Left side rear end damage - AR64.20-P-1200Y

MODEL 219

Fig 1: Identifying Rear Fender, Rear Center Section, Longitudinal Member Connection, Rear Crossmember, Reinforcement And Left Cover Plate

Courtesy of MERCEDES-BENZ USA

	Removing
	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel	No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding splatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes.	Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system.	AS00.00-Z-0007-01A
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the 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
	Measures for preventing damage to vehicles or components when performing electric welding work	All models	AH00.00-N-0005-01A
	General information on body repair	All models	AH60.00-N-0001-01A
	Guidelines for removing fuel tank when performing welding work on bodies	Model 171.4, 211.2, 169.0/3, 219.3	AH60.00-P-3000-01V
	Notes on paintwork repairs	Model 124, 126, 129, 140, 163, 168, 169, 170, 171, 199, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 240, 414, 463, 639	AH98.00-P-9408-02A
	General information on MB materials	Model 124, 126, 129, 140, 163, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 240, 414, 463, 639	AH98.00-P-9409-03A
1	Remove trunk lid		AR88.50-P-5000TX
2	Remove rear wall window		AR67.20-P-2000Y
3	Remove rear bumper		AR88.20-P-2200TX
4	Remove taillamps		AR82.10-P-4905TX
5	Remove spare tire well		AR88.30-P-1000TX
6	Cover all detachable parts remaining in vehicle	Tarp (fire-resistant)
7.1	Set up Celette straightening bench		AR60.10-P-1060Y
7.2	Car-Bench straightening bench setup		AR60.10-P-1090Y
8	Lift vehicle with two-post lift	Two-post lifting platform 3.0-3.5 t, electromechanical
9	Remove stop plugs from jack support points
10	Set vehicle onto straightening bench
11	Fasten vehicle to straightening bench
12.1	Install filler neck covering	When replacing right rear fender.	AR63.50-P-1400-01Y
13	Separate deformed rear area		AR64.20-P-1200-11Y
		Spot weld milling cutter	Figure
		Set of cutting templates	Fig 3
		Ball cutter, dia. 12 mm Vario Drill WS 91 spot weld removing tool Beading pliers Round wire brush, braided, dia. 70 mm Hot air gun 3000 W Drill Body jig saw Wet/dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
14	Prepare rear crossmember (2), reinforcement (5), longitudinal member connection (6) and left closing panel (7) for installation		AR64.20-P-1200-20Y
		Spot weld milling cutter Ball cutter, dia. 12 mm Round wire brush, braided, dia. 70 mm Drill Straight grinder	Figure
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
15	Prepare rear center section (4) and reinforcement (3) for installation		AR64.20-P-1000-07Y
		Round wire brush, braided, dia. 70 mm Drill
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
16	Install rear crossmember (2), reinforcement (5) and longitudinal member connection (6) and weld in		AR64.20-P-1200-03Y
	General information on riveting	Model 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639, 903 Electrode miller Clamping pliers Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver Blind rivet/punch riveting method MIG MAG gas welder (steel, brazing, aluminum) Inverter spot welder Drill Wet/dry vacuum cleaner	AH60.00-P-0003-01N
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Polygrip flat round head rivet, 6.4 14	*BR00.45-Z-1001-13A
17	Install and weld in left cover plate (7)		AR64.20-P-1200-05Y
	General information on riveting	Model 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639, 903 Electrode miller Clamping pliers Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver	AH60.00-P-0003-01N
		Taurus 3 blind rivet tool with 100 mm extension Blind rivet/punch riveting method unit MIG MAG gas welder (steel, brazing, aluminum) Inverter spot welder Drill Wet/dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Polygrip flat round head rivet, 6.4 14	*BR00.45-Z-1001-13A
18	Install rear fender (1) and weld in		AR63.50-P-1400-04Y
	General information on riveting	Model 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639, 903	AH60.00-P-0003-01N
		Rear door to side piece, bottom	*BE60.00-P-1002-01O
		Trunk lid to rear fender, top	*BE60.00-P-1003-01O
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01O
		Rear fender to lamp unit	*BE60.00-P-1003-01O
		Fuel filler flap	*BE60.00-P-1004-01O
		Feeler gauge	Figure
		Bending iron	Fig 5
		Electrode miller Clamping pliers Manual temporary fastener, dia. 6.4 mm - clamping range 0 to 15 mm, identification color silver Round wire brush, braided, dia. 70 mm Blind rivet/punch riveting method Hand riveter MIG MAG gas welder (steel, brazing, aluminum) Inverter spot welder Drill
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Polygrip flat round head rivet, 6.4 14	*BR00.45-Z-1001-13A
19	Install rear center section (4) and reinforcement (3) and weld in		AR64.20-P-1000-08Y
	General information on riveting	Model 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639, 903	AH60.00-P-0003-01N
		Trunk lid to rear fender, top	*BE60.00-P-1003-01O
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01O
		Rear fender to lamp unit	*BE60.00-P-1003-01O
		Feeler gauge	Figure
		Electrode miller Clamping pliers Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver Round wire brush, braided, dia. 70 mm Blind rivet/punch riveting method Hand riveter MIG MAG gas welder (steel, brazing, aluminum) Inverter spot welder Drill
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Polygrip flat round head rivet, 6.4 14	*BR00.45-Z-1001-13A
20	Adjust gap dimensions on hoods, doors and covers		AR60.00-P-0700-01Y
		Rear door to side piece, bottom	*BE60.00-P-1002-01O
		Trunk lid to rear fender, top	*BE60.00-P-1003-01O
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01O
		Rear fender to lamp unit	*BE60.00-P-1003-01O
		Fuel filler flap	*BE60.00-P-1004-01O
		Feeler gauge	Figure
21	Unfasten vehicle from straightening bench
22	Lift vehicle with two-post lift	Two-post lifting platform 3.0-3.5 t, electromechanical
23	Remove straightening bench.
24	Install stop plugs in jack support points
25	Clean weld joints and sheet metal flange with round wire brush	Round wire brush, braided, dia. 70 mm
26	Clean repair areas
27	Prime repair area using primer filler
28	Carry out seam sealing after repairs	Supplement standard sealant with MB body sealant	AR97.10-P-4000Y
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
29	Paint repair areas and adjacent surfaces
30	Apply additional cavity preservation		AR97.20-P-1500Y
	Notes on cavity preservation	Model 124, 126, 129, 140, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 463, 639, 671, 690.6, 901, 902, 903, 904, 905 Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7	AH97.20-P-0001-01B
	Cavity preservation gun, SATA HRS	Combination pressure spray gun (corrosion protection)
		MB cavity wax preservation, 1 l	*BR00.45-Z-1003-05A
31	Install rear wall window		AR67.20-P-2000Y
32	Install trunk lid		AR88.50-P-5000TX
33	Install rear bumper		AR88.20-P-2200TX
34	Install taillamps		AR82.10-P-4905TX
35	Install spare tire well		AR88.30-P-1000TX
36	Remove tarp	On all covered parts remaining in vehicle.

TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number	Designation				Model 219
BE60.00-P-1002-01O	Gap dimension	Fender to A-pillar	Dim. "D"	mm	3.0 (±1)
		Front door to fender	Dim. "E"	mm	4.0 (-0.5/+1)
		Front door to rear door	Dim. "F"	mm	5.0 (-1/+0.5)
		B-pillar cover to front window	Dim. "G"	mm	10 (±1)
		B-pillar cover to rear window	Dim. "H"	mm	10 (±1)
		Rear door to side piece, bottom	Dim. "I"	mm	3.5 (-0.5/+1)
		Rear door to side piece, bottom	See picture		AR60.00-P-0700-01Y
BE60.00-P-1003-01O	Gap dimension	Trunk lid to rear fender, top	Dim. "J"	mm	4.0 (±0.5)
		Trunk lid to rear lamp unit	Dim. "K"	mm	2.5 (±0.5)
		Trunk lid to bumper	Dim. "L"	mm	7.0 (±1)
		Rear fender to lamp unit	Dim. "M"	mm	2.5 (±0.5)
		Rear fender to lamp unit	See picture		AR60.00-P-0700-01Y
BE60.00-P-1004-01O	Gap dimension	Fuel filler flap	Dim. "N"	mm	3.5 (±0.5)
BE60.00-P-1004-01O	Gap dimension	Fuel filler flap	See picture		AR60.00-P-0700-01Y

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

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Set Of Cutting Templates (219 589 01 23 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Bending Iron (129 589 00 27 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-1003-05A	Cavity sealant, solvent-free (1 l 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-1001-13A	Blind rivet 6.4 14	A 003 990 35 97