LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 2011 >> S400 >> Repair and Diagnosis >> Collision >> Body Panels >> Rear Wall & Rear End - 221 Chassis >> Testing & Repair >> Left side rear end damage - AR64.20-P-1200SX

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

MODEL 221 

Fig 1: Identifying Left Side Rear End Damage Parts
G10128191Courtesy of MERCEDES-BENZ USA
REMOVING Removing     
DANGER 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
DANGER 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
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 at the lifting platform 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 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
NOTES General information on body repair   AH60.00-N-0001-01A
NOTES Pretreatment of bonding surfaces   AH60.00-P-0008-01SX
NOTES Notes on paintwork repairs   AH98.00-P-9408-02A
IMPORTANT General information on riveting   AH60.00-P-0003-01N
IMPORTANT Notes on various body materials   AH60.00-P-0011-01SX
IMPORTANT General information on dent removal and straightening aluminum parts   AH60.00-P-0012-01N
IMPORTANT General information on body connection techniques   AH60.00-P-0015-01SX
IMPORTANT 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 tail lamp   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 tool set. IMPORTANT Observe setup 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 set 82456		  
8 Lift vehicle with two-post lift Two-post lifting platform 3.0-3.5 t, electromechanical  
9 Set vehicle onto straightening bench    
10 Fasten vehicle to straightening bench    
11 Separate rear fender (1) Drill
Angle grinder		 AR63.50-P-1400-02SX
Body saw Body jig saw
Wet/dry vacuum cleaner
SPECIAL TOOL Spot weld milling cutter		  
SPECIAL TOOL Set of cutting templates Fig 4
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
REFER TO SHOP-MADE TOOLS Sheet metal crimping pliers for areas not easily accessible   WF58.50-P-6350-01Y
REFER TO FORMS Recycle aluminum parts   OS60.00-P-0001-01N
12 Separate bottom rear center section (2) with rear crossmember (3) Drill
Angle grinder		 AR64.20-P-1060-01SX
Body saw Body jig saw
Wet/dry vacuum cleaner		  
SPECIAL TOOL Spot weld milling cutter Figure
SPECIAL TOOL Spot weld cutter Figure
REFER TO FORMS 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
Wet/dry vacuum cleaner		 AR64.20-P-1260-01SX
SPECIAL TOOL Spot weld milling cutter Figure
14 Prepare new rear fender (1) Drill
Angle grinder		 AR63.50-P-1400-03SX
Body saw Body jig saw
Wet/dry vacuum cleaner		  
SPECIAL TOOL 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   AR64.20-P-1000-07SX
16 Prepare rear crossmember (3) for installation Drill AR64.20-P-1100-02SX
17 Prepare part of rear longitudinal member (4) and locking lug above rear axle (7) Drill
Angle grinder		 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		 AR64.20-P-1240-02SX
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING 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 welter, drill, wet/dry vacuum cleaner		 AR64.20-P-1260-03SX
Polygrip flat round head rivet, 6.4X14 *BR00.45-Z-1001-13A 
20 Install rear crossmember (3) Drill
Wet/dry vacuum cleaner		 AR64.20-P-1060-03SX
Polygrip flat round head rivet, 6.4X14 *BR00.45-Z-1001-13A 
Polygrip countersunk-head rivet, 6.4X14 *BR00.45-Z-1002-13A 
Adhesive *BR00.45-Z-1092-02A 
21 Install bottom rear section (2) Drill
Wet/dry vacuum cleaner		 AR64.20-P-1000-08SX
SPECIAL TOOL Feeler gauge Figure
Polygrip flat round head rivet, 6.4X14 *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 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 lids   AR60.00-P-0700-01SX
SPECIAL TOOL Feeler gauge Figure
Trunk lid to rear lamp unit *BE60.00-P-1003-01R 
Rear fender to 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 lifting platform 3.0-3.5 t, electromechanical  
25 Remove straightening bench.    
26 Install rear fender (1) and weld in   AR63.50-P-1400-04SX
BTR-Usibor drill, Ø 6.7 Drill bit and milling cutter for high-strength steels (USIBOR) and rivets  
Taurus 3 blind rivet tool with 100 mm extension unit Blind rivet/punch riveting method  
Inert gas welder, spot welder Inert gas welder (steel, brazing, aluminum)
Drill
Wet/dry vacuum cleaner		  
Rear door to side piece, bottom *BE60.00-P-1002-01R 
Trunk lid to rear lamp unit *BE60.00-P-1003-01R 
Rear fender to lamp unit *BE60.00-P-1003-01R 
Trunk lid license plate panel to rear lamp unit *BE60.00-P-1003-01R 
Fuel filler flap *BE60.00-P-1004-01R 
SPECIAL TOOL Feeler gauge Figure
SPECIAL TOOL Bending iron Fig 6
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
Polygrip flat round head rivet, 6.4X14 *BR00.45-Z-1001-13A 
Polygrip countersunk-head rivet, 6.4X14 *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
SPECIAL TOOL Feeler gauge Figure
Rear door to side piece, bottom *BE60.00-P-1002-01R 
Trunk lid to rear lamp unit *BE60.00-P-1003-01R 
Rear fender to lamp unit *BE60.00-P-1003-01R 
Trunk lid license plate panel to rear lamp unit *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  
29 Clean repair areas    
30 Prime repair area using primer filler    
31 Carry out seam sealing after repairs IMPORTANT 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   AR97.20-P-1500SX
Cavity preservation gun Sata HRS no. 11072 Combination pressure spray gun (corrosion protection)  
Preservation agent *BR00.45-Z-1003-05A 
NOTES Notes on cavity preservation   AH97.20-P-0001-01B
34 Remove tarp IMPORTANT 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 tail lamp   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 piece, 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 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)
G07692600Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Spot Weld Milling Cutter (215 589 00 51 00)
G07635063Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Set Of Cutting Templates (221 589 03 23 00)
G07321169Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Feeler Gauge (129 589 03 21 00)
G07699374Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Bending Iron (129 589 00 27 00)
G07501279Courtesy 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-1092-02A Adhesive kit, body, 2-component adhesive A 009 989 36 71
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 6.4X14 A 003 990 35 97
BR00.45-Z-1002-13A Polygrip countersunk-head rivet, 6.4X14 A 003 990 86 97 05
scientia non olet · About LEMON Manuals