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Completely Remove/Install Rear Longitudinal Member - Ar64.20-P-1220LW

Model 205.0/1/2/3 

Fig 1: Rear Longitudinal Member, Crossmembers And End Plate Locations (Model 205.0/1/2/3)
G13023469CAUTIONREMOVINGIMPORTANTIMPORTANTIMPORTANTIMPORTANTINSTALLINGREFER TO SPECIAL TOOLSREFER TO SPECIAL TOOLSIMPORTANTIMPORTANTREFER TO SPECIAL TOOLSIMPORTANTIMPORTANTIMPORTANTCourtesy of MERCEDES-BENZ USA
  Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. See AS00.00-Z-0010-01A .
CAUTION 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.		 See AS00.00-Z-0017-01A .
  Risk of death  when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC) Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines. AS00.00-Z-0035-01A
  Risk of explosion  from aluminum grinding dust, risk of injury to respiratory system from inhaling dust Wear dust filter mask, safety glasses and protective gloves.
Use a suitable, grounded dust extraction system.		 See AS60.00-Z-0007-01N .
  General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system   See AH00.00-Z-0300-01A .
  Information on preventing damage to electronic components due to electrostatic discharge   See AH54.00-P-0001-01A .
  Notes on battery   See AH54.10-P-0001-01A .
  General information on body repair   See AH60.00-N-0001-01A .
  Pretreatment of bonding surfaces   See AH60.00-P-0008-01SX .
  General information on crack diagnosis of aluminum parts   See AH60.00-P-0014-01N .
  Note on working on aluminum components and vehicles   See AH60.00-P-0034-01LW .
  General information on MB materials   See AH98.00-P-9409-03A .
REMOVING Remove     
1 Remove detachable parts in area to be repaired    
2 Cover all detachable parts remaining on vehicle with spark protection blanket    
3 Remove rear end assembly Model 205.0/1 See AR64.20-P-1020LW .
    Model 205.2 AR64.20-P-1020LWS
    Model 205.3 See AR64.20-P-1020CLW .
4.1 Remove inner C-pillar side wall Model 205.0/1 See AR63.10-P-0700LW .
4.2 Remove inner side wall with partial rear outer wheelhouse Model 205.2/3
Model 205.2		 AR63.10-P-6050LWS
    Model 205.3 See AR63.10-P-6050CLW .
5 Remove longitudinal member outer shell Model 205.0/1/2 AR63.30-P-1102LW
    Model 205.3
IMPORTANT Remove only rear section of longitudinal member outer shell.		 See AR63.30-P-1102CLW .
6 Remove rear-end door and partial rear longitudinal member IMPORTANTCommercially available devices/tools 
Round wire brush
Spot weld milling machine
Heat gun
Wet/dry vacuum cleaner
Body and aluminum workplace
Aluminum tools		 See AR64.20-P-1260-01LW .
    Zinc dust paint suitable for spot welding See *BR00.45-Z-1001-07A .
7 Remove crossmember above rear axle   See AR64.20-P-1301LW .
8 Remove rear longitudinal member (1) with end plate (4), bottom crossmember (2) and top crossmember (3) IMPORTANTCommercially available devices/tools 
Round wire brush
Body power jigsaw
Spot weld milling machine
Heat gun
Wet/dry vacuum cleaner
Body and aluminum workplace
Aluminum tools		 See AR64.20-P-1200-22LW .
    Zinc dust paint suitable for spot welding See *BR00.45-Z-1001-07A .
9 Prepare rear longitudinal member (1), bottom crossmember (2), top crossmember (3) and end plate (4) IMPORTANTCommercially available devices/tools 
Round wire brush
Body power jigsaw
Body and aluminum workplace
Aluminum tools		 See AR64.20-P-1200-23LW .
    Zinc dust paint suitable for spot welding See *BR00.45-Z-1001-07A .
INSTALLING Install     
  The high voltage used for electric welding presents a lethal hazard. Risk of explosion  from welding in areas close to highly inflammable materials. Risk of injury  from weld splatter and UV-light when welding. Risk of poisoning  from inhaling welding gases Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system. See AS00.00-Z-0007-01A .
