55 >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Rear Wall & Rear End >> Testing & Repair >> Replace complete bottom rear center section - AR64.20-P-1000 >> Replace complete bottom rear center section - AR64.20-P-1000TA >> Notes

Replace complete bottom rear center section - AR64.20-P-1000TA: Notes

MODEL 211.2 

Fig 1: Identifying Rear Center Section Internal Components And Outer Rear Center Section
G04985215
REMOVING Remove    
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 and position the four support plates below 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 arc welding. Risk of explosion  caused by welding in the area of highly inflammable materials. Injury hazard  from welding spatter and UV-light while welding. Risk of poisoning  caused by inhaling welding vapors. Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor. 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 arc welding work All models AH00.00-N-0005-01A
NOTES Notes on paintwork repairs All models AH98.00-P-9408-02A
IMPORTANT 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) Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
3 Separate outer rear center section   AR64.20-P-1010TA 
4 Cut off rear center section inner part   AR64.20-P-1000-11TA 
    SPECIAL TOOL Welding spot miller cutter Figure
    COMMERCIALLY AVAILABLE TOOLS Spherical milling cutter, dia. 12 mm *WH58.30-Z-1002-01A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot weld removing tool *WH58.30-Z-1006-01A 
    COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80m/s (max. 13,250 rpm) *WH58.30-Z-1024-04A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
5 Rear center section and outer section Preparation   AR64.20-P-1000-03TA 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80m/s (max. 13,250 rpm) *WH58.30-Z-1024-04A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install     
6 Install rear center section and outer section   AR64.20-P-1000-04TA 
IMPORTANT General information on riveting   AH60.00-P-0003-01N
    SPECIAL TOOL Spacer Figure
    SPECIAL TOOL Feeler gauge Figure
    COMMERCIALLY AVAILABLE TOOLS Electrode miller *WH58.30-Z-1003-01A 
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    COMMERCIALLY AVAILABLE TOOLS screw-on pliers, dia. 6.4 mm-Clamping range 0-15 mm, identification color silver *WH58.30-Z-1038-02A 
    COMMERCIALLY AVAILABLE TOOLS PowerBird blind rivet tool *WE58.40-Z-1003-14A 
    COMMERCIALLY AVAILABLE TOOLS Hand riveter *WH58.30-Z-1003-29A 
    Inert gas welder *WE58.40-Z-1001-02A 
    Spot welder *WE58.40-Z-1001-03A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Cavity preservation gun Sata HRS no. 11072 *WE58.40-Z-1006-08A 
    Polygrip flat/round head rivets, 6.4x14 *BR00.45-Z-1001-13A 
    MB preservative *BR00.45-Z-1003-05A 
    Sealant *BR00.45-Z-1003-01A 
    Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
7 Adjust gaps on hoods, doors and lids   AR60.00-P-0700-01TA
    Rear window and D-pillar *BE60.00-P-1005-01F 
    Rear-end doors to rear fender *BE60.00-P-1005-01F 
    Taillamp in tailgate and taillamp *BE60.00-P-1005-01F 
    Rear fender to taillamp *BE60.00-P-1003-01F 
    SPECIAL TOOL Feeler gauge Figure
8 Clean areas to be repaired and prime with priming filler    
9 Seam sealing following repair IMPORTANT Supplement standard seals with MB body sealant. AR97.10-P-4000T
    MB body sealant for sealing seams (suitable for painting / 310 ml tube). *BR00.45-Z-1003-01A 
    Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
10 Paint repair areas and adjacent surfaces    
11 Cavity preservation following repair work   AR97.20-P-1500T
NOTES Notes on cavity preservation Model 211 AH97.20-P-0001-01B
12 Install all removed detachable body components    
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number Designation Type 211.2
BE60.00-P-1003-01F Gap dimension Rear fender to taillamp Dimension "M" mm 2,5 (± 1)
  See picture in AR60.00-P-0700-01TA
BE60.00-P-1005-01F Gap dimension Rear-end door to rear fender Dimension "Q" mm 4.5 (± 1)
Taillamp in tailgate and taillamp Dimension "R" mm 5 (± 1)
Rear window and D-pillar Dimension "T" mm 4,5 (± 1
  See picture in AR60.00-P-0700-01TA
Fig 2: Identifying Feeler Gauge (129 589 03 21 00)
G04985216
Fig 3: Identifying Spacer (000 589 87 63 00)
G04985217
Fig 4: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G04985218
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1002-01A Ball cutter, dia. 12 mm
WH58.30-Z-1003-01A Electrode miller
WH58.30-Z-1006-01A Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1003-02A Clamping pliers
WH58.30-Z-1038-02A Manual temporary fastener, dia.6.4 mm - clamping range 0 -15 mm, identification color silver Firma Hausmann GmbH D-34346 Hann. Munden, Germany
WH58.30-Z-1001-03A Round wire brush, braided, dia. 70 mm
WH58.30-Z-1024-04A Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)
WH58.30-Z-1003-29A Hand riveter
WH58.30-Z-1001-40A Tarp (fire-resistant)
WORKSHOP EQUIPMENT

WE58.40-Z-1001-02A Inert gas welder
WE58.40-Z-1002-02A Spot welder
WE58.40-Z-1001-03A Drill (electric/pneumatic)
WE58.40-Z-1002-03A Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A Angle grinder (electric/pneumatic)
WE58.40-Z-1005-03A Wet/dry vacuum cleaner
WE58.40-Z-1001-05A Two-post lifting platform
WE58.40-Z-1006-08A Cavity preservation gun
WE58.40-Z-1003-14A Blind rivet tool
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1041-01A Seam sealant, sprayable 310 ml A 002 989 84 20
BR00.45-Z-1003-01A Sealant A 001 989 63 20
BR00.45-Z-1003-05A Preservation agent A 000 986 72 70 05
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
BR00.45-Z-1001-13A Rivet A 003 990 35 97
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