Repair Rear End On Left Side - Ar64.20-P-1200LWR

Rear Fender, Rear Floor, Rear Longitudinal Member, Components And Locations (Model 205.0/1/2/3)

Model 205.4 

Fig 1: Rear Fender, Rear Floor, Rear Longitudinal Member, Components And Locations (Model 205.4)

Courtesy 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 .
	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 .
	See 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 body repair		See AH60.00-N-0001-01A .
	Information on preventing damage to electronic components due to electrostatic discharge		See AH54.00-P-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 .
	Remove
1	Remove detachable parts in area to be repaired
2	Cover all detachable parts remaining on vehicle with spark protection blankets
3	Set up straightening bench with straightening bench crossmembers and straightening tool set
	000 588 01 23 00 Body straightening system		See WS60.00-P-0023K .
4	Place vehicle on straightening bench and fasten
5	Damage area, reshaping
6	Remove spare wheel well (5)		See AR64.20-P-1245LWR .
7	Remove rear fender (3)		See AR63.50-P-1401LWR .
8	Remove rear-end center section (6)		See AR64.20-P-1000LWR .
9	Remove side wall reinforcement (4)		See AR63.20-P-0861-01LWR .
10	Remove rear-end floor (1) and rear longitudinal member (2)		See AR64.20-P-1260-01LW .
	000 588 00 84 00 Heat gun	Commercially available devices/tools  Round wire brush Spot weld milling machine Wet/dry vacuum cleaner Body and aluminum workplace Aluminum tools	See WS54.00-P-0049B .
		Zinc dust paint suitable for spot welding	See *BR00.45-Z-1001-07A .
11	Prepare rear-end floor (1) and rear longitudinal member (2)	Commercially available devices/tools  Round wire brush	See AR64.20-P-1260-02LW .
		Zinc dust paint suitable for spot welding	See *BR00.45-Z-1001-07A .
12	Prepare side wall reinforcement (4)	Commercially available devices/tools  Round wire brush	See AR63.20-P-0861-03LWR .
	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 .
13	Install rear-end floor (1) and rear longitudinal member (2)		See AR64.20-P-1260-03LW .
	000 588 01 23 00 Body straightening system		See WS60.00-P-0023K .
	000 588 01 84 00 Welder	Commercially available devices/tools  Round wire brush Manual temporary fastener, 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Wet/dry vacuum cleaner Body and aluminum workplace Aluminum tools	See WS60.00-P-0021K .
		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 side wall reinforcement (4)		See AR63.20-P-0861-04LWR .
	000 588 02 84 00 Welder		See WS60.00-P-0022K .
15	Release vehicle from straightening bench, lift vehicle and remove straightening bench
16	Install rear-end center section (6)		See AR64.20-P-1000LWR .
17	Install rear fender (3)		See AR63.50-P-1401LWR .
18	Install spare wheel well (5)		See AR64.20-P-1245LWR .
19	Install all detachable body components in area to be repaired