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Replace rear portal - AR64.20-P-1001A

MODEL 461, 463 with CODE (ZS4) Special protection version FB4 with CODE (ZS6) Special protection version FB6 with CODE (ZS7) Special protection version FB7 

Illustrated on model 461 

Fig 1: Stowage Box/Tray And Stowage Box - Illustrated On Model 461
G10780966Courtesy of MERCEDES-BENZ USA

Illustrated on model 461 

Fig 2: Box, Headliner And Rear Wall Paneling - Illustrated On Model 461
G10780967Courtesy of MERCEDES-BENZ USA

Left side is shown on model 461 

Fig 3: Splinter Protection - Left Side Shown On Model 461
G10780968Courtesy of MERCEDES-BENZ USA

Shown on right side on model 461 

Fig 4: Splinter Protection - Shown On Right Side On Model 461
G10780969Courtesy of MERCEDES-BENZ USA

Illustrated on model 461 

Fig 5: Rear Side Window Armoring - Shown On Model 461
G10780970Courtesy of MERCEDES-BENZ USA

Left side is shown on model 461 

Fig 6: Roof Armoring, Stowage Box Armoring, Side Wall Armoring And Rear Area Armoring - Left Side Shown On Model 461
G10780971Courtesy of MERCEDES-BENZ USA

Shown on right side on model 461 

Fig 7: Roof Armoring, Stowage Box Armoring, Side Wall Armoring And Rear Area Armoring - Shown On Right Side On Model 461
G10780972Courtesy of MERCEDES-BENZ USA
Fig 8: Rear Door Surround
G10780973Courtesy of MERCEDES-BENZ USA

Illustrated on model 461 

Fig 9: Upper Striking Plate And Center High-Mounted Stop Lamp - Illustrated On Model 461
G10780974Courtesy of MERCEDES-BENZ USA

Illustrated on model 461 

Fig 10: Lower Striking Plate And Lower Locking Wedge - Illustrated On Model 461
G10780975Courtesy of MERCEDES-BENZ USA

