Replace complete bottom rear center section - AR64.20-P-1000T
MODEL 211.0
| Removing | |||
| 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 | |
| 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 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 | |
| General information on repairs to body | All models | AH60.00-N-0001-01A | |
| Measures for preventing damage to vehicles or components when performing electric welding work | All models | AH00.00-N-0005-01A | |
| Notes on paintwork repairs | All models | AH98.00-P-9408-02A | |
| General information on MB materials | All models | 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) | Tarp (fire-resistant) | |
| 3 | Cut off rear end center assembly | AR64.20-P-1000-02T | |
Ball cutter, dia. 12 mm Round wire brush, braided, dia. 70 mm Vario Drill WS 91 spot weld removing tool Abrasive disk, dia. 115 mm, 80m/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 Body saw (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com |
Figure | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 4 | Prepare bottom rear center section for installation | AR64.20-P-1000-07T | |
| Round wire brush, braided, dia. 70 mm Drill (electric/pneumatic) | |||
| http://gotis.aftersales.mercedes-benz.com Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 5 | Install and weld in bottom rear center section | AR64.20-P-1000-08T | |
Round wire brush, braided, dia. 70 mm Electrode miller Clamping pliers |
Figure | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| Hand riveter PowerBird blind rivet tool http://gotis.aftersales.mercedes-benz.com Manual temporary fastener, dia. 6.4 mm - clamping range 0 - 15 mm, identification color silver Polygrip flat round head rivet, 6.4 x 14 mm |
*BR00.45-Z-1001-13A | ||
| Inert gas welder http://gotis.aftersales.mercedes-benz.com |
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| 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 |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Sealant | *BR00.45-Z-1003-01A | ||
| MB preservative | *BR00.45-Z-1003-05A | ||
| 6 | Adjust gap dimensions on hoods, doors and covers | AR60.00-P-0700-01T | |
| Rear fender/taillamp | *BE60.00-P-1003-01F | ||
| Trunk lid/upper rear fender | *BE60.00-P-1003-01F | ||
| Trunk lid cover/taillamp | *BE60.00-P-1003-01F | ||
| Rear door/upper side section | *BE60.00-P-1002-01F | ||
| Rear door/bottom side section | *BE60.00-P-1002-01F | ||
| Fuel filler flap | *BE60.00-P-1004-01F | ||
| 7 | Clean weld joints and metal flanges with wire brush | ||
| 8 | Clean repair areas and prime using primer filler | ||
| 9 | Seam sealing following repair | AR97.10-P-4000T | |
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 10 | Paint repair areas and adjacent surfaces | ||
| 11 | Cavity preservation following repair work | ||
| Notes on cavity preservation | Models 124, 126, 129, 140, 170, 201, 202, 203, 208, 210, 211, 215, 220, 463, 671 | AH97.20-P-0001-01B | |
| 12 | Install all removed detachable body components |
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS
| Number | Designation | Model 211.0 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01F | Gap dimension | Front door to A-pillar | Dimension "D" | mm | 4.5 (±0.5) |
| Front door to fender | Dimension "E" | mm | 4 (±0.5) | ||
| Front door to rear door | Dimension "F" | mm | 4 (+1) | ||
| Front door to roof | Dimension "G" | mm | 4.5 (±0.5) | ||
| Rear door to top of side section | Dimension "H" | mm | 4.5 (±0.5) | ||
| Rear door to side section, bottom | Dimension "I" | mm | 3.5 (±0.5) | ||
| See picture | AR60.00-P-0700-01T | ||||
| BE60.00-P-1003-01F | Gap dimension | Trunk lid to rear fender, top | Dimension "J" | mm | 3.5 (+1) |
| Trunk lid to rear lamp unit | Dimension "K" | mm | 3.9 (+1) | ||
| Trunk lid to bumper | Dimension "L" | mm | 6.5 (-0.5/+1) | ||
| Rear fender to rear lamp unit | Dimension "M" | mm | 2.5 (±0.5) | ||
| Trunk lid license plate panel to rear lamp unit | Dimension "N" | mm | 4.3 (+1) | ||
| See picture | AR60.00-P-0700-01T | ||||
| BE60.00-P-1004-01F | Gap dimension | Fuel filler flap | Dimension "O" | mm | 3.5 (±0.5) |
| See picture | AR60.00-P-0700-01T | ||||
REPAIR MATERIALS CHART
| 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 14 | A 003 990 35 97 |