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Left side rear end damage - AR64.20-P-1200GQ

MODEL 166 

Fig 1: Identifying Left Side Rear End Damage Parts - Shown On Model (166.0)
G09982811Courtesy of MERCEDES-BENZ USA
DANGER Risk of explosion  caused by fuel igniting, Risk of poisoning  caused by inhaling and swallowing fuel as well as Risk of injury  to eyes and skin caused by contact with fuel. No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.		 AS47.00-Z-0001-01A
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
DANGER 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
DANGER 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
IMPORTANT Measures for preventing damage to components when performing electric welding and soldering work   AH60.00-P-0001-02A
IMPORTANT General information on MB materials   AH98.00-P-9409-03A
IMPORTANT General information on body repair   AH60.00-N-0001-01A
REMOVING Remove     
1 Remove all detachable parts in area to be repaired    
3 Set up straightening bench with module members, crossmember and straightening set IMPORTANT Observe set-up plans provided.
Straightening systems for passenger cars (Celette)
Straightening systems for passenger cars (Car Bench)
Straightening systems for passenger cars (Car-O-Liner)		  
4 Place vehicle on straightening bench and fasten    
5 Remove rear fender (1) MODEL 166.0
with CODE Z04 (Light armoring)		 AR63.50-P-1400-02GQS
    MODEL 166.0
without CODE Z04 (Light armoring)
without CODE Z05 (B5 armoring on special protection version)		 AR63.50-P-1400-02GQ
    MODEL 166.8 AR63.50-P-1400-02GQX
REFER TO SHOP-MADE TOOLS Sheet metal crimping pliers for areas not easily accessible   WF58.50-P-6350-01SC
    IMPORTANT When replacing right rear fender (1), the standard tank lock must be installed and the filler necks covered with fire-resistant welding protection blanket.  
    Zinc dust paint suitable for spot welding
Glass removal		 *BR00.45-Z-1001-07A 
6 Separate outer, center, inner rear center section (2, 3, 4) MODEL 166.0
with CODE Z04 (Light armoring)		 AR64.20-P-1000-01GQS
MODEL 166
without CODE Z04 (Light armoring)
without CODE Z05 (B5 armoring on special protection version)		 AR64.20-P-1000-01GQ
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
7 Remove rear cross member (5)   AR64.20-P-1100-01GQ
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
8 Remove spare wheel well (6)   AR64.20-P-1245-01GQ
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
9 Partially remove rear longitudinal member with locking lug (7)   AR64.20-P-1260-01GQ
10 Prepare rear fender (1) for installation MODEL 166.0
with CODE Z04 (Light armoring)		 AR63.50-P-1400-03GQS
MODEL 166.0
without CODE Z04 (Light armoring)
without CODE Z05 (B5 armoring on special protection version)		 AR63.50-P-1400-03GQ
MODEL 166.8 AR63.50-P-1400-03GQX
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
11 Prepare outer, center, inner rear center section (2, 3, 4) for installation MODEL 166.0
with CODE Z04 (Light armoring)		 AR64.20-P-1000-09GQS
MODEL 166
without CODE Z04 (Light armoring)
without CODE Z05 (B5 armoring on special protection version)		 AR64.20-P-1000-09GQ
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
12 Prepare rear crossmember (5) for installation   AR64.20-P-1100-02GQ
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
13 Prepare spare wheel well (6) for installation   AR64.20-P-1245-02GQ
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
14 Prepare part of rear longitudinal member with locking lug (7) for installation   AR64.20-P-1260-02GQ
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install     
15 Install part of rear longitudinal member with locking lug (7), fit and weld in   AR64.20-P-1260-03GQ
MIG-MAG inert gas welder (steel, brazing, aluminum)
16 Install spare wheel well (6), fit and weld in   AR64.20-P-1245-03GQ
IMPORTANT General information on riveting   AH60.00-P-0003-01N
    Blind rivet 6.5X12.5
Tools for disassembly/assembly
 
MIG-MAG inert gas welder (steel, brazing, aluminum)
Blind/self-piercing riveting		 *BR00.45-Z-1012-13A 
17 Install rear crossmember (5), fit and weld in   AR64.20-P-1100-05GQ
IMPORTANT General information on riveting   AH60.00-P-0003-01N
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
    Blind rivet 6.5X12.5
Tools for disassembly/assembly
Blind/self-piercing riveting		 *BR00.45-Z-1012-13A 
18 Install outer, inner center rear center section (2, 3, 4), fit and weld in MODEL 166.0
with CODE Z04 (Light armoring)		 AR64.20-P-1000-10GQS
IMPORTANT General information on riveting   AH60.00-P-0003-01N
    MODEL 166
without CODE Z04 (Light armoring)
without CODE Z05 (B5 armoring on special protection version)		 AR64.20-P-1000-10GQ
    Gap dimension *BE60.00-P-1003-01Z 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
    Blind rivet, 6.4 x 14
Tools for disassembly/assembly
 
