Repair Rear End On Left Side - Ar64.20-P-1200GQ
Model 166
Illustrated on model 166.0
| 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 | |
| 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 | |
| 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. | AS00.00-Z-0007-01A | |
| 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 | |
| Notice | General information on body repair | AH60.00-P-0001-01KOA | |
| Notice | 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 | Remove all detachable parts in area to be repaired | ||
| 3 | Set up straightening bench with module members, crossmember and straightening set | ||
| 000 588 01 23 00 Body straightening system | WS60.00-P-0023K | ||
| 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 except code Z04 (Light armoring) except code Z05 (B5 armoring on special protection version) |
AR63.50-P-1400-02GQ | ||
| Model 166.8 | AR63.50-P-1400-02GQX | ||
| Sheet metal crimping pliers for areas not easily accessible | WF58.50-P-6350-01SC | ||
| Zinc dust paint suitable for spot welding | *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 except code Z04 (Light armoring) except 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 crossmember (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 element (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 except code Z04 (Light armoring) except 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 except code Z04 (Light armoring) except 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 . | ||
| 14 | Prepare partial rear longitudinal member with lock element (7) for installation | AR64.20-P-1260-02GQ | |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A . | ||
| Install | |||
| 15 | Install partial longitudinal member with locking element (7), fit and weld in | AR64.20-P-1260-03GQ | |
| 000 588 02 84 00 Welder | WS60.00-P-0022K | ||
| 16 | Install spare wheel well (6), fit and weld in | AR64.20-P-1245-03GQ | |
| General information on riveting | AH60.00-P-0003-01N | ||
| 000 588 02 84 00 Welder | Tools for disassembly/assembly |
WS60.00-P-0022K | |
| Blind rivet Y2 6.5X12.5 (clamping range 2 mn to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A . | ||
| 17 | Install rear crossmember (5), fit and weld in General information on riveting | AR64.20-P-1100-05GQ | |
| AH60.00-P-0003-01N | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A . | ||
| Blind rivet Y2 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *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 |
| General information on riveting | AH60.00-P-0003-01N | ||
| Model 166 except code Z04 (Light armoring) except 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 6.4X14 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN) | *BR00.45-Z-1001-13A . | ||
| 19 | Install rear fender (1), fit and weld in | Model 166.0 with code Z04 (Light armoring) |
AR63.50-P-1400-04GQS |
| General information on riveting | AH60.00-P-0003-01N | ||
| Model 166.0 except code Z04 (Light armoring) except code Z05 (B5 armoring on special protection version) |
AR63.50-P-1400-04GQ | ||
| Model 166.8 | AR63.50-P-1400-04GQX | ||
| 000 588 02 84 00 Welder | Blind rivet tool |
WS60.00-P-0022K | |
| 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 . | ||
| Blind rivet with polygrip countersunk head 6.4 X14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN) | *BR00.45-Z-1002-13A . | ||
| 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 | ||
| 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 | Seal seam following repairs | 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 | |
| 27 | Paint repair area adjacent surfaces | Use only paints approved by Daimler AG. | |
| 28 | Add cavity preserving agent | 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) | ||
| For picture, see | AR60.00-P-0700-01GQ . | ||||
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) | ||
| Liftgate to rear window | Dimension "O" | mm | 4, 0 (±1, 0) | ||
| Rear fender to backup lamp | Dimension "M" | mm | 1, 4 (±0, 7) | ||
| D-pillar to rear window | Dimension "V" | mm | - | ||
| For picture, see | AR60.00-P-0700-01GQ . | ||||
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) |
| For picture, see | AR60.00-P-0700-01GQ . | ||||
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 6.4X14 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN) | A 003 990 35 97 |
| BR00.45-Z-1002-13A | Blind rivet with polygrip countersunk head 6.4X14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN) | A 003 990 86 97 05 |
| BR00.45-Z-1012-13A | Blind rivet Y2 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | A 004 990 16 97 |