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Home >> Mercedes Benz >> 2007 >> E280 >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Rear Wall & Rear End >> Testing & Repair >> Left side rear damage - AR64.20-P-1200 >> Left side rear damage - AR64.20-P-1200TA >> Notes

Left side rear damage - AR64.20-P-1200TA: Notes

MODEL 211.2 

Fig 1: Identifying D-Pillar, Left Cover Plate And Console - Model 211.2
G04985285
REMOVING Remove    
DANGER Risk of explosion  caused by fuel igniting, risk of poisoning  caused by inhaling and swallowing fuel as well as risk of injury  to eyes and skin caused by contact with fuel. 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
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. Risk of injury  caused by 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 hazard area. Use air extractor. AS00.00-Z-0007-01A
DANGER Risk of death  cased by vehicle slipping or toppling off of the lifting platform. Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
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 undeburred vehicle parts.
Deburr replacement panels.		 AS00.00-Z-0017-01A
NOTES Measures for preventing damage to vehicles or components when performing arc welding work All models AH00.00-N-0005-01A
NOTES General information on body repair All models AH60.00-N-0001-01A
NOTES Guidelines for removing fuel tank when performing welding work on bodies All models AH60.00-P-3000-01Z
NOTES Notes on paintwork repairs Model 124, 126, 129, 140, 163, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 240, 414, 463, 639 AH98.00-P-9408-02A
IMPORTANT General information on MB materials Model 124, 126, 129, 140, 163, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 240, 414, 463, 639 AH98.00-P-9409-03A
1 Remove all detachable body components in area to be repaired    
2.1 Install filler neck covering IMPORTANT When replacing right rear fender. AR63.50-P-1400-01TA
    SPECIAL TOOL Set of covers Figure
    SPECIAL TOOL Cover plate Fig 3
3 Cover detachable body components which remain in vehicle Tarpaulin (fireproof) *WH58.30-Z-1001-40A 
4 Equip straightening bench with modular members, cross members and straightening bracket set. IMPORTANT Observe the body plans provided.  
    Celette straightening bench M8S *WE58.40-Z-1001-01E 
    Celette straightening bench Sevenne *WE58.40-Z-1001-01E 
    Set of Celette modular members 955.940 *WE58.40-Z-1007-01E 
    Celette additional member 955.908 *WE58.40-Z-1008-01E 
    Car-Bench straightening bench BT 17 *WE58.40-Z-1003-01E 
    Car-Bench straightening bench BT 43/1 *WE58.40-Z-1003-01E 
    Car-Bench universal cross member set A 296 *WE58.40-Z-1010-01E 
    Multi-Z straightening set system MZ 450.000 *WE58.40-Z-1006-01E 
    Celette straightening bracket set 7211.300 (for Model 211) *WE58.40-Z-1039-01A 
    Car-Bench straightening bracket set 82441 (for model 211) *WE58.40-Z-1054-01A 
    Celette 7211.309 supplementary straightening set for Celette straightening bracket set 7211.300 for model S 211 *WE58.40-Z-1045-01A 
    Car-Bench 82450 supplementary straightening set for Car-Bench straightening bracket set 82441 (for model S 211) *WE58.40-Z-1046-01A 
    Celette 7211.308 supplementary straightening set for Celette straightening bracket set 7211.300 (for model 211 4MATIC) *WE58.40-Z-1051-01A 
    Car-Bench 82451 supplementary straightening set for Car-Bench straightening bracket set 82441 (for model 211 4MATIC) *WE58.40-Z-1055-01A 
5 Lift vehicle with two-column lift Two-column lift *WE58.40-Z-1001-05A 
6 Set vehicle onto straightening bench    
7 Attach vehicle to straightening bench    
8 Remove C-pillar (1)   AR63.20-P-2000TA
9 Separate deformed rear area   AR64.20-P-1200-11TA 
    SPECIAL TOOL Spot weld milling cutter Figure
    COMMERCIALLY AVAILABLE TOOLS Spherical milling cutter, dia. 12 mm *WH58.30-Z-1002-01A 
    COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot-weld loosening tool *WH58.30-Z-1006-01A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm) *WH58.30-Z-1024-04A 
    COMMERCIALLY AVAILABLE TOOLS Cutting disc, dia. 65 mm, 80 m/s (max. 23.500 rpm) *WH58.30-Z-1021-04A 
    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 
    Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Tarpaulin (fireproof) *WH58.30-Z-1001-40A 
    Zinc dust paint which can be spot welded *BR00.45-Z-1001-07A 
10 Prepare spare wheel recess (7) and inner cross member (6)   AR64.20-P-1245-02TA 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80 m/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 