  Measures for preventing damage to components when performing electric welding and soldering work   See AH60.00-P-0001-02A .
  General information on riveting   See AH60.00-P-0003-01N .
10 Install rear longitudinal member (1), bottom crossmember (2), top crossmember (3) and end plate (4)   See AR64.20-P-1200-24LW .
REFER TO SPECIAL TOOLS 000 588 02 84 00 Welder   See WS60.00-P-0022K .
REFER TO SPECIAL TOOLS 000 588 01 23 00 Body straightening system IMPORTANTCommercially available devices/tools 
Round wire brush
Manual temporary fastener 6.35 mm
Blind rivet gun (minimum pull-off force 19 kN)
Spot welder
Hole finder
Wet/dry vacuum cleaner
Body and aluminum workplace
Aluminum tools		 See WS60.00-P-0023K .
    Zinc dust paint suitable for spot welding See *BR00.45-Z-1001-07A .
    Parts kit for 2-component adhesive for body See *BR00.45-Z-1162-02A .
    Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) See *BR00.45-Z-1012-13A .
    Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) See *BR00.45-Z-1035-13A .
    Blind rivet 6.5X14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) See *BR00.45-Z-1016-13A .
11 Install crossmember above rear axle   See AR64.20-P-1301LW .
12 Prepare rear-end door and partial rear longitudinal member   See AR64.20-P-1260-02LW .
    IMPORTANTCommercially available devices/tools 
Round wire brush
Zinc dust paint suitable for spot welding		 See *BR00.45-Z-1001-07A .
13 Install rear-end floor and partial rear longitudinal member   See AR64.20-P-1260-03LW .
REFER TO SPECIAL TOOLS 000 588 01 23 00 Body straightening system IMPORTANTCommercially available devices/tools 
Round wire brush
Manual temporary fastener 6.35 mm
Blind rivet gun (minimum pull-off force 19 kN)
Spot welder
Wet/dry vacuum cleaner
Body and aluminum workplace
Aluminum tools
IMPORTANT Observe set-up plans provided.		 See WS60.00-P-0023K .
    Zinc dust paint suitable for spot welding See *BR00.45-Z-1001-07A .
    Parts kit for 2-component adhesive for body See *BR00.45-Z-1162-02A .
    Blind rivet with countersunk head 6.4x17.0 (clamping range 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) See *BR00.45-Z-1055-13A .
    Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) See *BR00.45-Z-1012-13A .
    Blind rivet 6.5X14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) See *BR00.45-Z-1016-13A .
    Blind rivet 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN) See *BR00.45-Z-1034-13A .
    Blind rivet 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN) See *BR00.45-Z-1032-13A .
14 Install longitudinal member outer shell Model 205.0/1/2 AR63.30-P-1102LW
    Model 205.3
IMPORTANT Install only rear section of longitudinal member outer shell.		 See AR63.30-P-1102CLW .
15.1 Install inner C-pillar side wall Model 205.0/1 See AR63.10-P-0700LW .
15.2 Install inner side wall with partial outer rear wheel well Model 205.2/3  
    Model 205.2 AR63.10-P-6050LWS
    Model 205.3 See AR63.10-P-6050CLW .
16 Install rear end assembly Model 205.0/1 See AR64.20-P-1020LW .
    Model 205.2 AR64.20-P-1020LWS
    Model 205.3 See AR64.20-P-1020CLW .
17 Install detachable parts in area to be repaired    
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
BR00.45-Z-1012-13A Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) A 004 990 16 97
BR00.45-Z-1016-13A Blind rivet 6.5X14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) A 004 990 17 97
BR00.45-Z-1032-13A Blind rivet 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN) A 003 990 81 97
BR00.45-Z-1034-13A Blind rivet 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN) A 003 990 80 97
BR00.45-Z-1035-13A Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) A 000 991 76 32
BR00.45-Z-1055-13A Blind rivet with countersunk head 6.4x17.0 (clamping range 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) A 000 991 86 32
BR00.45-Z-1162-02A Parts kit for 2-component adhesive for body A 012 989 17 71
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