Install and weld in bottom rear center section - AR64.20-P-1000-08SX

CHECK VALUES FOR GAPS

Number	Designation				Model 221
BE60.00-P-1003-01R	Gap dimension	Trunk lid to rear fender, top	Dimension "J"	mm	4 (±0.5)
		Trunk lid to rear lamp unit	Dimension "K"	mm	4 (±0.5)
		Trunk lid to bumper	Dimension "L"	mm	5, 5 (±1.5)
		Rear fender to rear lamp unit	Dimension "M"	mm	2.5 (±0.5)
		Trunk lid license plate panel to rear lamp unit	Dimension "N"	mm	4 (±0.5)
			See picture		AR60.00-P-0700-01S X

Fig 1: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1092-02A	Adhesive kit, body, 2-component adhesive	A 009 989 36 71
BR00.45-Z-1001-13A	Blind rivet 6.4X14	A 003 990 35 97

Fig 2: Identifying Bottom Rear Center Section And Taillamp

Courtesy of MERCEDES-BENZ USA

Repair performed on model 221. On model 216 some areas can deviate.

Install bottom rear center section (1) and mount below taillamp (2).
Install taillamp, rubber seal and locking eye.
Check and adjust gaps: trunk lid to taillamp (K), rear fender to taillamp (M), trunk lid cover to taillamp (N).

Gap dimension between trunk lid license plate panel and taillamp (N) only on model 221. Use feeler gauge

Fasten bottom rear center section (1) and mount below taillamp (2) with clamping pliers.
Remove taillamp, rubber seal and locking eye.

Fig 3: Identifying Gaps

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Fig 4: Identifying Rivet Holes In Mount Below Taillamp (Areas B, C, D And E)

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Drill dia. 6.5 mm rivet holes in mount below taillamp (2) (areas B, C, D and E).

Fig 5: Identifying Rivet Holes In Mount Below Taillamp (Areas A, F, G, H And I)

Courtesy of MERCEDES-BENZ USA

Drill dia. 6.5 mm rivet holes in bottom rear center section (1) (area A).
Drill dia. 6.5 mm rivet holes in mount below taillamp (2) (areas F, G, H and I).
Remove bottom rear center section (1) and mount below taillamp (2).
Deburr rivet holes on both sides.
Remove drill shavings using wet/dry vacuum cleaner.

Fig 6: Identifying Bottom Rear Center Section Mating Surfaces

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Grind mating surfaces on bottom rear center section (1) down to bare metal in cross-hatched areas with round wire brush consisting of stainless steel (areas J, K and L).
Apply 2-component adhesive in crosshatched areas at bottom rear center section (1).

Observe pretreatment of bonding surfaces.

Refer to manufacturer specifications for adhesive curing and application times.

Fig 7: Identifying Bottom Rear Center Section Adhesive Application Areas

Courtesy of MERCEDES-BENZ USA

Install bottom rear center section (1), fit and fasten with clamping pliers and manual temporary fasteners.
Apply 2-component adhesive in crosshatched areas at bottom rear center section (1) (areas M and N).
Apply 2-component adhesive in crosshatched areas to mount below rear lamp (2) (areas O and P).

Observe pretreatment of bonding surfaces.

Refer to manufacturer specifications for adhesive curing and application times.

Install mount below taillamp (2), fit and fasten with clamping pliers and manual temporary fasteners.

Fig 8: Identifying Rivet Areas Below Taillamp (B, C, D And E)

Courtesy of MERCEDES-BENZ USA

Rivet mount below taillamp (2) with Polygrip flat/round head rivet, dia. 6.4X14 (areas B and C).
Rivet bottom rear center section (1) with Polygrip flat/round head rivet, dia. 6.414 (areas D and E).

Remove clamping pliers on bottom rear center section (1) only after 2-component adhesive is cured.

Fig 9: Identifying Rivet Areas Below Taillamp (A, F, G H, And I)

Courtesy of MERCEDES-BENZ USA

Rivet mount below taillamp (2) with Polygrip flat/round head rivet, dia. 6.4X14 (areas F and G).
Rivet bottom rear center section (1) with Polygrip flat/round head rivet, dia. 6.4X14 (areas A, H and I).