Left side rear end damage - AR64.20-P-1200TA
WARNING: This page is about a different car, the 2009 Mercedes-Benz E350 and 2008 Mercedes-Benz E350. However, it is still accessible from the selected car via links, so may be relevant.
MODEL 211.2
| 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 spatter 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 repairs to body | All models | AH60.00-N-0001-01A | |
| Guidelines for removing fuel tank when performing welding work on bodies | All models | AH60.00-P-3000-01Z | |
| Notes on paintwork repairs | 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-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 all detachable parts in area to be repaired | ||
| 2.1 | Install filler neck covering | AR63.50-P-1400-01TA | |
| *211589009100 | |||
| *211589029100 | |||
| 3 | Cover detachable body components which remain in vehicle | Tarp (fire-resistant) | |
| 4 | Equip straightening bench with module members, cross members and straightening bracket set. | Celette straightening bench M8S http://gotis.aftersales.mercedes-benz.com Sevenne Celette straightening bench http://gotis.aftersales.mercedes-benz.com Set of Celette modular members 955.940 http://gotis.aftersales.mercedes-benz.com Celette auxiliary cross 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 tool set 7211.300 (for model 211) http://gotis.aftersales.mercedes-benz.com Car-Bench straightening tool 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 |
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| 5 | Lift vehicle with two-post lift | Two-post lift http://gotis.aftersales.mercedes-benz.com |
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| 6 | Set vehicle onto straightening bench | ||
| 7 | Fasten vehicle to straightening bench | ||
| 8 | Remove D-pillar (1) | AR63.20-P-2000TA | |
| 9 | Separate deformed rear area | AR64.20-P-1200-11TA | |
Ball cutter, dia. 12 mm Vario Drill WS 91 spot weld removing tool Round wire brush, braided, dia. 70 mm Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 RPM) Cutting disk, Ø 65 mm, 80 m/s (max. 23,500 RPM) Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Angle grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Body saw (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com Tarp (fire-resistant |
*201589005100 | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 10 | Prepare spare wheel well (7) and inner crossmember (6) | AR64.20-P-1245-02TA | |
| Round wire brush, braided, dia. 70 mm Abrasive disk, Ø 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 Angle grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 11 | Prepare left rear longitudinal member (3) with console (5) and reinforcement (4) | AR64.20-P-1200-30TA | |
| Round wire brush, braided, dia. 70 mm Abrasive disk, Ø 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 Angle grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 12 | Prepare left cover plate (2) on left rear longitudinal member (3) | AR64.20-P-1240-02TA | |
| Hole punching pliers, dia. 7 mm Round wire brush, braided, dia. 70 mm Abrasive disk, Ø 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 Angle grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 13 | Install spare wheel well (7), left rear longitudinal member (3) with console (5) and reinforcement (4) | AR64.20-P-1200-31TA | |
| General information on riveting | Models 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639 Electrode miller C-clamps 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 Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 RPM) PowerBird blind rivet tool http://gotis.aftersales.mercedes-benz.com Hand riveter Inert gas welder http://gotis.aftersales.mercedes-benz.com Spot welder http://gotis.aftersales.mercedes-benz.com Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com Tarp (fire-resistant) Two-post lift http://gotis.aftersales.mercedes-benz.com Cavity preservation gun, Sata HRS no. 11072 http://gotis.aftersales.daimlerchrysler.com |
AH60.00-P-0003-01N | |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Sealant | *BR00.45-Z-1003-01A | ||
| MB cavity wax preservation, 1 l | *BR00.45-Z-1003-05A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| Polygrip flat round head rivet, 6.4 x 14 | *BR00.45-Z-1001-13A | ||
| 14 | Install and weld in left cover plate (2) | AR64.20-P-1200-05T | |
| General information on riveting | Models 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639 Electrode miller Clamping pliers Hand riveter Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver PowerBird blind rivet tool http://gotis.aftersales.mercedes-benz.com Inert gas welder http://gotis.aftersales.mercedes-benz.com Spot welder http://gotis.aftersales.mercedes-benz.com |
AH60.00-P-0003-01N | |
| Sealant | *BR00.45-Z-1003-01A | ||
| MB cavity wax preservation, 1 l | *BR00.45-Z-1003-05A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 15 | Install inner rear center section (8) | AR64.20-P-1000-04TA | |
