Replace complete wheelhouse - AR62.20-P-1200T

WARNING: This page is about a different car, the 2009 Mercedes-Benz E550 and 2008 Mercedes-Benz E550. However, it is still accessible from the selected car via links, so may be relevant.

MODEL 211.0/2

Shown on model 211.0

Fig 1: Identifying Partition Wall, Wheelhouse And Bracket

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove
	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
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the hydraulic lifting platform and position the four support plates below the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	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
	General information on body repair		AH60.00-N-0001-01A
	Measures for preventing damage to vehicles or components during electro-welding		AH00.00-N-0005-01A
	Notes on paintwork repairs		AH98.00-P-9408-02A
1	Remove engine hood		AR88.40-P-3000T
2	Remove left front fender		AR88.10-P-1000T
3	Remove left front door		AR72.10-P-0500T
4	Remove left front seat		AR91.10-P-1000T
5	Remove foot mats
6	Remove cross member below instrument panel	Protect heater housing or AC housing against damage.
		Model 211.080/082/083/280/282/283/026/028/042/043/206/216/226/242/243/261/265/270 Model 211.004/006/016/061/065/070/076/276	AR62.30-P-1250T
7	Remove pedal assembly for parking brake	Model 211.080/082/083/280/282/283
		Model 211.004/006/016/026/028/042/043/061/065/070/076/206/216/226/242/243/261/265/270/276	AR42.20-P-0510T
8	Remove or free up electrical lines and vacuum lines in area to be repaired.
9	Remove front end with reinforcement		AR62.30-P-1570T
10	Remove exhaust system	Engine 646.951 in model 211.004 Engine 646.961 in model 211.006/206 Engine 647.961 in model 211.016/216 Engine 271.943 in model 211.043 Engine 112.913 in model 211.061/261	AR49.10-P-7000TB
		Engine 112.949 in model 211.065/265 Engine 113.967 in model 211.070/270 Engine 113.990 in model 211.076/276 Engine 112.917 in model 211.080/280 Engine 112.954 in model 211.082/282 Engine 113.969 in model 211.083/283 Engine 648.961 in model 211.026/226	AR49.10-P-7000T
		Engine 628.961 in model 211.028	AR49.10-P-7000TD
		Engine 271.941 in model 211.042/242	AR49.10-P-7000TK
11	Remove engine	Engine 271.943 in model 211.043 with transmission 716.628, 722.695 Engine 113.967 in model 211.070 with transmission 722.901 Engine 112.917 in model 211.080 with transmission 722.667 Engine 112.954 in model 211.082 with transmission 722.668 Engine 113.969 in model 211.083 with transmission 722.672 Engine 112.913 in model 211.261 with transmissions 716.623/634, 722.696 Engine 112.949 in model 211.265 with transmission 722.618 Engine 113.967 in model 211.270 with transmission 722.633/901 Engine 113.990 in model 211.276 with transmission 722.643/901 Engine 112.917 in model 211.280 with transmission 722.667 Engine 112.954 in model 211.282 with transmission 722.668 Engine 113.969 in model 211.283 with transmission 722.672 Engine 648.961 in model 211.026/226 with transmission 722.626	AR01.10-P-2400TA
		Engine 271.941 in model 211.042/242 with transmissions 722.695, 716.628	AR01.10-P-2400TK
		Engine 646.951 in model 211.004 with transmission 716.604	AR01.10-P-2400T
		Engine 646.961 in model 211.006/206 with transmission 716.649 Engine 647.961 in model 211.016/216 with transmission 716.649 Engine 646.951 in model 211.004 with transmission 722.699	AR01.10-P-2400TB
		Engine 646.961 in model 211.006/206 with transmission 722.699 Engine 647.961 in model 211.016/216 with transmission 722.640 Engine 112.913 in model 211.061 with transmission 716.623/634, 722.696	AR01.10-P-2400TC
		Engine 112.949 in model 211.065 with transmission 722.618 Engine 113.967 in model 211.070 with transmission 722.633 Engine 628.961 in model 211.028	AR01.10-P-2401TD
		Engine 113.990 in model 211.076	AR01.10-P-2400RVK
12	Remove front axle	Model 211.028/043/243/080/280/082/282/083/283
		Model 211.004/006/206/016/216/026/226/042/242/061/261/065/265/070/270/076/276	AR33.10-P-0100T
13	Remove detachable parts in area to be repaired
14	Cover all detachable body components remaining in vehicle (area to be repaired)	Tarpaulin (fireproof)
