Replace bottom rear center section together with rear crossmember - AR64.20-P-1060Y

MODEL 219 

Fig 1: Identifying Rear Center Section, Reinforcement And Rear Crossmember

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 splatter 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
	General information on body repair	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	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 rear bumper		AR88.20-P-2200TX
2	Remove taillamps		AR82.10-P-4905TX
3	Cover all detachable parts remaining in vehicle	Tarp (fire-resistant)
4	Set up Celette straightening bench		AR60.10-P-1060Y
5	Car-Bench straightening bench setup		AR60.10-P-1090Y
6	Lift vehicle with two-post lift	Two-post lifting platform 3.0-3.5 t, electromechanical
7	Set vehicle onto straightening bench
8	Fasten vehicle to straightening bench
9	Separate rear center section (1) and reinforcement (2)		AR64.20-P-1000-02Y
		Spot weld milling cutter	Figure
		Ball cutter, dia. 12 mm Vario Drill WS 91 spot weld removing tool Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Drill   Angle grinder   Wet/dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
10	Remove rear cross member (3)		AR64.20-P-1100-01Y
		Spot weld milling cutter	Figure
		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) Drill   Angle grinder   Wet/dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
11	Prepare rear center section (1) and reinforcement (2) for installation		AR64.20-P-1000-07Y
		Round wire brush, braided, dia. 70 mm Drill
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
12	Prepare rear crossmember (3) for installation		AR64.20-P-1060-02Y
		Spot weld milling cutter	Figure
		Ball cutter, dia. 12 mm Vario Drill WS 91 spot weld removing tool Round wire brush, braided, dia. 70 mm Drill
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
13	Install and weld in rear crossmember (3)		AR64.20-P-1060-03Y
	General information on riveting	Model 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639	AH60.00-P-0003-01N
		Electrode miller Clamping pliers Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver Blind rivet/punch riveting method   Hand riveter Inverter spot welder   Drill   Wet/dry vacuum cleaner
		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
		Polygrip countersunk-head rivet, 6.4 X 14	*BR00.45-Z-1002-13A
14	Install rear center section (1) and reinforcement (2)		AR64.20-P-1000-08Y
	General information on riveting	Model 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639	AH60.00-P-0003-01N
		Feeler gauge Electrode miller 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 Blind rivet/punch riveting method Hand riveter MIG MAG gas welder (steel, brazing, aluminum) Inverter spot welder Drill	Figure
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Polygrip flat round head rivet, 6.4 14	*BR00.45-Z-1001-13A
		Trunk lid to rear fender, top	*BE60.00-P-1003-01O
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01O
		Rear fender to lamp unit	*BE60.00-P-1003-01O
15	Adjust gap dimensions on hoods, doors and lids		AR60.00-P-0700-01Y
		Feeler gauge	Figure
		Trunk lid to rear fender, top	*BE60.00-P-1003-01O
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01O
		Rear fender to lamp unit	*BE60.00-P-1003-01O
16	Unfasten vehicle from straightening bench
17	Lift vehicle with two-post lift	Two-post lifting platform 3.0-3.5 t, electromechanical
18	Remove straightening bench.
19	Clean weld joints and sheet metal flange with round wire brush	Round wire brush, braided, dia. 70 mm Drill
20	Clean repair area
21	Prime repair area with primer filler
22	Carry out seam sealing after repairs	Supplement standard sealants with MB body sealant.	AR97.10-P-4000Y
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
23	Paint repair areas and adjacent surfaces
24	Cavity preservation following repair work		AR97.20-P-1500Y
	Notes on cavity preservation	Model 124, 126, 129, 140, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 219, 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	AH97.20-P-0001-01B
	Cavity preservation gun, SATA HRS	Combination pressure spray gun (corrosion protection)
		Preservation agent	*BR00.45-Z-1003-05A
25	Remove tarp	On all covered parts remaining in vehicle.
26	Install taillamps		AR82.10-P-4905TX
27	Install rear bumper		AR88.20-P-2200TX

TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number	Designation				Model 219
BE60.00-P-1003-01O	Gap dimension	Trunk lid to rear fender, top	Dim. "J"	mm	4.0 (±0.5)
		Trunk lid to rear lamp unit	Dim. "K"	mm	2.5 (±0.5)
		Trunk lid to bumper	Dim. "L"	mm	7.0 (±1)
		Rear fender to lamp unit	Dim. "M"	mm	2.5 (±0.5)
			See picture		AR60.00-P-0700-01Y

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

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	White sealing compound, 310 ml, DBL 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 sealant, 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
BR00.45-Z-1002-13A	Polygrip countersunk-head rivet, 6.4 14	A 003 990 86 97 05