Replace Bottom Rear Center Section Together With Rear Cross Member - Ar64.20-P-1060V

MODEL 171, 172 

Illustrated on model 171 

Courtesy of MERCEDES-BENZ USA

	Removing
	Risk of death  caused by high voltage used for electric welding. Risk of explosion  caused by welding in the area of highly inflammable materials. Risk of injury  caused by welding splatter and UV light while welding. Risk of poisoning  caused by inhaling welding fumes.	Use insulating mats. Wear protective clothing safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system.	See AS00.00-Z-0007-01A .
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.	See 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.	See AS00.00-Z-0017-01A .
	Measures for preventing damage to components when performing electric welding and soldering work		See AH60.00-P-0001-02A .
	General information on body repair		See AH60.00-N-0001-01A .
1	Remove detachable parts in area to be repaired
2	Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket + -	Welding protective blanket
3	Equip straightening bench with module members, cross members and straightening tool set.	Observe enclosed set-up plans. Straightening bracket set, passenger cars, cross-country vehicles (Celette) Straightening system, passenger cars (Car Bench)
4	Place vehicle on straightening bench lift and fasten	Two-column lift 3.0 - -3.5 t electromechanical Two-post lifting platform, 2.5 - 3.5 t electro hydraulic
5	Separate rear center section (1) with rear cross member (2)	Body jig saw	See AR64.20-P-1060-01V .
		Weld-spot milling machine Round wire brush Wet and dry vacuum cleaner Zinc dust paint suitable for spot welding	See *BR00.45-Z-1001-07A .
6	Prepare rear center section (1) with rear cross member (2)	Round wire brush	See AR64.20-P-1060-05V .
		Zinc dust paint suitable for spot welding	See *BR00.45-Z-1001-07A .
	Install
7	Install rear center section (1) with rear cross member (2) and weld in		See AR64.20-P-1060-06V .
		Spacer	See Fig 2.
		Feeler gauge	See Fig 1.
		Model 171	See *BE60.00-P-1003-01L .
		Model 172 Straightening bracket set, passenger cars, cross-country vehicles (Celette)	See *BE60.00-P-1003-01Y .
		Straightening system, passenger cars (Car Bench)   Multifunction device (spot welding) MIG-MAG inert gas welder Pneumatic/hydraulic blind rivet tool Vice grip pliers (standard) Wet and dry vacuum cleaner Round wire brush Zinc dust paint suitable for spot welding	See *BR00.45-Z-1001-07A .
8	Adjust gaps on hoods, doors and lids		See AR60.00-P-0700-01V .
		Feeler gauge	See Fig 1.
		Model 171	See *BE60.00-P-1003-01L .
		Model 172	See *BE60.00-P-1003-01Y .
9	Release vehicle from straightening bench, lift vehicle and remove straightening bench	Two-column lift 3.0 - -3.5 t electromechanical   Two-post lifting platform, 2.5 - 3.5 t electrohydraulic
10	Clean weld joints and sheet metal flanges with rotary wire brush	Round wire brush
11	Remove welding protection blankets
12	Clean repair area	Wet and dry vacuum cleaner
13	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 skin cream. Ensure that the area is well ventilated. Use only primer fillers approved by Daimler AG: See http://portal.aftersales.i.daimler.com	See AS98.00-Z-0002-01A .
14	Carry out seam sealing after repairs	Model 171	AR97.10-P-4000V
		Model 172	See AR97.10-P-4000W .
15	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 skin cream. Ensure that the area is well ventilated. Use only paints approved by Daimler AG. ↓ See http://portal.aftersales.i.daimler.com	See AS98.00-Z-0002-01A .
16	Apply additional cavity preservation	Model 171	AR97.20-P-1500V
		Model 172	See AR97.20-P-1500W .
17	Install all removed detachable parts

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				Model 171
BE60.00-P-1003-01L	Gap dimension	Trunk lid to rear fender	Dim. "F"	mm	3.5 (+1.5)
		Trunk lid to rear lamp unit	Dim. "M"	mm	4.0 (+1.6/-0.5)
		Trunk lid to bumper	Dim. "V"	mm	5.0 (+1.5/-1.0)
		Rear fender to rear lamp unit	Dim. "U"	mm	2.5 (±0.5)
		Trunk lid tip to rear fender	Dim. "E"	mm	5, 0 (+1, 5)
			See picture		AR60.00-P-0700-01V .

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				Model 172
BE60.00-P-1003-01Y	Gap dimension	Trunk lid to rear fender	Dim. "F"	mm	4.5 (±1)
		Trunk lid to rear lamp unit	Dim. "M"	mm	4.5 (+1.5/-0.5)
		Trunk lid to bumper	Dim. "V"	mm	6.0 (±1.5)
		Rear fender to rear lamp unit	Dim. "U"	mm	1.5 (±1)
		Trunk lid tip to rear fender	Dim. "E"	mm	6.5 (+1/-0.5)
			See picture		AR60.00-P-0700-01V .

Fig 1: Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Spacer (000 589 87 63 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