15	Equip straightening bench with modular members, cross members and straightening bracket set.	Observe enclosed set-up plans! Celette straightening bench M8S http://gotis.aftersales.mercedes-benz.com Celette straightening bench Sevenne http://gotis.aftersales.mercedes-benz.com Set of Celette modular members 955.94 http://gotis.aftersales.mercedes-benz.com Celette additional member 955.908 http://gotis.aftersales.mercedes-benz.com Car-Bench straightening bench BT 17 http://gotis.aftersales.mercedes-benz.com Car-Bench straightening bench BT 43/1 http://gotis.aftersales.mercedes-benz.com Car-Bench universal crossmember set A 296 http://gotis.aftersales.mercedes-benz.com Multi-Z straightening set system MZ 450.000 http://gotis.aftersales.mercedes-benz.com Celette straightening bench 7211.300 (for model 211) http://gotis.aftersales.mercedes-benz.com Car Bench straightening bracket set 82441 (for model 211) http://gotis.aftersales.mercedes-benz.com Celette 7211.309 supplementary straightening set for Celette straightening bracket set 7211.300 (for model S 211) http://gotis.aftersales.mercedes-benz.com Car-Bench 82450 supplementary straightening set for Car-Bench straightening bracket set 82441 (for model S 211) http://gotis.aftersales.mercedes-benz.com Celette 7211.308 supplementary straightening set for Celette straightening bracket set 7211.300 (for model 211 4MATIC) http://gotis.aftersales.mercedes-benz.com Car-Bench 82451 supplementary straightening set for Car-Bench straightening bracket set 82441 (for model 211 4MATIC) http://gotis.aftersales.mercedes-benz.com
16	Place vehicle on straightening bench using two-column lift	Two-column lift http://gotis.aftersales.mercedes-benz.com
17	Attach vehicle to straightening bench
18	Cutting off wheelhouse (2) on passenger compartment side		AR62.20-P-1200-11T
		Spot weld milling cutter Spherical milling cutter, dia. 12 mm Round wire brush, braided, dia. 70 mm Tarpaulin (fireproof) Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com	*201589005100
19	Cut off wheelhouse (2) on fender side		AR62.20-P-1200-12T
		Spot weld milling cutter Spherical milling cutter, dia. 12 mm Round wire brush, braided, dia. 70 mm Vario Drill WS 91 spot-weld loosening tool Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Body saw (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com	*201589005100
20	Cut off wheelhouse (2) on engine compartment side		AR62.20-P-1200-03T
		Spot weld milling cutter Spherical milling cutter, dia. 12 mm Round wire brush, braided, dia. 70 mm Vario Drill WS 91 spot-weld loosening tool Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com	*201589005100
21	Prepare body for welding in wheelhouse (2)		AR62.20-P-1200-13T
		Round wire brush, braided, dia. 70 mm Hole punching pliers, 7 mm dia. Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 RPM) Cutting disk, dia. 65 mm, 80 m/s (max. 23.500 RPM) Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Angular grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
22	Prepare wheelhouse (2) for welding in		AR62.20-P-1200-14T
		Spot weld milling cutter Spherical milling cutter, dia. 12 mm Round wire brush, braided, dia. 70 mm Vario Drill WS 91 spot-weld loosening tool Hole punching pliers, 7 mm dia. Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 RPM) Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Angular grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Zinc dust paint which can be spot welded	*201589005100
	Install
23	Install and weld in wheelhouse (2)		AR62.20-P-1200-17T
	General notes on riveting		AH60.00-P-0003-01N
		Electrode miller Hole punching pliers, 7 mm dia. Round wire brush, braided, dia. 70 mm Clamping pliers Hand riveter PowerBird blind rivet tool http://gotis.aftersales.mercedes-benz.com Manual temporary fastener, dia. 6.4 mm, clamping area 0 to 15 mm, identification color silver Inert gas welder http://gotis.aftersales.mercedes-benz.com Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Spot welder http://gotis.aftersales.mercedes-benz.com Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com Sealant	*BR00.45-Z-1003-01A
		Preservation agent	*BR00.45-Z-1003-05A
		Polygrip flat/round head rivet, 6.4x14	*BR00.45-Z-1001-13A
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
24	Replace bracket (3) for hydraulic unit on wheelhouse (2).	Only when replacing righthand wheelhouse (2). Bracket (3) for the hydraulic unit is riveted to wheelhouse (2) and the front longitudinal member. Manual temporary fastener, dia. 6.4 mm - Clamping range 0-15 mm, identification color silver PowerBird blind rivet tool http://gotis.aftersales.mercedes-benz.com Rivet	*BR00.45-Z-1012-13A
