Replace complete bottom rear center section - AR64.20-P-1000GQ

MODEL 166 

Shown on model 166.0 

Fig 1: Identifying Complete Bottom Rear Center Section - Shown On Model (166.0)

Courtesy of MERCEDES-BENZ USA

	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
	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
	Special notes regarding wax preservation		AH97.20-P-1000-02PV
	General information on body repair		AH60.00-N-0001-01A
	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A
	General information on MB materials		AH98.00-P-9409-03A
	Remove
1	Prepare all workshop equipment and commercially available tools required for repair
2	Remove all detachable parts in area to be repaired
3	Cover all detachable parts remaining in vehicle with welding protection blankets
4	Remove inner rear center section (1), center rear center section (2) and outer rear center section (3)	MODEL 166.0 with CODE Z04 (Light armoring)	AR64.20-P-1000-01GQS
		MODEL 166 without CODE Z04 (Light armoring)	AR64.20-P-1000-01GQ
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
5	Prepare inner rear center section (1), center rear center section (2) and outer rear center section (3) for installation	MODEL 166.0 with CODE Z04 (Light armoring)	AR64.20-P-1000-09GQS
		MODEL 166 without CODE Z04 (Light armoring)	AR64.20-P-1000-09GQ
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
6	Install inner rear center section (1), center rear center section (2) and outer rear center section (3), fit and weld in	MODEL 166.0 with CODE Z04 (Light armoring)	AR64.20-P-1000-10GQS
	General information on riveting		AH60.00-P-0003-01N
		MODEL 166 without CODE Z04 (Light armoring)	AR64.20-P-1000-10GQ
		Gap dimension	*BE60.00-P-1003-01Z
		Gap dimension	*BE60.00-P-1004-01Z
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Blind rivet, 6.4 x 14 MIG-MAG inert gas welder (steel, brazing, aluminum) Blind/self-piercing riveting	*BR00.45-Z-1001-13A
		Feeler gauge	Fig 2
7	Adjust gap dimensions on hoods, doors and lids		AR60.00-P-0700-01GQ
		Gap dimension	*BE60.00-P-1003-01Z
		Feeler gauge	Fig 2
8	Clean weld joints and sheet metal flanges with rotary wire brush
9	Clean repair area
10	Remove welding protection blankets	On all covered parts remaining in vehicle.
	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
11	Prime repair area with primer filler
	Notes on paintwork repairs		AH98.00-P-9408-02A
		Use only primer filler approved by Daimler AG
12	Carry out seam sealing after repairs	Seam sealing following repair Supplement standard seam seal.	AR97.10-P-4000GQ
	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
13	Paint repair area adjacent surfaces
	Notes on paintwork repairs		AH98.00-P-9408-02A
		Use only paints approved by Daimler AG
14	Apply additional cavity preservation		AR97.20-P-1500GQ
15	Install all removed detachable parts

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)

Courtesy 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