Illustrated on model 461 

Fig 11: Tailgate, Step Console, Rear Bumper, Left Taillamp And Right Taillamp - Illustrated On Model 461
G10780976Courtesy of MERCEDES-BENZ USA
REMOVING Removing     
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
NOTES Notes on self-locking nuts and bolts All models AH00.00-N-0001-01A
1 Remove stowage boxes/trays (1).    
2 Remove stowage boxes (2). Model 461 with rear stowage box AR68.72-P-0010SG
Model 463.236/248 with code (979) Special protection version, with code (ZS6) Special protection version FB6, with code (E26) Additional battery 100 Ah including cutoff relay
Model 463.236/248 with code (979) Special protection version, with code (ZS7) Special protection version FB7, with code (E26) Additional battery 100 Ah including cutoff relay		 AR68.72-P-0010PM
Model 463.241 with code (979) Special protection version, with code (ZS4) Special protection version FB4, with code (ZS6) Special protection version FB6, with code (ZS7) Special protection version FB7 AR68.72-P-0010PV
3 Remove box (3) between rear seats.    
4 Remove rear wall paneling (5). IMPORTANT Rear wall paneling (5) is fastened with double-sided adhesive tape. Carefully detach glue bead.  
5 Remove headliner (4) Model 461 with code (ZS4) Special protection version FB4, with code (ZS6) Special protection version FB6, with code (ZS7) Special protection version FB7 AR68.30-P-4300SG
Model 463.236/248 with code (979) Special protection version, with code (ZS6) Special protection version FB6
Model 463.236/248 with code (979) Special protection version, with code (ZS7) Special protection version FB7		 AR68.30-P-4300PM
6 Remove splinter protection (6) in entire repair area. Only on model 461, 463 with code (ZS6) Special protection version FB6, with code (ZS7) Special protection version FB7  
7 Remove rear side window armoring (7).    
8 Remove roof armoring (8), stowage box armoring (9), side wall armoring (10) and rear area armoring (11).    
9 Remove spare tire carrier Only on model 461.332/333/334 with code (R69) Pivotable spare tire carrier AR40.00-P-0250GA
10 Remove rear door frame (12). IMPORTANT Rear door frame (12) is bonded.  
11 Remove upper striking plate (13).    
12 Remove brake lamp (E21) Model 461 with code (ZS4) Special protection version FB4, with code (ZS6) Special protection version FB6, with code (ZS7) Special protection version FB7 AR82.10-P-5375SG
13 Remove lower striking plate (15) and lower locking wedges (16)    
14 Remove rear-end door(s) (17) IMPORTANT The rear-end door(s) (17) can be removed together with the door hinges.  
Model 461 with code (ZS4) Special protection version FB4, with code (ZS6) Special protection version FB6, with code (ZS7) Special protection version FB7 AR72.20-P-1901SG
Model 463.236/248 with code (979) Special protection version, code (ZS6) Special protection version FB6, Two-wing rear door with window, with code (979) Special protection version, code (ZS7) Special protection version FB7, Two-wing rear door with window AR72.20-P-1901PM
Model 463.241 with code (979) Special protection version, with code (ZS4) Special protection version FB4, Single-wing rear door AR72.20-P-1901PH
Model 463.241 with code (979) Special protection version, code (ZS6) Special protection version FB6, code (ZS7) Special protection version FB7, Two-wing rear door with window AR72.20-P-1901PV
15 Remove step console (18).    
16 Remove taillamps (E3, E4) Model 461.332/333/334 with code (E10) Stealth lighting circuit AR82.10-P-4905GL
Model 461.332/333/334 without code (E10) Stealth lighting circuit, Model 463.236/241/248 AR82.10-P-4905GX
17 Remove rear bumper (20). Model 461.332/333/334 AR88.20-P-2200GL
Model 463.236/248 AR88.20-P-2200GR
Model 463.241 AR88.20-P-2200GG
18 Remove right and left side window in cargo area Model 461 with code (ZS4) Special protection version FB4, with code (ZS6) Special protection version FB6, with code (ZS7) Special protection version FB7 AR67.30-P-2305SG
Model 463.236/248 with code (979) Special protection version, code (ZS6) Special protection version FB6 AR67.30-P-2305PM
Model 463.236/248 with code (979) Special protection version, code (ZS7) Special protection version FB7 AR67.30-P-2305PN
Model 463.241 with code (979) Special protection version, code (ZS4) Special protection version FB4, with code (ZS6) Special protection version FB6, with code (ZS7) Special protection version FB7, side wall AR67.30-P-2305PV
19 Remove ventilation grille Model 463.236/241/248  
Model 461.332/333/334 AR83.65-P-1000GL
20 Remove all electrical lines in repair area.    
21 Remove all other detachable parts in repair area.    
22 Cover all detachable parts remaining in repair area with welding protection blankets Welding protection blanket
 		  
23 Fabricate assembly struts.    
REFER TO SHOP-MADE TOOLS Upper assembly strut for fixing rear portal in place.   WF58.50-P-6420-01A
REFER TO SHOP-MADE TOOLS Lower assembly strut for fixing rear portal in place.   WF58.50-P-6420-02A
24 Remove rear portal   AR64.20-P-1001-01A
NOTES General information on repairs to body All models AH60.00-N-0001-01A
SPECIAL TOOL
Body jig saw
 
Round wire brush
 
Carbide cutter
 		 Fig 12
INSTALLING Install     
25 Prepare mating surfaces of body on rear portal for installation   AR64.20-P-1001-02A
NOTES General information on repairs to body All models AH60.00-N-0001-01A
NOTES Notes on paintwork repairs   AH98.00-P-9408-02A
Round wire brush
 
Punching pliers
 		  
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
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 spatter 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
26 Prepare rear portal for installation   AR64.20-P-1001-05A
NOTES Measures for preventing damage to vehicles or components when performing electric welding work All models AH00.00-N-0005-01A
NOTES General information on repairs to body All models AH60.00-N-0001-01A
NOTES Notes on paintwork repairs   AH98.00-P-9408-02A
Round wire brush
 
Body jig saw
 
Punching pliers
 		  
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
Passenger car primer filler 283-150 VOC *BR00.45-Z-1031-07A 
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 spatter 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
27 Install rear portal   AR64.20-P-1001-04A
NOTES Measures for preventing damage to vehicles or components when performing electric welding work All models AH00.00-N-0005-01A
NOTES General information on repairs to body All models AH60.00-N-0001-01A
REFER TO SHOP-MADE TOOLS Upper assembly strut for fixing rear portal in place.   WF58.50-P-6420-01A
REFER TO SHOP-MADE TOOLS Lower assembly strut for fixing rear portal in place.   WF58.50-P-6420-02A
    Vise grip pliers
 		  
