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

MODEL 230 except CODE (P99) "AMG Black Series" special model

Fig 1: Identifying Rear Fender, Rear End Center Assembly Complete And Spare Wheel Recess

Courtesy of MERCEDES-BENZ USA

	Remove
	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 death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of death caused by high voltage used for arc welding. Risk of explosion caused by welding in the area of highly inflammable materials. Injury hazard from 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
	General information on repairs to body	All models	AH60.00-N-0001-01A
	Measures for preventing damage to vehicles or components when performing arc welding work	All models	AH00.00-N-0005-01A
	Notes on paintwork repairs	Models 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463, 639	AH98.00-P-9408-02A
	General information on MB materials	Models 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 463, 414, 639	AH98.00-P-9409-03A
1	Remove detachable parts in area to be repaired
2	Cover detachable body components which remain in vehicle	Use fire-resistant tarp	*WH58.30-Z-1001-40A
3	Equip straightening bench with modular or cross members and straightening tools	Observe enclosed set-up plans!
		Celette straightening bench (MUF 5, MUF 7)	*WE58.40-Z-1001-01E
		Celette straightening unit Cobra 2	*WE58.40-Z-1002-01E
		Celette straightening bench M8S	*WE58.40-Z-1001-01E
		Celette straightening unit C8S	*WE58.40-Z-1002-01E
		Set of Celette modular members 955.940	*WE58.40-Z-1007-01E
		Celette additional member 955.908	*WE58.40-Z-1008-01E
		Car-Bench straightening bench BT 17	*WE58.40-Z-1003-01E
		Car-Bench alignment and lifting platform CB 41	*WE58.40-Z-1004-01E
		Car-Bench straightening unit PT 13	*WE58.40-Z-1005-01E
		Car-Bench universal cross member set A 296	*WE58.40-Z-1010-01E
		Car-Bench universal cross member set A 296/15 (all cross members 1500 mm long)	*WE58.40-Z-1011-01E
		Celette straightening bench MT 10, (without old hole pattern, model 123 cannot be repaired)	*WE58.40-Z-1001-01E
		Celette straightening bench Sevenne	*WE58.40-Z-1001-01E
		Car-Bench straightening bench BT 43/1	*WE58.40-Z-1003-01E
		Celette straightening bracket set 7230.300 (for model R230)	*WE58.40-Z-1037-01A
		Celette straightening bracket set 7202.300	*WE58.40-Z-1009-01E
		Car-Bench straightening bracket set 82437 (for model R230)	*WE58.40-Z-1038-01A
4	Set vehicle onto straightening bench using two-column lift and fasten	Two-post lift	*WE58.40-Z-1001-05A
5	Attach vehicle to straightening bench
6	Remove rear fender		AR63.50-P-1400R
7	Cut off rear center section with crossmember, spare wheel well and longitudinal member connection		AR64.20-P-1200-06R
		Pulling device	Figure
		Spot weld milling cutter	Figure
		Welding bead collector	Figure
		Protective mat	Figure
		Spherical milling 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
		Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM)	*WH58.30-Z-1024-04A
		Cutting disk, 65 mm dia., 80 m/s (max. 23, 500 RPM)	*WH58.30-Z-1021-04A
		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
		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 center section with crossmember, spare wheel well and longitudinal member connection with locking lug		AR64.20-P-1200-07R
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Grinding disc, dia. 115 mm, 80 m/s (max. 13, 250 RPM)	*WH58.30-Z-1024-04A
		Clamping pliers	*WH58.30-Z-1003-02A
		Manual temporary fastener, dia. 6.4 mm - clamping range 0 to 15 mm, identification color silver	*WH58.30-Z-1038-02A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Angular grinder (electric/pneumatic)	*WE58.40-Z-1003-03A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
9	Prepare rear floor assembly, outer B-pillar with inner reinforcement for rear lamp		AR64.20-P-1200-27R
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Grinding disc, dia. 115 mm, 80 m/s (max. 13, 250 RPM)	*WH58.30-Z-1024-04A
		Clamping pliers	*WH58.30-Z-1003-02A
		Manual temporary fastener, dia. 6.4 mm - clamping range 0 to 15 mm, identification color silver	*WH58.30-Z-1038-02A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Body saw (electric/pneumatic)	*WE58.40-Z-1004-03A
		Angular grinder (electric/pneumatic)	*WE58.40-Z-1003-03A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
10	Install longitudinal member with mounting console and crossmember		AR64.20-P-1200-28R
	General information on riveting	Model 203, 209, 211, 215, 230, 240, 414, 639	AH60.00-P-0003-01N
		Welding bead collector	Figure
		Protective mat	Figure
		Electrode miller	*WH58.30-Z-1003-01A
		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
		Manual temporary fastener, dia. 6.4 mm - clamping range 0 to 15 mm, identification color silver	*WH58.30-Z-1038-02A
		Clamping pliers	*WH58.30-Z-1003-02A
		Tarpaulin (fire-resistant)	*WH58.30-Z-1001-40A
		Spot welder	*WE58.40-Z-1002-02A
		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
		Polygrip flat/round head rivet, 6.4x14	*BR00.45-Z-1001-13A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
11	Install and weld in spare wheel well		AR64.20-P-1200-04R
	General information on riveting	Model 203, 209, 211, 215, 230, 240, 414, 639	AH60.00-P-0003-01N
		Welding bead collector	Figure
		Protective mat	Figure
		Electrode miller	*WH58.30-Z-1003-01A
		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
		Clamping pliers	*WH58.30-Z-1003-02A
		Manual temporary fastener, dia. 6.4 mm - clamping range 0 to 15 mm, identification color silver	*WH58.30-Z-1038-02A
		PowerBird blind rivet tool	*WE58.40-Z-1003-14A
		Spot welder	*WE58.40-Z-1002-02A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Angular grinder (electric/pneumatic)	*WE58.40-Z-1003-03A
		Tarpaulin (fire-resistant)	*WH58.30-Z-1001-40A
		Wet/dry vacuum cleaner	*WE58.40-Z-1005-03A
		Polygrip flat/round head rivet, 6.4x14	*BR00.45-Z-1001-13A
		Polygrip countersunk rivet, 6.4x14	*BR00.45-Z-1002-13A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
12	Install longitudinal member locking lug, rear floor assembly, outer B-pillar and inner reinforcement for rear lamp		AR64.20-P-1200-29R
	General information on riveting	Model 203, 209, 211, 215, 230, 240, 414, 639	AH60.00-P-0003-01N
		Welding bead collector	Figure
		Protective mat	Figure
		Electrode miller	*WH58.30-Z-1003-01A
		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
		Clamping pliers	*WH58.30-Z-1003-02A
		Manual temporary fastener, dia. 6.4 mm - clamping range 0 to 15 mm, identification color silver	*WH58.30-Z-1038-02A
		PowerBird blind rivet tool	*WE58.40-Z-1003-14A
		Tarpaulin (fire-resistant)	*WH58.30-Z-1001-40A
		Spot welder	*WE58.40-Z-1002-02A
		Inert gas welder	*WE58.40-Z-1001-02A
		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
		Cavity preservation gun Sata HRS no. 11072	*WE58.40-Z-1006-08A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Sealant	*BR00.45-Z-1003-01A
		Polygrip flat/round head rivet, 6.4x14	*BR00.45-Z-1001-13A
		MB preservative	*BR00.45-Z-1003-05A
13	Install rear fender		AR63.50-P-1400R
14	Unfasten vehicle from straightening bench
15	Lift vehicle with two-post lift	Two-post lift	*WE58.40-Z-1001-05A
16	Remove straightening bench.
17	Clean repair areas
18	Prime area to be repaired with priming filler
19	Seam sealing following repair	Supplement standard seals with MB body sealant.
		Model 230.475/474	AR97.10-P-4000R
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
20	Paint repair areas and adjacent surfaces
21	Apply additional cavity preservation
		Model 230.475	AR97.20-P-1500R
			*BR00.45-Z-1003-05A
	Notes on cavity preservation	Models 124, 126, 129, 140, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 639, 671, 690.6, 901, 902, 903, 904, 905 Models WD141, WD241, WD341, WD641, WD741, XD141, XD241, XD341, XD441, XD541, XD641, XD741, YD141, YD241, YD341, YD441, YD541, YD641, YD741	AH97.20-P-0001-01B
22	Remove fire-resistant tarp
23	Install detachable body components in area to be repaired

