Replace bottom rear center section together with rear crossmember - AR64.20-P-1060SX
MODEL 221, 216
Fig 1: Identifying Bottom Rear Center Section, Mount Below tail lamp, Rear Crossmember - Shown On Model 221
Shown on model 221
| Removing | |||
| 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 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 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 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 | ||
| 2 | Remove tail lamps | AR82.10-P-4905SX | |
| 3 | Remove spare tire well | AR88.30-P-1000SX | |
| 4 | Cover all detachable parts remaining in vehicle | Tarp (fire-resistant) | |
| 5 | Equip straightening bench with module members, cross members and straightening tool set. | Celette straightening bench Set of Celette module members 955.940 Celette additional member 955.908 Car-Bench straightening bench BT 17 Car-Bench straightening bench BT 43/1 Car-Bench straightening bench BT 140 Car-Bench universal crossmember set A 296 Car-Bench universal crossmember set 296/19 Multi-Z straightening set system MZ 450.000 Celette straightening bracket set 7221.300 (for model 221) Celette 7216.309 supplementary straightening set for Celette straightening bracket set 7221.300 (for model 221) Car-Bench straightening bracket set 82456 (for model 221) Passenger car straightening system (Celette) Straightening systems for passenger cars (Car Bench) |
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| 6 | Lift vehicle with two-post lift | Two-post lift | |
| 7 | Set vehicle onto straightening bench | ||
| 8 | Fasten vehicle to straightening bench | ||
| 9 | Separate bottom rear center section (1) with rear crossmember (3) | AR64.20-P-1060-01SX | |
| Figure | |||
Vario Drill WS 91 spot weld removing tool Round wire brush, braided, dia. 70 mm Abrasive disk, Ø 115 mm, 80 m/s (max. 13, 250 rpm) Hot air gun - 3000 W Aluminum workshop vehicle Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner |
Figure | ||
| Recycle aluminum parts | OS60.00-P-0001-01N | ||
| 10 | Prepare bottom rear center section (1) for installation | AR64.20-P-1000-07SX | |
| Round wire brush, braided, dia. 70 mm Aluminum workshop vehicle Drill (electric/pneumatic) |
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| 11 | Prepare rear crossmember (3) for installation | AR64.20-P-1100-02SX | |
| Round wire brush, braided, dia. 70 mm Aluminum workshop vehicle Drill (electric/pneumatic) |
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| Install | |||
| 12 | Install and weld in rear crossmember (3) | AR64.20-P-1060-03SX | |
| General information on riveting | AH60.00-P-0003-01N | ||
| Clamping pliers Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver Round wire brush, braided, dia. 70 mm Taurus 3 blind rivet tool with 100 mm extension unit Aluminum workshop vehicle Drill (electric/pneumatic) Wet/dry vacuum cleaner |
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| 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 | ||
| 13 | Install bottom rear section (1) | AR64.20-P-1000-08SX | |
| General information on riveting | AH60.00-P-0003-01N | ||
| Trunk lid to rear lamp unit | *BE60.00-P-1003-01R | ||
| Rear fender to lamp unit | *BE60.00-P-1003-01R | ||
| Trunk lid to rear fender, top | *BE60.00-P-1003-01R | ||
| Trunk lid to rear lamp unit | *BE60.00-P-1003-01T | ||
| Rear fender to lamp unit | *BE60.00-P-1003-01T | ||
Clamping pliers Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver Round wire brush, braided, dia. 70 mm Taurus 3 blind rivet tool with 100 mm extension unit Aluminum workshop vehicle Drill (electric/pneumatic) Wet/dry vacuum cleaner |
Figure | ||
| Polygrip flat round head rivet, 6.4X14 | *BR00.45-Z-1001-13A | ||
| Adhesive | *BR00.45-Z-1092-02A | ||
| 14 | Adjust gap dimensions on hoods, doors and lids | Model 221 gap dimensions | AR60.00-P-0700-01SX |
| Figure | |||
| Trunk lid to rear lamp unit | *BE60.00-P-1003-01R | ||
| Rear fender to lamp unit | *BE60.00-P-1003-01R | ||
| Trunk lid to rear fender, top | *BE60.00-P-1003-01R | ||
| Model 216 gap dimensions | AR60.00-P-0700-01SC | ||
| Figure | |||
| Trunk lid to rear lamp unit | *BE60.00-P-1003-01T | ||
| Rear fender to lamp unit | *BE60.00-P-1003-01T | ||
| 15 | Unfasten vehicle from straightening bench | ||
| 16 | Lift vehicle with two-post lift | Two-post lift | |
| 17 | Remove straightening bench. | ||
| 18 | Clean repair area | ||
| 19 | Prime repair area with primer filler | ||
| 20 | Carry out seam sealing after repairs | AR97.10-P-4000SX | |
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 21 | Paint repair areas and adjacent surfaces | ||
| 22 | 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 | ||
| 23 | Remove tarp | ||
| 24 | Install spare tire well | AR88.30-P-1000SX | |
| 25 | Install tail lamps | AR82.10-P-4905SX | |
| 26 | 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 |
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 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 | ||||
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 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 | ||||
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-1002-13A | Polygrip countersunk-head rivet, 6.4X14 | A 003 990 86 97 05 |
| BR00.45-Z-1001-13A | Blind rivet 6.4X14 | A 003 990 35 97 |