Replace complete rear end - AR64.20-P-1020CW: Notes
WARNING: This page is about a different car, the 2011 Mercedes-Benz C300, 2010 Mercedes-Benz C300, 2009 Mercedes-Benz C300, and 2008 Mercedes-Benz C300. However, it is still accessible from the selected car via links, so may be relevant.
MODEL 204.0/3
Shown on model 204.0
| Removing | ||||
| 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 | ||
| 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 | ||
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-N-0005-01A | |||
| General information on body repair | AH60.00-N-0001-01A | |||
| Notes on paintwork repairs | AH98.00-P-9408-02A | |||
| General information on MB materials | AH98.00-P-9409-03A | |||
| 1 | Prepare all workshop equipment and commercially available tools required for repair | |||
| 2 | Remove all detachable parts in area to be repaired | |||
| 3 | Cover all detachable parts remaining vehicle with fireproof tarpaulin | |||
| 4 | Remove rear end (1) | AR64.20-P-1020-01CW | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | |||
| 5 | Prepare rear end (1) for installation | AR64.20-P-1020-02CW | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | |||
| Install | ||||
| 6 | Install rear end (1), fit and weld in | AR64.20-P-1020-03CW | ||
| General information on riveting | AH60.00-P-0003-01N | |||
| Fig 2 | ||||
| Model 204.0 Trunk lid to rear fender, top |
*BE60.00-P-1003-01U | |||
| Trunk lid to rear lamp unit | *BE60.00-P-1003-01U | |||
| Rear fender to lamp unit | *BE60.00-P-1003-01U | |||
| Model 204.3 Trunk lid to rear fender, top |
*BE60.00-P-1003-01W | |||
| Trunk lid to bumper | *BE60.00-P-1003-01W | |||
| Rear fender to lamp unit | *BE60.00-P-1003-01W | |||
| 204.0, 204.3 Zinc dust paint suitable for spot welding |
*BR00.45-Z-1001-07A | |||
| Blind rivet 6.4x14 | *BR00.45-Z-1001-13A | |||
| 7 | Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01CW | ||
| Fig 2 | ||||
| Model 204.0 Trunk lid to rear fender, top |
*BE60.00-P-1003-01U | |||
| Trunk lid to rear lamp unit | *BE60.00-P-1003-01U | |||
| Rear fender to lamp unit | *BE60.00-P-1003-01U | |||
| Model 204.3 Trunk lid to rear fender, top |
*BE60.00-P-1003-01W | |||
| Trunk lid to bumper | *BE60.00-P-1003-01W | |||
| Rear fender to lamp unit | *BE60.00-P-1003-01W | |||
| 8 | Clean weld joints and sheet metal flange with round wire brush | |||
| 9 | Clean repair areas | |||
| 10 | Prime repair area using primer filler | |||
| 11 | Carry out seam sealing after repairs | AR97.10-P-4000CW | ||
| White sealing compound, 310 ml, DBL 6069.20 | *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 | AR97.20-P-1500CW | ||
| Notes on cavity preservation | AH97.20-P-0001-01B | |||
| Cavity sealant, solvent-free (1 l container) | *BR00.45-Z-1003-05A | |||
| 14 | Remove tarp | |||
| 15 | Install all removed detachable parts | |||
CHECK VALUES FOR GAPS
| Number | Designation | Model 204.0 | |||
|---|---|---|---|---|---|
| BE60.00-P-1003-01U | Gap dimension | Trunk lid to rear fender, top | Dim. "L" | mm | 4 (±1) |
| Trunk lid to rear lamp unit | Dim. "M" | mm | 4 (±1) | ||
| Trunk lid to bumper | Dim. "N" | mm | 5.5 (±1) | ||
| Rear fender to lamp unit | Dim. "O" | mm | 1 (±1) | ||
| Taillamp to bumper | Dim. "P" | mm | 2 (±1) | ||
| Taillamp, trunk lid to taillamp | Dim. "M1" | mm | - | ||
| See picture | AR60.00-P-0700-01CW |
CHECK VALUES FOR GAPS
| Number | Designation | Model 204.3 | |||
|---|---|---|---|---|---|
| BE60.00-P-1003-01W | Gap dimension | Trunk lid to rear fender, top | Dim. "H" | mm | 4 (±1) |
| Trunk lid to bumper | Dim. "I" | mm | 5.5 (±2) | ||
| Rear fender to lamp unit | Dim. "J" | mm | 2 (+1.5/-1) | ||
| Taillamp to bumper | Dim. "K" | mm | 2 (±1) | ||
| Taillamp, trunk lid to taillamp | Dim. "L" | mm | 4 (±1) | ||
| See picture | AR60.00-P-0700-01CW |
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-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 |