Replace bottom rear end center assembly together with rear cross member - AR64.20-P-1060T
MODEL 211.0
| 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. Pour fuels only into suitable and appropriately marked containers. | AS47.00-Z-0001-01A | |
| 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 | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1 | Remove detachable parts in vehicle interior (repair area) | ||
| 2 | Cover all detachable body components remaining in vehicle (area to be repaired) | Tarpaulin (fireproof) | |
| 3 | Equip straightening bench with modular members, cross members and straightening bracket set. | ||
| 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 | |||
| 4 | Place vehicle on straightening bench using two-column lift | Two-column lift http://gotis.aftersales.mercedes-benz.com | |
| 5 | Attach vehicle to straightening bench | ||
| 6 | Cut off bottom rear end center assembly (1) | AR64.20-P-1000-02T | |
| 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) | |||
| 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 | |||
| Body saw (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 | ||
| 7 | Remove rear cross member (3) | AR64.20-P-1100-01T | |
| Figure | |||
| Spherical milling cutter, dia. 12 mm | |||
| Round wire brush, braided, dia. 70 mm | |||
| Vario Drill WS 91 spot-weld loosening tool | |||
| 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 | |||
| Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com | |||
| Zinc dust paint which can be spot welded | *BR00.45-Z-1001-07A | ||
| 8 | Prepare new parts | AR64.20-P-1060-02T | |
| Figure | |||
| Spherical milling cutter, dia. 12 mm | |||
| Round wire brush, braided, dia. 70 mm | |||
| Vario Drill WS 91 spot-weld loosening tool | |||
| 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 | ||
| Install | |||
| 9 | Install and weld in rear cross member (3) | AR64.20-P-1060-03T | |
| General notes on riveting | AH60.00-P-0003-01N | ||
| Electrode miller | |||
| 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 | |||
| Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com | |||
| Two-column lift http://gotis.aftersales.mercedes-benz.com | |||
| Inert gas welder http://gotis.aftersales.mercedes-benz.com | |||
| Spot welder http://gotis.aftersales.mercedes-benz.com | |||
| Sealant | *BR00.45-Z-1003-01A | ||
| Preservation agent | *BR00.45-Z-1003-05A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 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 | ||
| 10 | Install and weld in bottom rear end center assembly (1) | AR64.20-P-1000-08T | |
| Figure | |||
| Round wire brush, braided, dia. 70 mm Electrode miller | |||
| Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 RPM) | |||
| Clamping pliers | |||
| Manual temporary fastener, dia. | |||
| 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 | |||
| Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com | |||
| Tarpaulin (fireproof) | |||
| Spot welder http://gotis.aftersales.mercedes-benz.com | |||
| Angular grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com | |||
| Polygrip flat/round head rivet, 6.4x14 | *BR00.45-Z-1001-13A | ||
| Sealant | *BR00.45-Z-1003-01A | ||
| Preservation agent | *BR00.45-Z-1003-05A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 11 | Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01T | |
| Rear fender to taillamp | *BE60.00-P-1003-01F | ||
| Trunk lid to top of rear fender | *BE60.00-P-1003-01F | ||
| Trunk lid cover to taillamp | *BE60.00-P-1003-01F | ||
| Trunk lid to taillamp | *BE60.00-P-1003-01F | ||
| 12 | Unfasten vehicle from straightening bench | ||
| 13 | Lift vehicle with two-column lift | Two-column lift http://gotis.aftersales.mercedes-benz.com | |
| 14 | Remove straightening bench. | ||
| 15 | Clean weld joints and metal flanges with wire brush | ||
| 16 | Clean area to be repaired | ||
| 17 | Prime area to be repaired with primer/filler | ||
| 18 | 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 | ||
| 19 | Paint repair areas and adjacent surfaces | ||
| 20 | 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 | ||
| 21 | Remove tarpaulin from all covered parts that remained in the vehicle | Tarpaulin (fireproof) | |
| 22 | Install all removed detachable body components in passenger compartment area repaired |
TEST VALUES FOR GAPS ON HOODS, DOORS AND LIDS
| Number | Designation | Model 211.0 | |||
|---|---|---|---|---|---|
| BE60.00-P-1003-01F | Size of gap | Trunk lid to top of rear fender | Dimension "J" | mm | 3.5 (+1) |
| Trunk lid to taillamp | Dimension "K" | mm | 3.9 (+1) | ||
| Trunk lid to bumper | Dimension "L" | mm | 6.5 (-0.5/+1) | ||
| Rear fender to taillamp | Dimension "M" | mm | 2.5 (±0.5) | ||
| Trunk lid cover to taillamp | Dimension "N" | mm | 4.3 (+1) | ||
| Fig. see | AR60.00-P-0700-01T |
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 6.4x14 | A 003 990 35 97 |