Left side rear end damage - AR64.20-P-1200SX

MODEL 221 

Fig 1: Identifying Rear End Components

Courtesy of MERCEDES-BENZ USA

	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
	Risk of explosion  from aluminum grinding dust, risk of injury  to respiratory system from inhaling dust	Wear protective respiratory mask, protective gloves and safety glasses. Use suitable, grounded vacuum cleaner	AS60.00-Z-0007-01N
	General information on repairs to body		AH60.00-N-0001-01A
	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	Notes on paintwork repairs		AH98.00-P-9408-02A
	General information on riveting		AH60.00-P-0003-01N
	Notes on various body materials		AH60.00-P-0011-01SX
	General information on dent removal and straightening aluminum parts		AH60.00-P-0012-01N
	General information on body connection techniques		AH60.00-P-0015-01SX
	General information on MB materials		AH98.00-P-9409-03A
1	Remove rear door sill molding	Vehicles without code (Z07) Top protection	AR68.30-P-4100SX
		Vehicles with code (Z07) Top protection	AR68.30-P-4100SXS
2	Remove rear wall window	Vehicles without code (Z07) Top protection	AR67.20-P-2000SX
		Vehicles with code (Z07) Top protection	AR67.20-P-2000SXS
3	Remove taillamp		AR82.10-P-4905SX
4	Remove rear bumper	Vehicles without code (Z07) Top protection	AR88.20-P-2200SX
		Vehicles with code (Z07) Top protection	AR88.20-P-2200SXS
5	Remove spare tire well (6)		AR88.30-P-1000SX
6	Cover all detachable parts remaining in vehicle with tarp
7	Equip straightening bench with module members, cross members and straightening bracket set.	Observe body plans provided. Celette straightening bench Set of Celette module members 955.940, Celette auxiliary member 955.908, Car-Bench straightening bench BT 17, Car-Bench universal crossmember set A 296, Car-Bench straightening bench BT 43/1, Multi-Z straightening set system MZ 450.000, Car-Bench straightening bench BT 140, Car-Bench universal crossmember set 296/19, Celette straightening bracket set 7221.300, Car-Bench straightening bracket set 82456, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM
8	Lift vehicle with two-post lift	Two-post lift, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM
9	Set vehicle onto straightening bench
10	Fasten vehicle to straightening bench
11	Separate rear fender (1)	Drill, angle grinder, body saw, dry vacuum cleaner, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM	AR63.50-P-1400-02SX
		Spot weld milling cutter	Figure
		Spot weld milling cutter	Figure
		Set of cutting templates	Fig 4
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Sheet metal crimping pliers for areas not easily accessible		WF58.50-P-6350-01Y
	Recycle aluminum parts		OS60.00-P-0001-01N
12	Separate bottom rear center section (2) with rear crossmember (3)	Drill, angle grinder, body saw, dry vacuum cleaner, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM	AR64.20-P-1060-01SX
		Spot weld milling cutter	Figure
		Spot weld cutter	Figure
	Recycle aluminum parts		OS60.00-P-0001-01N
13	Partially remove rear longitudinal member (4), rear locking lug (5) and locking lug above rear axle (7)	Drill, angle grinder, dry vacuum cleaner, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM	AR64.20-P-1260-01SX
		Spot weld milling cutter	Figure
14	Prepare new rear fender (1)	Drill, angle grinder, body saw, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM	AR63.50-P-1400-03SX
		Set of cutting templates	Fig 4
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
15	Prepare bottom rear center section (2) for installation	Drill, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM	AR64.20-P-1000-07SX
16	Prepare rear crossmember (3) for installation	Drill, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM	AR64.20-P-1100-02SX
17	Prepare part of rear longitudinal member (4) and locking lug above rear axle (7)	Drill, angle grinder, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM	AR64.20-P-1260-02SX
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
18	Prepare rear locking lug (5)	Drill, angle grinder, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM	AR64.20-P-1240-02SX
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
19	Install part of rear longitudinal member (4), rear locking lug (5) and locking lug above rear axle (7)	Taurus 3 blind rivet tool with 100 mm long extension unit Celette straightening bench Set of Celette module members 955.940, Celette auxiliary member 955.908, Car-Bench straightening bench BT 17, Car-Bench universal crossmember set A 296, Car-Bench straightening bench BT 43/1, Multi-Z straightening set system MZ 450.000, Car-Bench straightening bench BT 140, Car-Bench universal crossmember set 296/19, Celette straightening bracket set 7221.300, Car-Bench straightening bracket set 82456, inert gas welder, spot welder, drill, dry vacuum cleaner, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM	AR64.20-P-1260-03SX
		Polygrip flat round head rivet, 6.4 x14	*BR00.45-Z-1001-13A
20	Install rear crossmember (3)	Drill, dry vacuum cleaner, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM	AR64.20-P-1060-03SX
		Polygrip flat round head rivet, 6.4 x14	*BR00.45-Z-1001-13A
		Polygrip countersunk head rivet, 6.4 x14	*BR00.45-Z-1002-13A
		Adhesive	*BR00.45-Z-1092-02A
21	Install bottom rear section (2)	Drill, dry vacuum cleaner, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM	AR64.20-P-1000-08SX
		Feeler gauge	Figure
		Polygrip flat round head rivet, 6.4 x14	*BR00.45-Z-1001-13A
		Adhesive	*BR00.45-Z-1092-02A
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01R
		Rear fender to rear lamp unit	*BE60.00-P-1003-01R
		Trunk lid license plate panel to rear lamp unit	*BE60.00-P-1003-01R
22	Adjust gap dimensions on hoods, doors and		AR60.00-P-0700-01SX
		Feeler gauge	Figure
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01R
		Rear fender to rear lamp unit	*BE60.00-P-1003-01R
		Trunk lid license plate panel to rear lamp unit	*BE60.00-P-1003-01R
23	Unfasten vehicle from straightening bench
24	Lift vehicle with two-post lift	Two-post lift, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM
25	Remove straightening bench.
26	Install rear fender (1) and weld in	BTR-Usibor drill bit, dia. 6.7, Taurus 3 blind rivet tool with 100 mm extension unit, inert gas welder, spot welder, drill, dry vacuum cleaner, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM	AR63.50-P-1400-04SX
		Rear door to side section, bottom	*BE60.00-P-1002-01R
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01R
		Rear fender to rear lamp unit	*BE60.00-P-1003-01R
		Trunk lid license plate panel to rear lamp	*BE60.00-P-1003-01R
		Fuel filler flap	*BE60.00-P-1004-01R
		Feeler gauge	Figure
		Bending iron	Fig 6
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Polygrip flat round head rivet, 6.4 x14	*BR00.45-Z-1001-13A
		Polygrip countersunk head rivet, 6.4 x14	*BR00.45-Z-1002-13A
		Adhesive	*BR00.45-Z-1092-02A
27	Adjust gap dimensions on hoods, doors and lids		AR60.00-P-0700-01SX
		Feeler gauge	Figure
		Rear door to side section, bottom	*BE60.00-P-1002-01R
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01R
		Rear fender to rear lamp unit	*BE60.00-P-1003-01R
		Trunk lid license plate panel to rear lamp	*BE60.00-P-1003-01R
		Fuel filler flap	*BE60.00-P-1004-01R
28	Clean weld joints and sheet metal flange with round wire brush	Drill, see GOTIS ht.://GOTIS.aftersales.Mercedes-Benz.COM
29	Clean repair areas
30	Prime area to be repaired using primer filler
31	Carry out seam sealing after repairs	Supplement standard sealants with MB body sealant.	AR97.10-P-4000SX
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
32	Paint repair areas and adjacent surfaces
33	Cavity preservation following repair work	Cavity preservation gun HRS no. 11072, see	AR97.20-P-1500SX
		GOTIS
		ht.://GOTIS.aftersales.Mercedes-Benz.COM
		Preservation agent	*BR00.45-Z-1003-05A
	Notes on cavity preservation		AH97.20-P-0001-01B
34	Remove tarp	On all covered parts remaining in vehicle.
35	Install rear wall window	Vehicles without code (Z07) Top protection	AR67.20-P-2000SX
		Vehicles with code (Z07) Top protection	AR67.20-P-2000SXS
36	Install spare tire well (6)		AR88.30-P-1000SX
37	Install taillamp		AR82.10-P-4905SX
38	Install rear bumper	Vehicles without code (Z07) Top protection	AR88.20-P-2200SX
		Vehicles with code (Z07) Top protection	AR88.20-P-2200SXS
39	Install rear door sill molding	Vehicles without code (Z07) Top protection	AR68.30-P-4100SX
		Vehicles with code (Z07) Top protection	AR68.30-P-4100SXS