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

Fig 4: Identifying Welding Bead Catcher (230 589 01 98 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Protective Mat (230 589 00 98 00)

Courtesy of MERCEDES-BENZ USA

Fig 6: Identifying Puller (230 589 01 27 00)

Courtesy of MERCEDES-BENZ USA

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1002-01A	Ball cutter, dia. 12 mm
WH58.30-Z-1003-01A	Electrode miller
WH58.30-Z-1006-01A	Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1003-02A	Clamping pliers
WH58.30-Z-1038-02A	Manual temporary fastener, dia.6.4 mm - clamping range 0 -15 mm, identification color silver Firma Hausmann GmbH D-34346 Hann. Munden, Germany
WH58.30-Z-1001-03A	Round wire brush, braided, dia. 70 mm
WH58.30-Z-1021-04A	Cutting disk, dia. 65 mm, 80 m/s (max. 23, 500 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-1037-01A	Celette straightening bracket set 7230.300 (model R230)
WE58.40-Z-1038-01A	Car-Bench straightening bracket set 82437 (model R230)
WE58.40-Z-1001-01E	Celette straightening bench
WE58.40-Z-1002-01E	Celette straightening unit
WE58.40-Z-1003-01E	Car-Bench straightening bench
WE58.40-Z-1004-01E	Car-Bench straightening lifting platform
WE58.40-Z-1005-01E	Car-Bench straightening equipment
WE58.40-Z-1007-01E	Celette module crossmember set 955.940
WE58.40-Z-1008-01E	Celette additional member 955.908
WE58.40-Z-1009-01E	Celette straightening bracket set 7202.300
WE58.40-Z-1010-01E	Car-Bench universal cross member set A 296
WE58.40-Z-1011-01E	Car-Bench Universal crossmember set A 296/15 (all crossmembers 1500 mm long)
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
WE58.40-Z-1001-05A	Two-post lifting platform
WE58.40-Z-1006-08A	Cavity preservation gun
WE58.40-Z-1003-14A	Blind rivet tool

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	Sealant	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	Preservation agent	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	Rivet	A 003 990 35 97
BR00.45-Z-1002-13A	Polygrip countersunk head rivet, 6.4 x 14	A 003 990 86 97 05