    Sealant *BR00.45-Z-1003-01A 
28 Clean welds and sheet metal flange    
NOTES General information on repairs to body All models
Rotary wire brush
 		 AH60.00-N-0001-01A
29 Remove welding protection blanket    
30 Clean repair areas Wet and dry vacuum cleaner
 		  
31 Prime repair areas with primer/filler    
NOTES Notes on paintwork repairs   AH98.00-P-9408-02A
Passenger car primer filler 283-150 VOC *BR00.45-Z-1031-07A 
32 Restore standard seam sealing after repair Sealant *BR00.45-Z-1003-01A 
Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
33 Paint area repaired and adjacent surfaces    
NOTES Notes on paintwork repairs   AH98.00-P-9408-02A
34 Supplement cavity wax preservation    
NOTES Notes on cavity preservation   AH97.20-P-0001-01B
Preservation agent *BR00.45-Z-1003-05A 
35 Install detachable parts in repair area. IMPORTANT Detachable parts removed in step 21.  
36 Reposition electrical lines to original installation position in repair area. IMPORTANT All electrical lines removed from repair area in operation step 20.  
37 Install rear ventilation grate Model 463.236/241/248  
Model 461.332/333/334 AR83.65-P-1000GL
38 Install right and left side window in cargo area Model 461 with code (ZS4) Special protection version FB4, with code (ZS6) Special protection version FB6, with code (ZS7) Special protection version FB7 AR67.30-P-2305SG
Model 463.236/248 with code (979) Special protection version, code (ZS6) Special protection version FB6 AR67.30-P-2305PM
Model 463.236/248 with code (979) Special protection version, code (ZS7) Special protection version FB7 AR67.30-P-2305PN
Model 463.241 with code (979) Special protection version, code (ZS4) Special protection version FB4, with code (ZS6) Special protection version FB6, with code (ZS7) Special protection version FB7, side wall AR67.30-P-2305PV
39 Install rear bumper (20) Model 461.332/333/334 AR88.20-P-2200GL
Model 463.236/248 AR88.20-P-2200GR
Model 463.241 AR88.20-P-2200GG
40 Install taillamps (E3, E4) Model 461.332/333/334 with code (E10) Stealth lighting circuit AR82.10-P-4905GL
Model 461.332/333/334 without code (E10) Stealth lighting circuit, Model 463.236/241/248 AR82.10-P-4905GX
41 Install step console (18).    
42 Install rear-end door(s) (17) IMPORTANT Install rear-end doors (17) together with door hinges.  
Model 461 with code (ZS4) Special protection version FB4, with code (ZS6) Special protection version FB6, with code (ZS7) Special protection version FB7 AR72.20-P-1901SG
Model 463.236/248 with code (979) Special protection version, code (ZS6) Special protection version FB6, Two-wing rear door with window, with code (979) Special protection version, code (ZS7) Special protection version FB7, Two-wing rear door with window AR72.20-P-1901PM
Model 463.241 with code (979) Special protection version, with code (ZS4) Special protection version FB4, Single-wing rear door AR72.20-P-1901PH
Model 463.241 with code (979) Special protection version, code (ZS6) Special protection version FB6, code (ZS7) Special protection version FB7, Two-wing rear door with window AR72.20-P-1901PV
43 Install lower striking plate (15) and lower locking wedges (16).    
44 Install brake lamp (E21) Only on model 461 with code (ZS4) Special protection version FB4, with code (ZS6) Special protection version FB6, with code (ZS7) Special protection version FB7 AR82.10-P-5375SG
45 Install upper striking plate (13).    
46 Install rear door frame (12). IMPORTANT Glue in rear door frame (12) with universal glue. *BR00.45-Z-1003-02A 
47 Install spare tire carrier. Only on model 461.332/333/334 with code (R69) Pivotable spare tire carrier AR40.00-P-0250GA
48 Install roof armoring (8), stowage box armoring (9), side wall armoring (10) and rear area armoring (11). IMPORTANT Replace self-locking bolts or, if applicable, secure normal bolts with instant glue.  
TORQUE SPECIFICATION *BA68.30-P-1006-01B 
TORQUE SPECIFICATION *BA68.30-P-1008-01B 
TORQUE SPECIFICATION *BA68.30-P-1009-01B 
TORQUE SPECIFICATION *BA68.30-P-1010-01B 
TORQUE SPECIFICATION only for model 461.332/333/334 with code (ZS4) Special protection version FB4, or code (ZS6) Special protection version FB6, or code (ZS7) Special protection version FB7 *BA68.30-P-1014-01B 
Loctite 243 *BR00.45-Z-1133-02A 
49 Install rear side window armoring (7). IMPORTANT Replace self-locking bolts or, if applicable, secure normal bolts with instant glue.  
TORQUE SPECIFICATION *BA68.30-P-1010-01B 
Loctite 243 *BR00.45-Z-1133-02A 
50 Install splinter protection (6) in entire reonly for model r area. Only on model 461, 463 with code (ZS6) Special protection version FB6, with code (ZS7) Special protection version FB7
IMPORTANT Replace self-locking bolts or, if applicable, secure normal bolts with instant glue.		  
TORQUE SPECIFICATION *BA68.30-P-1005-01B 
TORQUE SPECIFICATION *BA68.30-P-1008-01B 
TORQUE SPECIFICATION *BA68.30-P-1010-01B 
TORQUE SPECIFICATION only for model 461.332/333/334 with code (ZS4) Special protection version FB4, or code (ZS6) Special protection version FB6, or code (ZS7) Special protection version FB7 *BA68.30-P-1015-01B 
Loctite 243 *BR00.45-Z-1133-02A 
51 Install headliner (4) Model 461 with code (ZS4) Special protection version FB4, with code (ZS6) Special protection version FB6, with code (ZS7) Special protection version FB7 AR68.30-P-4300SG
Model 463.236/248 with code (979) Special protection version, with code (ZS6) Special protection version FB6
Model 463.236/248 with code (979) Special protection version, with code (ZS7) Special protection version FB7		 AR68.30-P-4300PM
52 Install rear wall paneling (5). IMPORTANT Replace double-sided adhesive tape.  
53 Install box (3) between rear seats.    
54 Install stowage boxes (2). Model 461 with rear stowage box AR68.72-P-0010SG
Model 463.236/248 with code (979) Special protection version, with code (ZS6) Special protection version FB6, with code (E26) Additional battery 100 Ah including cutoff relay
Model 463.236/248 with code (979) Special protection version, with code (ZS7) Special protection version FB7, with code (E26) Additional battery 100 Ah including cutoff relay		 AR68.72-P-0010PM
Model 463.241 with code (979) Special protection version, with code (ZS4) Special protection version FB4, with code (ZS6) Special protection version FB6, with code (ZS7) Special protection version FB7 AR68.72-P-0010PV
55 Install stowage boxes/trays (1).    
TRIMS, ORNAMENTAL FRAMES

