Replace complete rear end - AR64.20-P-1020NKC

MODEL 117 

Shown on MODEL 117.3 

Fig 1: Complete Rear End Area - Shown On Model 117.3

Courtesy of MERCEDES-BENZ USA

	Risk of poisoning  caused by inhaling vapors or swallowing adhesive. Risk of injury  caused by adhesive coming into contact with skin and eyes	Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only.	AS00.00-Z-0016-01A
	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
	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
	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A
	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	General information on body repair		AH60.00-P-0001-01A
	General information on riveting		AH60.00-P-0003-01N
	General information on MB materials		AH98.00-P-9409-03A
	Remove
1	Remove detachable parts in area to be repaired
2	Cover all detachable parts remaining on vehicle with spark protection blanket
3	Separate rear area (1)		AR64.20-P-1020-01NKC
		Commercially available devices/tools  Round wire brush Body jig saw Spot weld milling machine Hot air gun Wet and dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
4	Prepare rear area (1) for installation		AR64.20-P-1020-05NKC
		Commercially available devices/tools  Round wire brush
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
5	Install rear area (1)		AR60.00-P-1020-06NKC
	000 588 02 39 00 Rivet press tool		WS60.00-P-0010B
	000 588 02 84 00 Welder		WS60.00-P-0022K
		Commercially available devices/tools  Spot welder Round wire brush Vise grip pliers Manual temporary fasteners Ø 6.35 mm Wet and dry vacuum cleaner
		Adhesive kit, body, 2-component adhesive	*BR00.45-Z-1092-02A
		Blind rivet, 6.5 x 14.5	*BR00.45-Z-1016-13A
		Blind rivet 6.5 X 12.5	*BR00.45-Z-1012-13A
		Feeler gauge For measuring points of gap dimensions on body see: ↓	Fig 2
		Gap dimensions on hoods, doors and lids	AR60.00-P-0700-01NKC
		Gap dimension	*BE60.00-P-1011-01ZA
		Gap dimension	*BE60.00-P-1012-01ZA
		Gap dimension	*BE60.00-P-1015-01ZA
		Gap dimension	*BE60.00-P-1016-01ZA
6	Clean weld joints and sheet metal flange with round wire brush	Commercially available devices/tools  Round wire brush
7	Remove spark protection blankets
8	Clean repair area	Commercially available devices/tools  Wet and dry vacuum cleaner
	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
9	Prime repair area sing primer filler
	Notes on paintwork repairs		AH98.00-P-9408-02A
		Use only primer filler approved by Daimler AG.
10	Seam sealing following repair		AR97.10-P-4000NKB
		Supplement standard seals with sealant.
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
		White sealing compound, 310 ml, DBL 6069.20	*BR00.45-Z-1003-01A
	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	Paint repair areas and adjacent surfaces
	Notes on paintwork repairs		AH98.00-P-9408-02A
		Use only paints approved by Daimler AG.
12	Apply additional cavity preservation	Cavity preservation following repair work	AR97.20-P-1500NKC
13	Install all detachable body components in area to be repaired

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				Model 117.3	Model 117.9
BE60.00-P-1011-01ZA	Gap dimension	Rear door to rear fender	Dimension "L"	mm	4, 0 (± 1, 0)	3, 8 (± 1, 0)
			For picture, see		AR60.00-P-0700-01NKC	AR60.00-P-0700-01NKC

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				Model 117.3	Model 117.9
BE60.00-P-1012-01ZA	Gap dimension	Taillamp to rear fender	Dimension "T"	mm	1, 5 (± 1, 0)	1, 5 (± 0, 7)
			For picture, see		AR60.00-P-0700-01NKC	AR60.00-P-0700-01NKC

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				Model 117.3	Model 117.9
BE60.00-P-1015-01ZA	Gap dimension	Trunk lid/liftgate to rear fender	Dimension "O1"	mm	4, 0 (± 1, 0)	4, 0 (± 1, 0)
			For picture, see		AR60.00-P-0700-01NKC	AR60.00-P-0700-01NKC

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				Model 117.3	Model 117.9
BE60.00-P-1016-01ZA	Gap dimension	Trunk lid/liftgate to taillamp	Dimension "R1"	mm	4, 5 (± 1, 0)	5, 0 (± 1, 0)
			For picture, see		AR60.00-P-0700-01NKC	AR60.00-P-0700-01NKC

Fig 2: 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-1003-01A	White sealing compound, 310 ml, DBL 6069.20	A 001 989 63 20
BR00.45-Z-1012-13A	Blind rivet 6.5 X 12.5	A 004 990 16 97
BR00.45-Z-1016-13A	Blind rivet, 6.5 x 14.5	A 004 990 17 97
BR00.45-Z-1041-01A	Seam sealant, sprayable 310 ml	A 002 989 84 20
BR00.45-Z-1092-02A	Adhesive kit, body, 2-component adhesive	A 009 989 36 71