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Home >> Mercedes Benz >> 2007 >> E280 >> Repair and Diagnosis >> Collision >> General Collision Information >> Rear Wall & Rear End >> Testing & Repair >> Left side rear damage - AR64.20-P-1200 >> Left side rear damage - AR64.20-P-1200T >> Separate deformed rear area - AR64.20-P-1200-11T

Separate deformed rear area - AR64.20-P-1200-11T

Fig 1: Identifying Cutting Templates (211 589 05 23 00)
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Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
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Fig 3: Identifying When Replacing Right Rear Fender. (211 589 00 91 00)
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COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1002-01A Ball cutter, dia. 12 mm
WH58.30-Z-1006-01A Vario Drill WS 91 spot weld removing tool
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-1004-20A Hot-air gun
WH58.30-Z-1001-40A Tarp (fire-resistant)
WORKSHOP EQUIPMENT

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
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
Fig 4: Identifying Body Cutting Area
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  1. Mark separation points with cutting templates (areas A and B).
  2. Cut separation points with body saw (areas A and B).

    IMPORTANT Do not damage C-pillar located below and outer side longitudinal member.

    Fig 5: Identifying Body Cutting Area
    G04985249
  3. Mark separation point (area C).
  4. Cut separation point with body saw (area C).
  5. Mark separation point (area I).
  6. Cut separation point with body saw (area I).
  7. Remove section.
    Fig 6: Identifying Cut Separation Point With Body Saw Section
    G04985250
  8. Mark separation point (area H).
  9. Cut separation point with body saw (area H).
  10. Remove section.

    IMPORTANT Area H approx. 30 mm parallel to edge.

    Fig 7: Identifying Cutting Section Area
    G04985251
    Fig 8: Identifying Spot Welding Area
    G04985252
  11. Expose spot welds (areas J, K, L, M, R and S).
  12. Cut out spot welds with SPECIAL TOOL spot weld milling cutter (areas J, K, L, M, R and S).
  13. Expose spot welds (areas G and T).
  14. Cut out spot welds with SPECIAL TOOL spot weld milling cutter (areas G and T).
    Fig 9: Identifying Spot Welding Area
    G04985253
    Fig 10: Identifying Cutting And Spot Welding Area
    G04985254
  15. Expose spot welds (areas C, D, E and F).
  16. Cut out spot welds with SPECIAL TOOL spot weld milling cutter (areas C, D, E and F).
  17. Expose spot welds (area D).
  18. Perforate spot welds with Ø 7 mm bit (area D).
    Fig 11: Identifying Welding And Cutting Area
    G04985255
  19. Expose spot welds (areas N, O, P and Q).
  20. Cut out spot welds with SPECIAL TOOL spot weld milling cutter (areas N, O, P and Q).
  21. Heat rear fender with hot air blower in shaded areas.

    IMPORTANT Shaded areas are foam filled.

  22. Remove rear fender.
  23. Heat reinforcement in shaded area with hot air blower and remove.

    IMPORTANT Shaded area is glued

  24. Remove reinforcement.
    Fig 12: Identifying Shaded Area
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    Fig 13: Identifying Welding Area
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  25. Expose spot welds (areas u, v, w, x, Y, Z, AA, AB, AC and AD).
  26. Cut out spot welds with SPECIAL TOOL spot weld milling cutter (areas u, v, w, x, Y, Z, AA, AB, AC and AD).
  27. Remove sections.
    Fig 14: Identifying Grinding Surfaces Area
    G04985258
  28. Sand connection surfaces down to bare metal in the shaded areas.

    IMPORTANT Sand spot weld flanges down to bare metal on both sides.

  29. Remove grinding and drilling chips using wet/dry vacuum cleaner.
  30. Coat insides of spot welding flanges and rivet connections with zinc dust paint.
    Fig 15: Identifying Welding Area
    G04985259
  31. Crimp rear fender in area of C-pillar at top with sheet metal crimping pliers toward inside (arrow).
    Fig 16: Identifying Crimping Rear Fender Area
    G04985260
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