Left side rear damage - AR64.20-P-1200T

MODEL 211.0 

Fig 1: Identifying Rear End Center Assembly, Rear Crossmember And Left Rear Longitudinal Member

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove
	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.
	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
	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
	Risk of explosion  caused by fuel igniting, risk of poisoning  caused by inhaling and swallowing fuel as well as risk of injury  to eyes and skin caused by contact with fuel.	No fire, sparks, open flames or smoking.	AS47.00-Z-0001-01A
		Pour fuels only into suitable and appropriately marked containers.
		Wear protective clothing when handling fuel.
	General information on body repair		AH60.00-N-0001-01A
	Measures for preventing damage to vehicles or components during electro-welding		AH00.00-N-0005-01A
	Notes on paintwork repairs		AH98.00-P-9408-02A
	Guidelines for removing fuel tank when performing welding work on bodies		AH60.00-P-3000-01Z
	General information on MB materials		AH98.00-P-9409-03A
1	Remove detachable parts in area to be repaired
2.1	Install fuel filler neck covering	When replacing right rear fender.	AR63.50-P-1400-01T
		Set of covers	Figure
3	Cover detachable body components which remain in vehicle	Tarpaulin (fireproof)
4	Equip straightening bench with modular members, cross members and straightening bracket set.	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 7211.308 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
5	Place vehicle on straightening bench using two-column lift	Two-column lift http://gotis.aftersales.mercedes-benz.com
6	Attach vehicle to straightening bench
7	Remove spare wheel well		AR88.30-P-1000T
8	Separate deformed rear area		AR64.20-P-1200-11T
		Spot weld milling cutter	Figure
		Cutting template	Figure
		Set of covers	Figure
		Spherical milling cutter, dia. 12 mm
		Vario Drill WS 91 spot-weld loosening tool
		Round wire brush, braided, dia. 70 mm
		Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 RPM)
		Hot air blower - 3000 W
		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
		Body saw (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com
		Two-column lift http://gotis.aftersales.mercedes-benz.com
		Tarpaulin (fireproof)
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
9	Prepare left rear longitudinal member (6) for installation	AR64.20-P-1200-20T
		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
10	Prepare rear fender for installation		AR63.50-P-1400-03T
		Round wire brush, braided, dia. 70 mm
		Hole punching pliers, 7 mm dia.
		Drill (electric/pneumatic)
		http://gotis.aftersales.mercedes-benz.com
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
11	Prepare bottom rear end center assembly (2) 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 which can be spot welded	*BR00.45-Z-1001-07A
	Install
12	Install and weld in left rear longitudinal member (6) and rear cross member (4)		AR64.20-P-1200-03T
	General notes on riveting		AH60.00-P-0003-01N
		Electrode miller
		Clamping pliers
		PowerBird blind rivet tool http://gotis.aftersales.mercedes-benz.com
		Hand riveter
		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
		Spot welder http://gotis.aftersales.mercedes-benz.com
		Drill (electric/pneumatic)
		http://gotis.aftersales.mercedes-benz.com
		Angular grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com
		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
13	Install and weld in left rear longitudinal member (6)		AR64.20-P-1200-05T
		Electrode miller
		Hole punching pliers, 7 mm dia.
		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
		Spot welder http://gotis.aftersales.mercedes-benz.com
		Sealant	*BR00.45-Z-1003-01A
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
		Preservation agent	*BR00.45-Z-1003-05A
14	Install rear end center assembly (2)		AR64.20-P-1000T
15	Installing rear fender		AR63.50-P-1400-04T
		Round wire brush, braided, dia. 70 mm
		Electrode miller
		PowerBird blind rivet tool http://gotis.aftersales.mercedes-benz.com
		Clamping pliers
		Hand riveter
		Manual temporary fastener, dia.
		6.4 mm, clamping area 0 to 15 mm, identification color silver
		Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 RPM)
		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
		Angular grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
	Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com
		Sealant	*BR00.45-Z-1003-01A
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
		Preservation agent	*BR00.45-Z-1003-05A
		Polygrip flat/round head rivet, 6.4x14	*BR00.45-Z-1001-13A
16	Unfasten vehicle from straightening bench
17	Lift vehicle with two-column lift	Two-column lift http://gotis.aftersales.mercedes-benz.com
18	Remove straightening bench.
19	Clean area to be repaired
20	Prime area to be repaired with primer/filler
21	Carry out seam sealing after repairs	Supplement standard sealant with MB body sealant	AR97.10-P-4000T
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
22	Paint repair areas and adjacent surfaces
23	Install spare wheel well		AR88.30-P-1000T
24	Cavity preservation following repair work		AR97.20-P-1500T
	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
25	Remove tarpaulin from all covered parts that remained in the vehicle	Tarpaulin (fireproof)
26	Install detachable body components removed

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Cutting Templates (211 589 05 23 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Tool When Replacing Right Rear Fender (211 589 00 91 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Feeler Gage (129 589 03 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1041-01A	Seam sealant, sprayable 310 ml	A 002 989 84 20
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-1001-13A	Blind rivet 6.4 14	A 003 990 35 97