CHECK VALUES FOR GAPS

Number	Designation				Model 221
BE60.00-P-1002-01R	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	4.5 (±0.5)
		Trim strip at front door to roof frame	Dimension "G"	mm	4.5 (±0.5)
		Trim strip at rear door to roof frame	Dimension "H"	mm	4.5 (±0.5)
		Rear door to side section, bottom	Dimension "I"	mm	4.5 (±0.5)
		Front door cover to rear door cover	Dimension "S"	mm	4.5 (±0.5)
			See picture		AR60.00-P-0700-01SX
BE60.00-P-1003-01R	Gap dimension	Trunk lid to rear fender, top	Dimension "J"	mm	4 (±0.5)
		Trunk lid to rear lamp unit	Dimension "K"	mm	4 (±0.5)
		Trunk lid to bumper	Dimension "L"	mm	5.5 (±1.5)
		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 (±0.5)
			See picture		AR60.00-P-0700-01SX
BE60.00-P-1004-01R	Gap dimension	Fuel filler flap	Dimension "O"	mm	3.5 (±0.5)
			See picture		AR60.00-P-0700-01SX

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

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Spot Weld Milling Cutter (215 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Set Of Cutting Templates (221 589 03 23 00)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

Fig 6: Identifying Bending Iron (129 589 00 27 00)

Courtesy of MERCEDES-BENZ USA

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-1092-02A	Adhesive kit, body, 2-component adhesive	A 009 989 36 71
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
BR00.45-Z-1002-13A	Polygrip countersunk head rivet, 6.4 x14	A 003 990 86 97 05