Replace complete rear end - AR64.20-P-1020CLW

MODEL 205.3 

MODIFICATION NOTES

14.01.2016	Polygrip 6.4 X 14 countersunk-head rivet replaced by 6.4 14.0 blind countersunk-head rivet.	Operation step 5
14.01.2016	Adhesive set for body, 2-component adhesive replaced by 2-component adhesive parts kit.	Operation step 5
14.01.2016	Zinc dust paint suitable for spot welding replaced by 1-component zinc dust paint.1K	Operation steps 3, 4 and 5

Fig 1: Complete Rear End Remove/Install Components

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.	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 death  when touching components on vehicles with high-voltage on-board electrical system	Do not touch components and open lines of the high-voltage on-board electrical system. Persons who wear electronic implants (e.g. cardiac pacemakers), must not carry out any work on high-voltage on-board electrical systems.	AS54.00-Z-0001-01A
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Note on high-voltage on-board electrical system		AH54.00-P-0010-01A
	Note on high-voltage battery		AH54.10-P-0006-01MEV
	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	Evaluation of high-voltage components		AH54.00-P-6500-01SXH
	General information on body repair		AH60.00-P-0001-01A
	General information on MB materials		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	Separate rear end (1)		AR64.20-P-1020-01CLW
	000 588 00 84 00 Heat gun		WS54.00-P-0049B
		Commercially available devices/tools  Round wire brush Body power jigsaw Spot weld milling machine Wet/dry vacuum cleaner Glass removal 1K-zinc dust paint	*BR00.45-Z-1056-07A
4	Prepare rear end (1) for installation		AR64.20-P-1020-05CLW
		Commercially available devices/tools  Round wire brush Body power jigsaw 1K-zinc dust paint	*BR00.45-Z-1056-07A
	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 flammable materials from the hazard area. Use air extraction system.	AS00.00-Z-0007-01A
	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A
	General information on riveting		AH60.00-P-0003-01N
5	Install rear end assembly (1)		AR64.20-P-1020-06CLW
	000 588 01 84 00 Welder		WS60.00-P-0021K
		Gap dimensions on hoods, doors and lids	AR60.00-P-0700-01LW
		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 Trunk lid to fender at rear, top	*BE60.00-P-1012-01BB
		Blind rivet 6.4 12 (clamping range 1 mm to 3.5 mm)	*BR00.45-Z-1035-13A
		Blind rivet with 6.4 14.0 countersunk head (clamping range 1.5 mm to 3.5 mm)	*BR00.45-Z-1043-13A
		1K-zinc dust paint	*BR00.45-Z-1056-07A
		Glazing repair kit, 2-component adhesive	*BR00.45-Z-1049-02A
		Parts kit for 2-component adhesive for body	*BR00.45-Z-1162-02A
		Feeler gauge	Figure
6	Clean welds and sheet metal flanges	Commercially available devices/tools  Round wire brush
7	Remove spark protection blankets
8	Clean repair area	Commercially available devices/tools  Wet/dry vacuum cleaner
9	Prime repair area using primer filler
	Notes on paintwork repairs	Use only primer filler approved by Daimler AG.	AH98.00-P-9408-02A
10	Seal seam following repairs		AR97.10-P-4000LW
11	Paint repair areas and adjacent surfaces
	Notes on paintwork repairs	Use only paints approved by Daimler AG.	AH98.00-P-9408-02A
12	Add cavity preserving agent		AR97.20-P-1500LW
13	Install all detachable body components in area to be repaired

CHECK VALUES FOR GAP DIMENSIONS

Number	Designation			Model 205.3
BE60.00-P-1012-01BB	Trunk lid to fender at rear, top	Dimension "K"	mm	3, 5 (±1)
		Dimension "K1"	mm	4 (+1, 5/-1)
		For picture, see		AR60.00-P-0700-01LW

Fig 2: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1035-13A	Blind rivet 6.4 12 (clamping range 1 mm to 3.5 mm)	A 000 991 76 32
BR00.45-Z-1043-13A	Blind rivet with 6.4 14.0 countersunk head (clamping range 1.5 mm to 3.5 mm)	A 000 991 82 32
BR00.45-Z-1049-02A	Glazing repair kit, 2-component adhesive	A 168 670 00 93
BR00.45-Z-1056-07A	1K-zinc dust paint	A 000 986 28 00
BR00.45-Z-1162-02A	Parts kit for 2-component adhesive for body	A 012 989 17 71