Replace complete bottom rear center section - AR64.20-P-1000SX

MODEL 221, 216

Fig 1: Identifying Bottom Rear Center Section And Mount Below tail lamp - Shown On Model 221

Courtesy of MERCEDES-BENZ USA

Shown on model 221

	Removing
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of explosion from pressurized spray cans	Protect cans from direct sunlight and temperatures above 50 °C	AS00.00-Z-0015-01A
	Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes	Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only.	AS00.00-Z-0016-01A
	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 body repair		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 side paneling in trunk	Model 216, Model 221 without code (Z07) Top protection	AR68.30-P-4600SX
1	Remove side paneling in trunk	Model 221 with code (Z07) Highest protection	AR68.30-P-4600SXS
2	Remove rear bumper	Model 216	AR88.20-P-2200SC
		Model 221 without code (Z07) Top protection	AR88.20-P-2200SX
		Model 221 with code (Z07) Highest protection	AR88.20-P-2200SXS
3	Remove tail lamp		AR82.10-P-4905SX
4	Cover all detachable parts remaining in vehicle with tarp	Tarp (fire-resistant)
5	Separate bottom rear center section (1).		AR64.20-P-1000-02SX
		Spot weld cutter	Fig 3
		Spot weld cutter Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Hot-air gun - 3000 W Aluminum workshop vehicle Drill (electric/pneumatic) Straight grinder (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner	Fig 4
	Recycle aluminum parts		OS60.00-P-0001-01N
6	Prepare bottom rear center section (1) for installation		AR64.20-P-1000-07SX
6	Prepare bottom rear center section (1) for installation	Round wire brush, braided, dia. 70 mm Aluminum workshop vehicle Drill (electric/pneumatic)
	Install
7	Install bottom rear center section (1) and weld in		AR64.20-P-1000-08SX
		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
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01T
		Rear fender to rear lamp unit	*BE60.00-P-1003-01T
		Feeler gauge Clamping pliers Round wire brush, braided, dia. 70 mm Manual temporary fastener, dia. 6.4 mm, clamping area 0 to 15 mm, identification color silver Taurus 3 blind rivet tool with 100 mm long extension unit Aluminum workshop vehicle Drill (electric/pneumatic) Wet/dry vacuum cleaner	Fig 2
		Polygrip flat round head rivet, 6.4X14	*BR00.45-Z-1001-13A
		Adhesive	*BR00.45-Z-1092-02A
8	Adjust gaps on hoods, doors and lids	Model 221 gap dimensions	AR60.00-P-0700-01SX
		Feeler gauge	Fig 2
		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
		Model 216 gap dimensions	AR60.00-P-0700-01SC
		Feeler gauge	Fig 2
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01T
		Rear fender to rear lamp unit	*BE60.00-P-1003-01T
9	Clean repair area
10	Prime area to be repaired using primer filler
11	Seam sealing following repair	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
12	Paint repair areas and adjacent surfaces
13	Apply additional cavity preservation	Model 221	AR97.20-P-1500SX
		Model 216	AR97.20-P-1500SC
	Notes on cavity preservation		AH97.20-P-0001-01B
		Cavity preservation gun Sata HRS no. 11072
		Preservation agent	*BR00.45-Z-1003-05A
14	Remove tarp	On all covered parts remaining in vehicle.
15	Install tail lamp		AR82.10-P-4905SX
16	Install rear bumper	Model 216	AR88.20-P-2200SC
		Model 221 without code (Z07) Top protection	AR88.20-P-2200SX
		Model 221 with code (Z07) Highest protection	AR88.20-P-2200SXS
17	Install paneling on side in trunk	Model 221 without code (Z07) Top protection	AR68.30-P-4600SX
17	Install paneling on side in trunk	Model with code (Z07) Top protection	AR68.30-P-4600SXS

CHECK VALUES FOR GAPS

Number	Designation				Model 221
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 "L"	mm	2.5 (±0.5)
		Trunk lid license plate panel to rear lamp unit	Dimension "N"	mm	4 (±0.5)
		Trunk lid license plate panel to rear lamp unit	See picture		AR60.00-P-0700-01SX

CHECK VALUES FOR GAPS

Number	Designation				Model 216 up to model year 2011	Model 216 as of model year 2011
BE60.00-P-1003-01T	Gap dimension	Trunk lid to rear fender, top	Dimension "J"	mm	3.5 (±0.8)	3.5 (±0.8)
		Trunk lid to rear lamp unit	Dimension "K"	mm	3.5 (±0.8)	3.5 (±0.8)
		Trunk lid to bumper	Dimension "L"	mm	5, 5 (±1.5)	5, 5 (±1.5)
		Rear fender to rear lamp unit	Dimension "M"	mm	2.5 (±0.5)	2.5 (±0.5)
			See picture		AR60.00-P-0700-01SC	AR60.00-P-0700-01SC

Fig 2: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Spot Weld Milling Cutter (215 589 00 51 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-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-1001-13A	Blind rivet 6.4X14	A 003 990 35 97