    Zinc dust paint which can be spot welded *BR00.45-Z-1001-07A 
11 Prepare left rear longitudinal member (3) with console (5) and reinforcement (4)   AR64.20-P-1200-30TA 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80 m/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 
    Zinc dust paint which can be spot welded *BR00.45-Z-1001-07A 
12 Prepare left locking lug (2) on left rear longitudinal member (3)   AR64.20-P-1240-02TA 
    COMMERCIALLY AVAILABLE TOOLS Hole punching pliers, 7 mm dia. *WH58.30-Z-1002-02A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80 m/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 
    Zinc dust paint which can be spot welded *BR00.45-Z-1001-07A 
INSTALLING Install     
13 Install spare wheel recess (7), left rear longitudinal member (3) with console (5) and reinforcement (4)   AR64.20-P-1200-31TA 
IMPORTANT General notes on riveting Model 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639 AH60.00-P-0003-01N
    COMMERCIALLY AVAILABLE TOOLS Electrode miller *WH58.30-Z-1003-01A 
    COMMERCIALLY AVAILABLE TOOLS C-clamps *WH58.30-Z-1031-02A 
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    COMMERCIALLY AVAILABLE TOOLS Manually temporary fastener, 6.4 mm dia., clamping area 0 to 15 mm, identification color silver *WH58.30-Z-1038-02A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm) *WH58.30-Z-1024-04A 
    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-1002-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Tarpaulin (fireproof) *WH58.30-Z-1001-40A 
    Two-column lift *WE58.40-Z-1001-05A 
    Cavity preservation gun Sata HRS no. 11072 *WE58.40-Z-1006-08A 
    Zinc dust paint which can be spot welded *BR00.45-Z-1001-07A 
    Sealant *BR00.45-Z-1003-01A 
    MB cavity wax preservation, 1 l *BR00.45-Z-1003-05A 
    Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
    Rivet *BR00.45-Z-1001-13A 
14 Install left end section (2) and weld in   AR64.20-P-1200-05T 
IMPORTANT General notes on riveting Model 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639 AH60.00-P-0003-01N
    COMMERCIALLY AVAILABLE TOOLS Electrode miller *WH58.30-Z-1003-01A 
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    COMMERCIALLY AVAILABLE TOOLS Hand riveter *WH58.30-Z-1003-29A 
    COMMERCIALLY AVAILABLE TOOLS Manually temporary fastener, 6.4 mm dia., clamping area 0 to 15 mm, identification color silver *WH58.30-Z-1038-02A 
    COMMERCIALLY AVAILABLE TOOLS PowerBird blind rivet tool *WE58.40-Z-1003-14A 
    Inert gas welder *WE58.40-Z-1001-02A 
    Spot welder *WE58.40-Z-1002-02A 
    Sealant *BR00.45-Z-1003-01A 
    MB cavity wax preservation, 1 l *BR00.45-Z-1003-05A 
    Zinc dust paint which can be spot welded *BR00.45-Z-1001-07A 
15 Install inner rear center section (8)   AR64.20-P-1000-04TA 
IMPORTANT General notes on riveting Model 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639 AH60.00-P-0003-01N
    SPECIAL TOOL Feeler gauge Figure
    SPECIAL TOOL Spacer Figure
    COMMERCIALLY AVAILABLE TOOLS Electrode miller *WH58.30-Z-1003-01A 
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    COMMERCIALLY AVAILABLE TOOLS Manual temporary fastener, 6.4 mm dia., clamping area 0 to 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-1002-02A 
    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 
    Tarpaulin (fireproof) *WH58.30-Z-1001-40A 
    Cavity preservation gun Sata HRS no. 11072 *WE58.40-Z-1006-08A 
    Sealant *BR00.45-Z-1003-01A 
    MB cavity wax preservation, 1 l *BR00.45-Z-1003-05A 
    Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
    Zinc dust paint which can be spot welded *BR00.45-Z-1001-07A 
    Rivet *BR00.45-Z-1001-13A 
    Rear fender to taillamp *BE60.00-P-1003-01F 
    Tailgate and rear fender *BE60.00-P-1005-01F 
    Taillamp in rear door to taillamp *BE60.00-P-1005-01F 
    Rear window to D-pillar *BE60.00-P-1005-01F 
16 Install D-pillar (1)   AR63.20-P-2000TA
17 Install outer rear center section (9)   AR64.20-P-1000-04TA 
IMPORTANT General notes on riveting Model 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639 AH60.00-P-0003-01N
    SPECIAL TOOL Feeler gauge Figure
    SPECIAL TOOL Spacer Figure
    COMMERCIALLY AVAILABLE TOOLS Electrode miller *WH58.30-Z-1003-01A 
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    COMMERCIALLY AVAILABLE TOOLS Manual temporary fastener, 6.4 mm dia., clamping area 0 to 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-1002-02A 
