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Completely remove/install rear longitudinal member - AR64.20-P-1220GZ

Model 164.1 

Fig 1: Identifying Rear Longitudinal Member Components
G05259508Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVING Remove     
DANGER 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 below the hoist support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
DANGER 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
DANGER 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 danger zone. Use air extractor. AS00.00-Z-0007-01A
NOTES General information on body repair All models AH60.00-N-0001-01A
1 Remove detachable body components in the repair area    
2 Cover detachable body components remaining in vehicle (area to be repaired). Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
3 Set up straightening bench and position vehicle on straightening bench IMPORTANT Use straightening bench to replace rear longitudinal member AR60.10-P-1060GZ
4 Completely separate C and D-pillar side wall   AR63.10-P-0800GZ
5 Separate deformed rear area   AR64.20-P-1200GZ
6 Remove rear longitudinal member (6)   AR64.20-P-1200-22GZ 
    SPECIAL TOOL Spot weld milling cutter Figure
    COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot weld removing tool *WH58.30-Z-1006-01A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Cutting disk, dia. 50 mm, 80 m/s (max. 30,600 rpm) *WH58.30-Z-1022-04A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
    Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
7 Prepare connection surfaces on vehicle for rear longitudinal member (6)   AR64.20-P-1200-34GZ 
    COMMERCIALLY AVAILABLE TOOLS Hole punching pliers, dia. 7 mm *WH58.30-Z-1002-02A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
8 Prepare rear longitudinal member (6) for installation   AR64.20-P-1200-23GZ 
    COMMERCIALLY AVAILABLE TOOLS Hole punching pliers, dia. 7 mm *WH58.30-Z-1002-02A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install     
9 Install rear longitudinal member (6)   AR64.20-P-1200-24GZ 
NOTES Measures for preventing damage to vehicles or components when performing arc welding work All models AH00.00-N-0005-01A
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    COMMERCIALLY AVAILABLE TOOLS Hole punching pliers, dia. 7 mm *WH58.30-Z-1002-02A 
    Inert gas welder *WE58.40-Z-1001-02A 
    Spot welder *WE58.40-Z-1002-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
10 Prepare connection surfaces on vehicle for inner C and D-pillar   AR63.10-P-0800-09GZ
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disc, dia. 115 mm, 80 m/s (max. 13,250 rpm) *WH58.30-Z-1024-04A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
11 Prepare inner C and D-pillar side wall   AR63.10-P-0800-02GZ
    COMMERCIALLY AVAILABLE TOOLS Hole punching pliers, dia. 7 mm *WH58.30-Z-1002-02A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
12 Install and weld in inner C and D-pillar side wall   AR63.10-P-0800-03GZ
NOTES Measures for preventing damage to vehicles or components when performing arc welding work All models AH00.00-N-0005-01A
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disc, dia. 115 mm, 80 m/s (max. 13,250 rpm) *WH58.30-Z-1024-04A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disc, dia. 50 mm, 80 m/s (max. 23,000 rpm) *WH58.30-Z-1023-04A 
    Inert gas welder *WE58.40-Z-1001-02A 
    Spot welder *WE58.40-Z-1002-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Heat gun *WH58.30-Z-1004-20A 
13 Prepare connection surfaces on vehicle   AR64.20-P-1200-32GZ 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disc, dia. 115 mm, 80 m/s (max. 13,250 rpm) *WH58.30-Z-1024-04A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
14 Prepare new parts   AR64.20-P-1060-02GZ 
    COMMERCIALLY AVAILABLE TOOLS Hole punching pliers, dia. 7 mm *WH58.30-Z-1002-02A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
15 Install new parts, left side rear damage   AR64.20-P-1200-33GZ 
NOTES Measures for preventing damage to vehicles or components when performing arc welding work All models AH00.00-N-0005-01A
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disc, dia. 115 mm, 80 m/s (max. 13,250 rpm) *WH58.30-Z-1024-04A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disc, dia. 50 mm, 80 m/s (max. 23,000 rpm) *WH58.30-Z-1023-04A 
    Inert gas welder *WE58.40-Z-1001-02A 
    Spot welder *WE58.40-Z-1002-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
16 Install outer side wall   AR63.10-P-0805GZ
17 Install vehicle identification number   AR60.00-P-0800GZ
18 Remove vehicle from straightening bench   AR60.10-P-1060GZ
19 Clean repair areas    
20 Prime area to be repaired with priming filler IMPORTANT See Paintwork Manual.  
21 Perform seam sealing after repair   AR97.10-P-4000GZ
22 Paint repair areas and adjacent surfaces IMPORTANT See Paintwork Manual.  
23 Apply additional cavity preservation   AR97.20-P-1500GZ
24 Remove tarpaulin from all covered parts that remained in the vehicle. Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
25 Reinstall all detachable body components removed    
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G05259509Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1006-01A Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1002-02A Hole punching pliers, dia. 7 mm
WH58.30-Z-1003-02A Clamping pliers
WH58.30-Z-1001-03A Round wire brush, braided, dia. 70 mm
WH58.30-Z-1022-04A Cutting disk, dia. 50 mm, 80 m/s (max. 30,600 rpm)
WH58.30-Z-1023-04A Abrasive disk, dia. 50 mm, 80 m/s (max. 23,000 rpm)
WH58.30-Z-1024-04A Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)
WH58.30-Z-1004-20A Hot-air gun
WH58.30-Z-1001-40A Tarp (fire-resistant)
WORKSHOP EQUIPMENT

WE58.40-Z-1001-02A Inert gas welder
WE58.40-Z-1002-02A Spot welder
WE58.40-Z-1001-03A Drill (electric/pneumatic)
WE58.40-Z-1002-03A Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A Body saw (electric/pneumatic)
WE58.40-Z-1005-03A Wet/dry vacuum cleaner
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
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