Blind/self-piercing riveting		 *BR00.45-Z-1001-13A 
    SPECIAL TOOL Feeler gauge Figure
19 Install rear fender (1), fit and weld in MODEL 166.0
with CODE Z04 (Light armoring)		 AR63.50-P-1400-04GQS
IMPORTANT General information on riveting   AH60.00-P-0003-01N
    MODEL 166.0
without CODE Z04 (Light armoring)
without CODE Z05 (B5 armoring on special protection version)		 AR63.50-P-1400-04GQ
    MODEL 166.8 AR63.50-P-1400-04GQX
    Gap dimension *BE60.00-P-1001-01Z 
    Gap dimension *BE60.00-P-1003-01Z 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
    Polygrip countersunk-head rivet, 6.4X14
Tools for disassembly/assembly
MIG-MAG inert gas welder (steel, brazing, aluminum)
Blind/self-piercing riveting		 *BR00.45-Z-1002-13A 
    SPECIAL TOOL Feeler gauge Figure
20 Set gap dimensions Gap dimensions on hoods, doors and lids AR60.00-P-0700-01GQ
Gap dimension *BE60.00-P-1001-01Z 
Gap dimension *BE60.00-P-1003-01Z 
Gap dimension *BE60.00-P-1004-01Z 
21 Release vehicle from straightening bench, lift vehicle and remove straightening bench    
22 Clean weld joints and sheet metal flanges with rotary wire brush    
23 Clean repair area    
24 Remove welding protection blankets IMPORTANT On all covered parts remaining in vehicle.  
DANGER Risk of explosion  caused by paint vapors igniting. Risk of poisoning  caused by inhaling paint vapors. No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. AS98.00-Z-0002-01A
25 Prime repair area with primer filler Use only primer filler approved by Daimler AG  
26 Carry out seam sealing after repairs   AR97.10-P-4000GQ
IMPORTANT Supplement standard seam seal.
DANGER Risk of explosion  caused by paint vapors igniting. Risk of poisoning  caused by inhaling paint vapors. No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. AS98.00-Z-0002-01A
27 Paint repair area adjacent surfaces Use only paints approved by Daimler AG  
28 Apply additional cavity preservation   AR97.20-P-1500GQ
29 Install all removed detachable parts    
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number Designation MODEL 166
BE60.00-P-1001-01Z Gap dimension Engine hood to fender Dimension "A" mm 3, 8 (±1)
Engine hood to headlamp Dimension "B" mm 3, 9 (±1)
Engine hood to bumper Dimension "C" mm 5, 4 (±1, 5)
Fender to A-pillar Dimension "D" mm 3, 5 (±1)
Front door to fender Dimension "E" mm 4, 3 (±0, 7)
Front door to rear door Dimension "F" mm 4, 8 (±0, 7)
Rear door to rear fender Dimension "I" mm 4, 3 (±0, 7)
  AR60.00-P-0700-01G
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number Designation MODEL 166
BE60.00-P-1003-01Z Gap dimension Liftgate to bumper at bottom Dimension "L" mm 5, 5 (±1, 5)
Liftgate to rear fender Dimension "J" mm 4, 8 (±1)
Liftgate to bumper at side Dimension "K" mm 4, 9 (±1, 3)
Liftgate to roof Dimension "W" mm 5, 5 (±1, 5)
Rear fender to lamp unit Dimension "M" mm 1, 4 (±0, 7)
  AR60.00-P-0700-01G Q
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number Designation MODEL 166
BE60.00-P-1004-01Z Gap dimension Fuel filler flap Dimension "N" mm 2, 7 (±0, 3)
  AR60.00-P-0700-01G Q
Fig 2: Identifying Feeler Gauge (129 589 03 21 00)
G07648023Courtesy of MERCEDES-BENZ USA
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-1001-13A Blind rivet, 6.4 x 14 A 003 990 35 97
BR00.45-Z-1002-13A Polygrip countersunk-head rivet, 6.4X14 A 003 990 86 97 05
BR00.45-Z-1012-13A Blind rivet 6.5X12.5 A 004 990 16 97
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