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Partially replace bottom rear center section - AR64.20-P-1050R: Notes

MODEL 230 

Shown on model 230 without code (P99) "AMG Black Series" special model 

Fig 1: Identifying Bottom Rear Center Section Assembly
G05074630Courtesy of MERCEDES-BENZ USA
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 non-deburred vehicle parts.
Deburr repair panels.		 AS00.00-Z-0017-01A
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between the columns of the 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. Injury hazard  from 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 danger zone. Use air extractor. AS00.00-Z-0007-01A
NOTES General information on repairs to body All models AH60.00-N-0001-01A
NOTES Measures for preventing damage to vehicles or components when performing arc welding work All models AH00.00-N-0005-01A
NOTES Notes on paintwork repairs Models 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463, 639 AH98.00-P-9408-02A
IMPORTANT General information on MB materials Models 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 463, 414, 639 AH98.00-P-9409-03A
1 Remove detachable parts in area to be repaired    
2 Cover all detachable body components remaining in vehicle (area to be repaired) Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
3 Separate rear center section   AR64.20-P-1050-01R 
    SPECIAL TOOL Spot weld milling cutter Figure
    SPECIAL TOOL Protective mat Figure
    SPECIAL TOOL Welding bead collector Figure
    COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot weld removing tool *WH58.30-Z-1006-01A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
4 Prepare new part   AR64.20-P-1050-02R 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install     
5 Install rear center section   AR64.20-P-1050-04R 
IMPORTANT General information on riveting Models 203, 209, 211, 215, 230, 240, 414, 639 AH60.00-P-0003-01N
    SPECIAL TOOL Welding bead collector Figure
    SPECIAL TOOL Protective mat Figure
    SPECIAL TOOL Feeler gauge Figure
    COMMERCIALLY AVAILABLE TOOLS Electrode miller *WH58.30-Z-1003-01A 
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    COMMERCIALLY AVAILABLE TOOLS Manual temporary fastener, dia. 5.0 mm - clamping range 0 up to 6 mm, identification color black *WH58.30-Z-1037-02A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS PowerBird blind rivet tool *WE58.40-Z-1003-14A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disc, dia. 115 mm, 80 m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
    Two-post lift *WE58.40-Z-1001-05A 
    Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Spot welder *WE58.40-Z-1002-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Rivet *BR00.45-Z-1005-13A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
    Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
    Sealant *BR00.45-Z-1003-01A 
6 Adjust gaps on hoods, doors and lids   AR60.00-P-0700-01R
    Gap dimensions *BE60.00-P-1003-01A 
    SPECIAL TOOL Feeler gauge Figure
7 Clean repair areas    
8 Prime area to be repaired with priming filler    
9 Seam sealing following repair IMPORTANT Supplement standard seals with MB body sealant.  
    Model 230.475/474 AR97.10-P-4000R
    Sealant *BR00.45-Z-1003-01A 
    Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
10 Paint repair areas and adjacent surfaces    
11 Apply additional cavity preservation    
    Model 230.475 AR97.20-P-1500R
    MB preservative *BR00.45-Z-1003-05A 
NOTES Notes on cavity preservation Models 124, 126, 129, 140, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 639, 671, 690.6, 901, 902, 903, 904, 905
Models WD141, WD241, WD341, WD641, WD741, XD141, XD241, XD341, XD441, XD541, XD641, XD741, YD141, YD241, YD341, YD441, YD541, YD641, YD741		 AH97.20-P-0001-01B
12 Install all removed detachable body components    
TEST AND ADJUSTMENT VALUES, GAP DIMENSIONS AT HOODS, DOORS AND COVERS

Number Designation Model 230 with code P99 AMG Black Series Model 230
BE60.00-P-1003-01A Gap dimension Trunk lid to rear fender, top Dimension "F" mm 4.0 (±1) -
Trunk lid to bottom of rear fender Dimension "M" mm - -
Trunk lid to rear fender Dimension "F" mm 4.0 (±1) 3, 0 (+1, 2)
Trunk lid to taillamp Dimension "M" mm 3.0 (±1) 4.0 (+1.6/-0.8)
Trunk lid to bumper Dimension "V" mm 5.0 (±1) 5.0 (+1.5/-1.0)
Rear fender to taillamp Dimension "U" mm 1.5 (±1) 2.5 ± 0.5
See picture in   AR60.00-P-0700-01R AR60.00-P-0700-01R
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G05074631Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Feeler Gauge (129 589 03 21 00)
G05074632Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Protective Mat (230 589 00 98 00)
G05074633Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Welding Bead Catcher (230 589 01 98 00)
G05074634Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1003-01A Electrode miller
WH58.30-Z-1006-01A Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1003-02A Clamping pliers
WH58.30-Z-1037-02A Manual temporary fastener, 5.0 mm dia. - clamping range 0-6 mm, identification color black Firma Hausmann GmbH D-34346 Hann. Munden, Germany
WH58.30-Z-1001-03A Round wire brush, braided, dia. 70 mm
WH58.30-Z-1021-04A Cutting disk, dia. 65 mm, 80 m/s (max. 23, 500 RPM)
WH58.30-Z-1024-04A Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM)
WH58.30-Z-1001-40A Tarp (fire-resistant)
WORKSHOP EQUIPMENT

WE58.40-Z-1002-02A Spot welder
WE58.40-Z-1001-03A Drill (electric/pneumatic)
WE58.40-Z-1002-03A Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A Body saw (electric/pneumatic)
WE58.40-Z-1005-03A Wet/dry vacuum cleaner
WE58.40-Z-1001-05A Two-post lifting platform
WE58.40-Z-1003-14A Blind rivet tool
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1003-01A Sealant 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 Preservation agent 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-1005-13A Rivet A 003 990 75 97
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