    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 
    Tarpaulin (fireproof) *WH58.30-Z-1001-40A 
    Cavity preservation gun Sata HRS no. 11072 *WE58.40-Z-1006-08A 
    Sealant *BR00.45-Z-1003-01A 
    MB cavity wax preservation, 1 l *BR00.45-Z-1003-05A 
    Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
    Zinc dust paint which can be spot welded *BR00.45-Z-1001-07A 
    Rivet *BR00.45-Z-1001-13A 
    Rear fender to taillamp *BE60.00-P-1003-01F 
    Tailgate and rear fender *BE60.00-P-1005-01F 
    Taillamp in rear door to taillamp *BE60.00-P-1005-01F 
    Rear window to D-pillar *BE60.00-P-1005-01F 
18 Adjust gaps on hoods, doors and covers   AR60.00-P-0700-01TA
    SPECIAL TOOL Feeler gauge Figure
    Rear fender to taillamp *BE60.00-P-1003-01F 
    Tailgate and rear fender *BE60.00-P-1005-01F 
    Taillamp in rear door to taillamp *BE60.00-P-1005-01F 
    Rear window to D-pillar *BE60.00-P-1005-01F 
19 Unfasten vehicle from straightening bench    
20 Lift vehicle with two-column lift Two-column lift *WE58.40-Z-1001-05A 
21 Remove straightening bench.    
22 Clean welds and sheet metal flange with round wire brush COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
23 Clean repair areas    
24 Prime area to be repaired with priming filler    
25 Carry out seam sealing after repairs IMPORTANT Supplement standard sealing with MB body sealant. AR97.10-P-4000T
    Sealant *BR00.45-Z-1003-01A 
    Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
26 Paint repair areas and adjacent surfaces    
27 Apply additional cavity preservation   AR97.20-P-1500T
NOTES Notes on cavity preservation Model 124, 126, 129, 140, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 463, 639, 671, 690.6, 901, 902, 903, 904, 905
Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7		 AH97.20-P-0001-01B
    Cavity preservation gun Sata HRS no. 11072 *WE58.40-Z-1006-08A 
    MB cavity wax preservation, 1 l *BR00.45-Z-1003-05A 
28 Remove tarpaulin IMPORTANT On all covered parts remaining in vehicle.  
29 Install all removed detachable body components    
TEST VALUES FOR GAPS ON HOODS, DOORS AND LIDS

Number Designation Model 211.2
BE60.00-P-1003-01F Size of gap Rear fender to taillamp Dimension "M" mm 2.5 (± 1)
    Fig. see AR60.00-P-0700-01TA
BE60.00-P-1005-01F Size of gap Tailgate and rear fender Dimension "Q" mm 4.5 (± 1)
Taillamp in rear door to taillamp Dimension "R" mm 5 (± 1)
Rear window to D-pillar Dimension "T" mm 4.5 (± 1)
    Fig. see AR60.00-P-0700-01TA
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G04985286
Fig 3: Identifying Cover Panel (211 589 02 91 00)
G04985287
Fig 4: Identifying Set Of Covers. (211 589 00 91 00)
G04985288
Fig 5: Identifying Feeler Gauge (129 589 03 21 00)
G04985289
Fig 6: Identifying Spacer (000 589 87 63 00)
G04985290
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-1002-02A Hole punching pliers, dia. 7 mm
WH58.30-Z-1003-02A Clamping pliers
WH58.30-Z-1031-02A C-clamp
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-1021-04A Cutting disk, dia. 65 mm, 80 m/s (max. 23,500 rpm)
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-1039-01A Celette straightening bracket set 7211.300 (model 211)
WE58.40-Z-1045-01A Celette 7211.309 supplementary straightening set for Celette straightening bracket set 7211.300 (model S 211)
WE58.40-Z-1046-01A Car-Bench 82450 supplementary straightening set for Car Bench straightening bracket set 82441 (model S 211)
WE58.40-Z-1051-01A Celette 7211.308 supplementary straightening set for Celette straightening bracket set 7211.300 (model 211 4Matic)
WE58.40-Z-1054-01A Car bench straightening bracket set 82441, (model 211)
WE58.40-Z-1055-01A Car-Bench 82451 supplementary straightening set for Car-Bench straightening bracket set 82441 (model 211 4Matic)
WE58.40-Z-1001-01E Celette straightening bench
WE58.40-Z-1003-01E Car-Bench straightening bench
WE58.40-Z-1006-01E Celette Multi-Z straightening set system
WE58.40-Z-1007-01E Celette module crossmember set 955.940
WE58.40-Z-1008-01E Celette additional member 955.908
WE58.40-Z-1010-01E Car-Bench universal cross member set A 296
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-1004-03A Body saw (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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