| General information on riveting | Models 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639 | AH60.00-P-0003-01N | |
| *129589032100 | |||
Electrode miller Clamping pliers Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver PowerBird blind rivet tool http://gotis.aftersales.mercedes-benz.com Hand riveter Inert gas welder http://gotis.aftersales.mercedes-benz.com Spot welder http://gotis.aftersales.mercedes-benz.com Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Angle grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com Tarp (fire-resistant) Cavity preservation gun, Sata HRS no. 11072 http://gotis.aftersales.daimlerchrysler.com |
*000589876300 | ||
| Sealant | *BR00.45-Z-1003-01A | ||
| MB cavity wax preservation, 1 l | *BR00.45-Z-1003-05A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Polygrip flat round head rivet, 6.4 x 14 | *BR00.45-Z-1001-13A | ||
| Rear fender to rear lamp unit | *BE60.00-P-1003-01F | ||
| Rear-end door to rear fender | *BE60.00-P-1005-01F | ||
| Taillamp in rear-end door to taillamp | *BE60.00-P-1005-01F | ||
| Rear window and D-pillar | *BE60.00-P-1005-01F | ||
| 16 | Install D-pillar (1) | AR63.20-P-2000TA | |
| 17 | Install outer rear center section (9) | AR64.20-P-1000-04TA | |
| General information on riveting | Models 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639 | AH60.00-P-0003-01N | |
| *129589032100 | |||
Electrode miller Clamping pliers Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver PowerBird blind rivet tool http://gotis.aftersales.mercedes-benz.com Hand riveter Inert gas welder http://gotis.aftersales.mercedes-benz.com Spot welder http://gotis.aftersales.mercedes-benz.com Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Angle grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com Tarp (fire-resistant) Cavity preservation gun, Sata HRS no. 11072 http://gotis.aftersales.daimlerchrysler.com |
*000589876300 | ||
| Sealant | *BR00.45-Z-1003-01A | ||
| MB cavity wax preservation, 1 l | *BR00.45-Z-1003-05A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Polygrip flat round head rivet, 6.4 x 14 | *BR00.45-Z-1001-13A | ||
| Rear fender to rear lamp unit | *BE60.00-P-1003-01F | ||
| Rear-end door to rear fender | *BE60.00-P-1005-01F | ||
| Taillamp in rear-end door to taillamp | *BE60.00-P-1005-01F | ||
| Rear window and D-pillar | *BE60.00-P-1005-01F | ||
| 18 | Adjust gaps on hoods, doors and lids | AR60.00-P-0700-01TA | |
| *129589032100 | |||
| Rear fender to rear lamp unit | *BE60.00-P-1003-01F | ||
| Rear-end door to rear fender | *BE60.00-P-1005-01F | ||
| Taillamp in rear-end door to taillamp | *BE60.00-P-1005-01F | ||
| Rear window and D-pillar | *BE60.00-P-1005-01F | ||
| 19 | Unfasten vehicle from straightening bench | ||
| 20 | Lift vehicle with two-post lift | Two-post lift http://gotis.aftersales.mercedes-benz.com |
|
| 21 | Remove straightening bench. | ||
| 22 | Clean weld joints and sheet metal flange with round wire brush | Round wire brush, braided, dia. 70 mm | |
| 23 | Clean repair areas | ||
| 24 | Prime area to be repaired using primer filler | ||
| 25 | Carry out seam sealing after repairs | AR97.10-P-4000T | |
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 26 | Paint repair areas and adjacent surfaces | ||
| 27 | Apply additional cavity preservation | AR97.20-P-1500T | |
| 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 Cavity preservation gun, Sata HRS no. 11072 http://gotis.aftersales.daimlerchrysler.com |
AH97.20-P-0001-01B | |
| MB cavity wax preservation, 1 l | *BR00.45-Z-1003-05A | ||
| 28 | Remove tarp | ||
| 29 | Install all removed detachable body components |
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS
| Number | Designation | Model 211.2 | |||
|---|---|---|---|---|---|
| BE60.00-P-1003-01F | Gap dimension | Trunk lid to rear fender, top | Dimension "J" | mm | - |
| Trunk lid to rear lamp unit | Dimension "K" | mm | - | ||
| Trunk lid to bumper | Dimension "L" | mm | - | ||
| Rear fender to rear lamp unit | Dimension "M" | mm | 2.5 (±1) | ||
| Trunk lid license plate panel to rear lamp unit | Dimension "N" | mm | - | ||
| See picture | AR60.00-P-0700-01TA | ||||
| BE60.00-P-1005-01F | Gap dimension | Liftgate spoiler/roof | Dimension "P" | mm | 7 (-0.5/+1) |
| Rear-end door to rear fender | Dimension "Q" | mm | 4.5 (±1) | ||
| Taillamp in rear-end door to taillamp | Dimension "R" | mm | 5 (±1) | ||
| Rear-end door to bumper | Dimension "S" | mm | 6 (±1.5) | ||
| Rear window and D-pillar | Dimension "T" | mm | 4.5 (±1) | ||
| Front door to roof | Dimension "U" | mm | 4.5 (-0.5/+1) | ||
| See picture | AR60.00-P-0700-01TA | ||||
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-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 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-1001-13A | Blind rivet 6.4 x 14 | A 003 990 35 97 |