Repair Rear End On Left Side - AR64.20-P-1200GQ

MODEL 166 

Shown 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 contactwith 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 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  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
	General information on body repair		AH60.00-P-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	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	Observe set-up plans provided.	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
		Commercially available devices/tools  Glass removal 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, replaced by A 000 986 28 00 1K zinc dust paint	*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, replaced by A 000 986 28 00 1K zinc dust paint	*BR00.45-Z-1001-07A
7	Remove rear cross member (5)		AR64.20-P-1100-01GQ
		Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint	*BR00.45-Z-1001-07A
8	Remove spare wheel well (6)		AR64.20-P-1245-01GQ
		Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint	*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, replaced by A 000 986 28 00 1K zinc dust paint	*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, replaced by A 000 986 28 00 1K zinc dust paint	*BR00.45-Z-1001-07A
12	Prepare rear crossmember (5) for installation		AR64.20-P-1100-02GQ
		Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint	*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, replaced by A 000 986 28 00 1K zinc dust paint	*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, replaced by A 000 986 28 00 1K zinc dust paint	*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 General information on riveting		AR64.20-P-1245-03GQ  AH60.00-P-0003-01N
	000 588 02 84 00 Welder	Commercially available devices/tools  Blind rivet tool Tools for disassembly/assembly	WS60.00-P-0022K
		Blind rivet 6.5 x 12.5 (clamping range 2 mm 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
		Commercially available devices/tools  Blind rivet tool Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint	*BR00.45-Z-1001-07A
		Blind rivet 6.5 x 12.5 (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) Commercially available devices/tools  Blind rivet tool	AR64.20-P-1000-10GQ
		Gap dimension	*BE60.00-P-1003-01Z
		Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint	*BR00.45-Z-1001-07A
		Blind rivet 6.4 x 14 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)	*BR00.45-Z-1001-13A
		Feeler gauge	Fig 1
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		WS60.00-P-0022K
		Commercially available devices/tools  Blind rivet tool
		Gap dimension	*BE60.00-P-1001-01Z
		Gap dimension	*BE60.00-P-1003-01Z
		Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint	*BR00.45-Z-1001-07A
		Blind rivet with polygrip countersunk head 6.4 x 14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)	*BR00.45-Z-1002-13A
		Feeler gauge	Fig 1
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	On all covered parts remaining in vehicle.
25	Risk of explosion  caused by paint vapors igniting. Risk of poisoning  caused by inhaling paint vapors. Prime repair area with primer filler	No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. Use only primer filler approved by Daimler AG.	AS98.00-Z-0002-01A
26	Seal seam following repairs	Supplement standard seam seal.	AR97.10-P-4000GQ
27	Risk of explosion  caused by paint vapors igniting. Risk of poisoning  caused by inhaling paint vapors. Paint repair area adjacent surfaces	No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. Use only paints approved by Daimler AG.	AS98.00-Z-0002-01A
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

Fig 1: 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, replaced by A 000 986 28 00 1K zinc dust paint	A 000 986 34 42
BR00.45-Z-1001-13A	Blind rivet 6.4 x 14 (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 6.4 x 14 (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 6.5 x 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	A 004 990 16 97