LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 2008 >> CL550 >> Repair and Diagnosis >> Collision >> General Collision Information >> Rear Wall & Rear End >> Testing & Repair >> Install and weld in bottom rear center section - AR64.20-P-1000-08SX

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-0700-01SX
CHECK VALUES FOR GAPS

Number Designation Model 216 up to model year 2011 Model 216 as of model year 2011
BE60.00-P-1003-01T Gap dimension Trunk lid to rear fender, top Dimension "J" mm 3.5 (±0.8) 3.5 (±0.8)
Trunk lid to rear lamp unit Dimension "K" mm 3.5 (±0.8) 3.5 (±0.8)
Trunk lid to bumper Dimension "L" mm 5, 5 (±1.5) 5, 5 (±1.5)
Rear fender to rear lamp unit Dimension "M" mm 2.5 (±0.5) 2.5 (±0.5)
See picture   AR60.00-P-0700-01SC AR60.00-P-0700-01SC
Fig 1: Identifying Feeler Gauge (129 589 03 21 00)
G07469060Courtesy 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 6.4 X14 A 003 990 35 97
Fig 2: Identifying Bottom Rear Center Section And Mount Below Taillamp (2)
G07321184Courtesy of MERCEDES-BENZ USA

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

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

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

  4. Fasten bottom rear center section (1) and mount below taillamp (2) with COMMERCIALLY AVAILABLE TOOLS clamping pliers.
  5. Remove taillamp, rubber seal and locking eye.
    Fig 3: Identifying Gap Dimension Between Trunk Lid, Rear Fender And Taillamp
    G07321185Courtesy of MERCEDES-BENZ USA
    Fig 4: Identifying Rivet Holes In Mount Below Taillamp Areas (B, C, D And E)
    G07321186Courtesy of MERCEDES-BENZ USA
  6. 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 (F, G, H And I)
    G07321187Courtesy of MERCEDES-BENZ USA
  7. Drill dia. 6.5 mm rivet holes in bottom rear center section (1) (area A).
  8. Drill dia. 6.5 mm rivet holes in mount below taillamp (2) (areas F, G, H and I).
  9. Remove bottom rear center section (1) and mount below taillamp (2).
  10. Deburr rivet holes on both sides.
  11. Remove drill shavings using wet/dry vacuum cleaner.
    Fig 6: Identifying Bottom Rear Center Section Grinding Surfaces (Cross-Hatched Areas)
    G07321188Courtesy of MERCEDES-BENZ USA
  12. Grind mating surfaces on bottom rear center section (1) down to bare metal in cross-hatched areas with COMMERCIALLY AVAILABLE TOOLS round wire brush consisting of stainless steel (areas J, K and L).
  13. Apply 2-component adhesive in crosshatched areas at bottom rear center section (1).

    IMPORTANT Observe pretreatment of bonding surfaces.

    IMPORTANT Refer to manufacturer specifications for adhesive curing and application times.

    Fig 7: Identifying Bottom Rear Center Section Crosshatched Areas
    G07321189Courtesy of MERCEDES-BENZ USA
  14. Install bottom rear center section (1), fit and fasten with COMMERCIALLY AVAILABLE TOOLS clamping pliers and COMMERCIALLY AVAILABLE TOOLS manual temporary fasteners.
  15. Apply 2-component adhesive in crosshatched areas at bottom rear center section (1) (areas M and N).

    IMPORTANT Observe pretreatment of bonding surfaces.

    IMPORTANT Refer to manufacturer specifications for adhesive curing and application times.

  16. Apply 2-component adhesive in crosshatched areas to mount below rear lamp (2) (areas O and P).
  17. Install mount below taillamp (2), fit and fasten with COMMERCIALLY AVAILABLE TOOLS clamping pliers and COMMERCIALLY AVAILABLE TOOLS manual temporary fasteners.
    Fig 8: Identifying Polygrip Flat/Round Head Rivet Areas (B, C, D And E)
    G07321190Courtesy of MERCEDES-BENZ USA
  18. Rivet mount below taillamp (2) with Polygrip flat/round head rivet, dia. 6.4 X14 (areas B and C).
  19. Rivet bottom rear center section (1) with Polygrip flat/round head rivet, dia. 6.4 X14 (areas D and E).

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

    Fig 9: Identifying Polygrip Flat/Round Head Rivet Areas (A, F, G, H And I)
    G07321191Courtesy of MERCEDES-BENZ USA
  20. 20 Rivet mount below taillamp (2) with Polygrip flat/round head rivet, dia. 6.4 X14 (areas F and G).
  21. 21 Rivet bottom rear center section (1) with Polygrip flat/round head rivet, dia. 6.4 X14 (areas A, H and I).
scientia non olet · About LEMON Manuals