Left side rear end damage - AR64.20-P-1200GY: Notes

MODEL 164.8

Fig 1: Identifying Left Side Rear End Damage Parts Location

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove
	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 repairs to body	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).	Tarp (fire-resistant)	*WH58.30-Z-1001-40A
3	Set up straightening bench and position vehicle on straightening bench		AR60.10-P-1060GZ
4	Separate deformed rear area		AR64.20-P-1200-11GX
		Set of cutting templates	Figure
		Template	Figure
		Cutting template	Figure
		Spot weld milling cutter	Figure
		Ball cutter, dia. 12 mm	*WH58.30-Z-1002-01A
		Vario Drill WS 91 spot weld removing tool	*WH58.30-Z-1006-01A
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		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
5	Prepare mating surfaces on vehicle		AR64.20-P-1200-32GX
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)	*WH58.30-Z-1024-04A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Angle 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
6	Prepare new parts		AR64.20-P-1060-02GW
		Hole punching pliers, 7 mm dia.	*WH58.30-Z-1002-02A
		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
	Install
	Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly Remove 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. inflammable materials from the hazard area. Use air extractor system.	AS00.00-Z-0007-01A
7	Install new parts, left side rear damage		AR64.20-P-1200-33GY
	Measures for preventing damage to vehicles or components when performing electric welding work	All models	AH00.00-N-0005-01A
		Clamping pliers	*WH58.30-Z-1003-02A
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)	*WH58.30-Z-1024-04A
		Abrasive disk, 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
		Angle 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
8	Install rear fender		AR63.50-P-1400GY
9	Install outer rear center section		AR64.20-P-1000-10GY
10	Remove vehicle from straightening bench		AR60.10-P-1060GZ
11	Clean repair areas
12	Prime area to be repaired with primer filler
13	Perform seam sealing after repair		AR97.10-P-4000GZ
14	Paint repair areas and adjacent surfaces
15	Apply additional cavity preservation		AR97.20-P-1500GZ
16	Remove tarpaulin from vehicle Tarp (fire-resistant)		*WH58.30-Z-1001-40A
17	Reinstall all detachable body components removed

Fig 2: Identifying Set Of Cutting Templates (164 589 04 23 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Template (164 589 08 23 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Cutting Template (164 589 18 23 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1002-01A	Ball cutter, dia. 12 mm
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-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