25	Unfasten vehicle from straightening bench
26	Lift vehicle with two-column lift	Two-column lift http://gotis.aftersales.mercedes-benz.com
27	Remove straightening bench.
28	Clean area to be repaired
29	Prime area to be repaired with primer/filler
30	Carry out seam sealing after repairs	Supplement standard sealing with MB body sealant.	AR97.10-P-4000T
		Sealant	*BR00.45-Z-1003-01A
31	Paint wheelhouse (2) and adjacent surfaces
32	Cavity preservation following repair work		AR97.20-P-1500T
	Notes on cavity preservation		AH97.20-P-0001-01B
		Cavity preservation gun Sata HRS no. 11072 http://gotis.aftersales.mercedes-benz.com Preservation agent	*BR00.45-Z-1003-05A
33	Remove tarpaulin from all covered parts that remained in the vehicle	Tarpaulin (fireproof)
34	Install parking brake pedal assembly	Model 211.080/082/083/280/282/283
		Model 211.004/006/016/026/028/042/043/061/065/070/076/206/216/226/242/243/261/265/270/276	AR42.20-P-0510T
35	Install front axle	Model 211.028/043/243/080/280/082/282/083/283
		Model 211.004/006/206/016/216/026/226/042/242/061/261/065/265/070/270/076/276	AR33.10-P-0100T
36	Install engine	Engine 271.943 in model 211.043 with transmission 716.628, 722.695 Engine 113.967 in model 211.070 with transmission 722.901 Engine 112.917 in model 211.080 with transmission 722.667 Engine 112.954 in model 211.082 with transmission 722.668 Engine 113.969 in model 211.083 with transmission 722.672 Engine 112.913 in model 211.261 with transmissions 716.623/634, 722.696 Engine 112.949 in model 211.265 with transmission 722.618 Engine 113.967 in model 211.270 with transmission 722.633/901 Engine 113.990 in model 211.276 with transmission 722.643/901 Engine 112.917 in model 211.280 with transmission 722.667 Engine 112.954 in model 211.282 with transmission 722.668 Engine 113.969 in model 211.283 with transmission 722.672 Engine 648.961 in model 211.026/226 with transmission 722.626	AR01.10-P-2400TA
		Engine 271.941 in model 211.042/242 with transmission 722.695, 716.628	AR01.10-P-2400TK
		Engine 646.951 in model 211.004 with transmission 716.604	AR01.10-P-2400T
		Engine 646.961 in model 211.006/206 with transmission 716.649 Engine 647.961 in model 211.016/216 with transmission 716.649 Engine 646.951 in model 211.004 with transmission 722.699	AR01.10-P-2400TB
		Engine 646.961 in model 211.006/206 with transmission 722.699 Engine 647.961 in model 211.016/216 with transmission 722.640 Engine 112.913 in model 211.061 with transmission 716.623/634, 722.696	AR01.10-P-2400TC
		Engine 112.949 in model 211.065 with transmission 722.618 Engine 113.967 in model 211.070 with transmission 722.633 Engine 628.961 211.028	AR01.10-P-2401TD
		Engine 113.990 in model 211.076	AR01.10-P-2400RVK
37	Install exhaust system	Engine 646.951 in model 211.004 Engine 646.961 in model 211.006/206 Engine 647.961 in model 211.016/216 Engine 271.943 in model 211.043 Engine 112.913 in model 211.061/261	AR49.10-P-7000TB
		Engine 112.949 in model 211.065/265 Engine 113.967 in model 211.070/270 Engine 113.990 in model 211.076/276 Engine 112.917 in model 211.080/280 Engine 112.954 in model 211.082/282 Engine 113.969 in model 211.083/283 Engine 648.961 in model 211.026/226	AR49.10-P-7000T
		Engine 628.961 in model 211.028	AR49.10-P-7000TD
		Engine 271.941 in model 211.042/242	AR49.10-P-7000TK
38	Install cross member below instrument panel	Protect heater housing or AC housing against damage.
		Model 211.080/082/083/280/282/283/026/028/042/043/206/216/226/242/243/261/265/270
		Model 211.004/006/016/061/065/070/076/276	AR62.30-P-1250T
39	Install electrical lines and vacuum lines in area to be repaired
40	Install left front seat		AR91.10-P-1000T
41	Install foot mats
42	Install engine hood		AR88.40-P-3000T
43	Install left front door		AR72.10-P-0500T
44	Install front end with front reinforcement		AR62.30-P-1570T
45	Install left front fender		AR88.10-P-1000T
46	Install all removed detachable body components

Special tools

Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	Sealant, white, 310 ml, DB supply specification 6069.20	A 001 989 63 20
BR00.45-Z-1003-05A	Cavity preservation, solvent-free (1\|container)	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-1012-13A	Blind rivet 6.5 12.5	A 004 990 16 97
BR00.45-Z-1001-13A	Blind rivet 6.4 14	A 003 990 35 97