Number Designation Model 461.332/333/334 with code ZS4 or code ZS6 or code ZS7
BA68.30-P-1005-01B Screw, splinter protection on roof Nm 15
BA68.30-P-1006-01B Screw, steel cover on roof Nm 15
BA68.30-P-1008-01B Bolt, splinter guard to rear pillar Nm 15
BA68.30-P-1009-01B Screw, stowage box with thrust piece on rear pillar Nm 15
BA68.30-P-1010-01B Bolt, splinter protection to side wall Nm 15
BA68.30-P-1014-01B Bolt, partition wall Nm 15
BA68.30-P-1015-01B Screw, wheel well splinter protection Nm 15
TRIMS, ORNAMENTAL FRAMES

Number Designation Model 463.241 with code 979 Model 463.236/248 with code ZS6 or code ZS7 or code 979
BA68.30-P-1005-01B Screw, splinter protection on roof Nm 15 15
BA68.30-P-1006-01B Screw, steel cover on roof Nm 15 15
BA68.30-P-1008-01B Bolt, splinter guard to rear pillar Nm 15 15
BA68.30-P-1009-01B Screw, stowage box with thrust piece on rear pillar Nm 15 15
BA68.30-P-1010-01B Bolt, splinter protection to side wall Nm 15 15
Fig 12: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G07692600Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1003-01A Sealant, white, 310 ml, DB supply specification 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-1003-02A Adhesive/Dekalin 3649 A 000 989 82 71
BR00.45-Z-1133-02A Loctite 243 A 613 989 09 71
BR00.45-Z-1003-05A Cavity preservation, 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-1031-07A Passenger car primer filler 283-150 VOC Glasurit GmbH
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