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Home >> Mercedes Benz >> 2008 >> E550 Base >> Repair and Diagnosis >> Collision >> Body Panels >> Front End & Fire Wall -- E550 (211.072) >> Testing & Repair >> Replace complete wheelhouse - AR62.20-P-1200T

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

MODEL 211.0/2 

Shown on model 211.0 

Fig 1: Identifying Partition Wall, Wheelhouse And Bracket
G07508095Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVING Remove     
DANGER 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. AS00.00-Z-0017-01A
    Deburr replacement panels.  
DANGER 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
DANGER 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
NOTES General information on body repair   AH60.00-N-0001-01A
NOTES Measures for preventing damage to vehicles or components during electro-welding   AH00.00-N-0005-01A
NOTES 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 IMPORTANT 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. IMPORTANT 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 955.940 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 
    SPECIAL TOOL Spot weld milling cutter Figure
    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   
19 Cut off wheelhouse (2) on fender side   AR62.20-P-1200-12T 
    SPECIAL TOOL Spot weld milling cutter Figure
    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   
20 Cut off wheelhouse (2) on engine compartment side   AR62.20-P-1200-03T 
    SPECIAL TOOL Spot weld milling cutter Figure
    SPECIAL TOOL 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   
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 
    SPECIAL TOOL Spot weld milling cutter Figure
    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 *BR00.45-Z-1001-07A 
INSTALLING Install     
23 Install and weld in wheelhouse (2)   AR62.20-P-1200-17T 
IMPORTANT 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) IMPORTANT Only when replacing righthand wheelhouse (2).  
    IMPORTANT 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 IMPORTANT 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 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 NOTES 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)
G07508096Courtesy 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 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-1012-13A Blind rivet 6.5x12.5 A 004 990 16 97
BR00.45-Z-1001-13A Blind rivet 6.4x14 A 003 990 35 97
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