Replace bottom rear center section together with rear crossmember - AR64.20-P-1060SX

MODEL 221, 216 

Shown on model 221 

Fig 1: Identifying Bottom Rear Center Section, Mount Below Taillamp And Rear Crossmember

Courtesy of MERCEDES-BENZ USA

	Removing
	Risk of explosion from pressurized spray cans	Protect cans from direct sunlight and temperatures above 50 °C	AS00.00-Z-0015-01A
	Risk of poisoning  caused by inhaling vapors or swallowing adhesive. Risk of injury  caused by adhesive coming into contact with skin and eyes	Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only.	AS00.00-Z-0016-01A
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	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
	Risk of explosion  from aluminum grinding dust, risk of injury  to respiratory system from inhaling dust	Wear protective respiratory mask, protective gloves and safety glasses. Use suitable, grounded vacuum cleaner	AS60.00-Z-0007-01N
	General information on body repair		AH60.00-N-0001-01A
	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	Notes on paintwork repairs		AH98.00-P-9408-02A
	General information on riveting		AH60.00-P-0003-01N
	Notes on various body materials		AH60.00-P-0011-01SX
	General information on dent removal and straightening aluminum parts		AH60.00-P-0012-01N
	General information on body connection techniques		AH60.00-P-0015-01SX
	General information on MB materials		AH98.00-P-9409-03A
1	Remove rear bumper	Model 216	AR88.20-P-2200SC
		Model 221 without code (Z07) Top protection	AR88.20-P-2200SX
		Model 221 with code (Z07) Highest protection	AR88.20-P-2200SXS
2	Remove taillamps		AR82.10-P-4905SX
3	Remove spare tire well		AR88.30-P-1000SX
4	Cover all detachable parts remaining in vehicle	Tarp (fire-resistant)
5	Equip straightening bench with module members, cross members and straightening tool set.	Observe setup plans provided. Celette straightening bench
		Set of Celette module members 955.940 Celette additional member 955.908 Car-Bench straightening bench BT 17 Car-Bench straightening bench BT 43/1 Car-Bench straightening bench BT 140 Car-Bench universal crossmember set A 296 Car-Bench universal crossmember set 296/19 Multi-Z straightening set system MZ 450.000 Celette straightening bracket set 7221.300 (for model 221) Celette 7216.309 supplementary straightening set for Celette straightening bracket set 7221.300 (for model 221) See also GOTIS: http://gotis.aftersales.mercedes-benz.com
		Car-Bench straightening bracket set 82456 (for model 221)
6	Lift vehicle with two-post lift	Two-post lift
7	Set vehicle onto straightening bench
8	Fasten vehicle to straightening bench
9	Separate bottom rear center section (1) with rear crossmember (3)		AR64.20-P-1060-01SX
		Spot weld milling cutter	Figure
		Spot weld milling cutter Vario Drill WS 91 spot weld removing tool Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM) Hot-air gun - 3000 W Aluminum workshop vehicle Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner	Figure
	Recycle aluminum parts		OS60.00-P-0001-01N
10	Prepare bottom rear center section (1) for installation	Round wire brush, braided, dia. 70 mm Aluminum workshop vehicle Drill (electric/pneumatic)	AR64.20-P-1000-07SX
11	Prepare rear crossmember (3) for installation	Round wire brush, braided, dia. 70 mm Aluminum workshop vehicle Drill (electric/pneumatic)	AR64.20-P-1100-02SX
	Install
12	Install and weld in rear crossmember (3)		AR64.20-P-1060-03SX
	General information on riveting	Clamping pliers Blind rivets with manual temporary fastener, 6.4 mm dia., clamping range 0 to 15 mm, identification color silver Round wire brush, braided, dia. 70 mm Taurus 3 blind rivet tool with 100 mm long extension unit Aluminum workshop vehicle Drill (electric/pneumatic) Wet/dry vacuum cleaner	AH60.00-P-0003-01N
		Polygrip flat round head rivet, 6.4 14	*BR00.45-Z-1001-13A
		Polygrip countersunk-head rivet, 6.4X14	*BR00.45-Z-1002-13A
		Adhesive	*BR00.45-Z-1092-02A
13	Install bottom rear section (1)		AR64.20-P-1000-08SX
	General information on riveting		AH60.00-P-0003-01N
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01R
		Rear fender to rear lamp unit	*BE60.00-P-1003-01R
		Trunk lid to rear fender, top	*BE60.00-P-1003-01R
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01T
		Rear fender to rear lamp unit	*BE60.00-P-1003-01T
		Feeler gauge Clamping pliers	Figure
		Blind rivets with manual temporary fastener, 6.4 mm dia., clamping range 0 to 15 mm, identification color silver Round wire brush, braided, dia. 70 mm Taurus 3 blind rivet tool with 100 mm long extension unit Aluminum workshop vehicle Drill (electric/pneumatic) Wet/dry vacuum cleaner Polygrip flat round head rivet, 6.4 X14	*BR00.45-Z-1001-13A
		Adhesive	*BR00.45-Z-1092-02A
14	Adjust gap dimensions on hoods, doors and lids	Model 221 gap dimensions	AR60.00-P-0700-01 SX
		Feeler gauge	Figure
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01 R
		Rear fender to rear lamp unit	*BE60.00-P-1003-01 R
		Trunk lid to rear fender, top	*BE60.00-P-1003-01 R
		Model 216 gap dimensions	AR60.00-P-0700-01 SC
		Feeler gauge	Figure
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01T
		Rear fender to rear lamp unit	*BE60.00-P-1003-01T
15	Unfasten vehicle from straightening bench
16	Lift vehicle with two-post lift	Two-post lift
17	Remove straightening bench.
18	Clean repair area
19	Prime repair area with primer filler
20	Carry out seam sealing after repairs	Supplement standard sealants with MB body sealant.	AR97.10-P-4000SX
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
21	Paint repair areas and adjacent surfaces
22	Apply additional cavity preservation	Model 221	AR97.20-P-1500SX
		Model 216	AR97.20-P-1500SC
	Notes on cavity preservation	Cavity preservation gun Sata HRS no. 11072	AH97.20-P-0001-01B
		Preservation agent	*BR00.45-Z-1003-05A
23	Remove tarp	On all covered parts remaining in vehicle.
24	Install spare tire well		AR88.30-P-1000SX
25	Install taillamps		AR82.10-P-4905SX
26	Install rear bumper	Model 216	AR88.20-P-2200SC
		Model 221 without code (Z07) Top protection	AR88.20-P-2200SX
		Model 221 with code (Z07) Highest protection	AR88.20-P-2200SXS

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 (±3.5)
		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 2: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Spot Weld Milling Cutter (215 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	White sealing compound, 310 ml, DBL 6069.20	A 001 989 63 20
BR00.45-Z-1041-01A	Seam sealant, sprayable 310 ml	A 002 989 84 20
BR00.45-Z-1092-02A	Adhesive kit, body, 2-component adhesive	A 009 989 36 71
BR00.45-Z-1003-05A	Cavity preservation, solvent-free (1 l container)	A 000 986 72 70 05
BR00.45-Z-1002-13A	Polygrip countersunk-head rivet, 6.4X14	A 003 990 86 97 05
BR00.45-Z-1001-13A	Blind rivet 6.4X14	A 003 990 35 97