Rear End On Left Side Repair - Ar64.20-P-1200MFC

Model 118.3 

Courtesy of MERCEDES-BENZ USA

	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
	Risk of injury  . Skin or eye injuries may result when handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	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	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	Notes on acoustic foam and structural foam in the vehicle		AH60.00-P-0039-01MFA
	General information on MB materials		AH98.00-P-9409-03A
	Remove
1	Remove detachable parts in area of repair point.
2	Cover all detachable parts remaining in vehicle with spark protection blankets.	Commercially available devices/tools  Spark-proof blankets
3	Set up straightening bench with straightening bench support members and straightening set.
	000 588 50 23 00 Body straightening system		WS60.00-P-0439K
4	Place vehicle on straightening bench and fasten.
5	Reshape damage area.
6	Remove rear-end center section (5).		AR64.20-P-1000-02MFC
	000 588 15 84 00 Heat gun	Commercially available devices/tools  Round wire brush Spot weld milling machine Wet/dry vacuum cleaner	WS54.00-P-0125B
		1K-zinc dust paint	*BR00.45-Z-1056-07A
		Spot weld milling cutter	Fig 1
7	Remove rear fender (1).		AR63.50-P-1400-02MFD
	000 588 15 84 00 Heat gun	Commercially available devices/tools  Round wire brush Body saw Spot weld milling machine Wet/dry vacuum cleaner	WS54.00-P-0125B
		1K-zinc dust paint	*BR00.45-Z-1056-07A
8	Remove spare wheel well (4).		AR64.20-P-1245-01MFC
	000 588 15 84 00 Heat gun	Commercially available devices/tools  Round wire brush Spot weld milling machine Wet/dry vacuum cleaner	WS54.00-P-0125B
		1K-zinc dust paint	*BR00.45-Z-1056-07A
		Spot weld milling cutter	Fig 1
9	Remove rear longitudinal member (3) with left rear-end floor (2).		AR64.20-P-1200-22MFD
	000 588 15 84 00 Heat gun	Commercially available devices/tools  Round wire brush Body saw Spot weld milling machine Wet/dry vacuum cleaner	WS54.00-P-0125B
		1K-zinc dust paint	*BR00.45-Z-1056-07A
	Install
	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
	Risk of explosion and poisoning  caused by solvent vapors and gasses. Risk of injury  to skin and eyes when working with anticorrosion agents	Never spray corrosion protection on flames or hot, glowing objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection.	AS97.00-Z-0001-01A
	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 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
Notice	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A
	General information on riveting		AH60.00-P-0003-01N
10	Prepare rear longitudinal member (3) and left rear-end floor (2).		AR64.20-P-1200-23MFD
	000 588 13 84 00 Welder		WS60.00-P-0437K
		Commercially available devices/tools  Round wire brush Body saw Wet/dry vacuum cleaner
		Parts kit for 2-component adhesive for body	*BR00.45-Z-1162-02A
		1K-zinc dust paint	*BR00.45-Z-1056-07A
11	Install rear longitudinal member (3) and left rear-end floor (2).		AR64.20-P-1200-24MFD
	000 588 50 23 00 Body straightening system	Commercially available devices/tools  Round wire brush Wet/dry vacuum cleaner Blind rivet gun (minimum pull-off force 19 kN)	WS60.00-P-0439K
		Parts kit for 2-component adhesive for body	*BR00.45-Z-1162-02A
		Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	*BR00.45-Z-1012-13A
		Blind rivet Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)	*BR00.45-Z-1016-13A
		1K-zinc dust paint	*BR00.45-Z-1056-07A
12	Release vehicle from straightening bench, lift and remove straightening bench.
13	Clean weld joints and sheet metal flange.	Commercially available devices/tools  Round wire brush
14	Prepare spare wheel well (4) for installation.		AR64.20-P-1245-02MFC
15	Install spare wheel well (4).		AR64.20-P-1245-03MFC
	000 588 13 84 00 Welder	Commercially available devices/tools  Round wire brush Wet/dry vacuum cleaner Blind rivet gun (minimum pull-off force 19 kN)	WS60.00-P-0437K
		Parts kit for 2-component adhesive for body	*BR00.45-Z-1162-02A
		1K-zinc dust paint	*BR00.45-Z-1056-07A
		Countersunk-head blind rivet Z3 6.4x17.0 (clamping area 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN)	*BR00.45-Z-1055-13A
16	Prepare rear fender (1) for installation.		AR63.50-P-1400-03MFD
		1K-zinc dust paint	*BR00.45-Z-1056-07A
17	Install rear fender (1).		AR63.50-P-1400-04MFD
	000 588 13 84 00 Welder		WS60.00-P-0437K
	000 588 12 84 00 Welder		WS00.00-P-0318K
		Gap dimensions on hoods, doors and lids Commercially available devices/tools  Round wire brush Blind rivet gun (minimum pull-off force 19 kN) Hand riveter Wet/dry vacuum cleaner	AR60.00-P-0700-01MFC
		Parts kit for 2-component adhesive for body	*BR00.45-Z-1162-02A
		Basic body filler	*BR00.45-Z-1057-07A
		Rear door to side wall	*BE60.00-P-1011-01NA
		Bumper at rear to side wall	*BE60.00-P-1022-01NA
		Outer tail lamp to side wall	*BE60.00-P-1017-01NA
		Liftgate/trunk lid to side wall	*BE60.00-P-1015-01NA
		Fuel filler flap/fuel filler flap hybrid to side wall (circumferential)	*BE60.00-P-1012-01NA
		1K-zinc dust paint	*BR00.45-Z-1056-07A
		White sealing compound, 310 ml, DBL 6069.20	*BR00.45-Z-1003-01A
		Parts kit for 2-component adhesive for body	*BR00.45-Z-1162-02A
		Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	*BR00.45-Z-1012-13A
		Feeler gauge If a basic body filler is used as an alternative to the restoration of surfaces with body solder, ↓ Apply basic body filler.	Fig 2
			AR60.00-P-0031-01LWG
		Basic body filler	*BR00.45-Z-1057-07A
18	Prepare rear-end center section (5) for installation.		AR64.20-P-1000-07MFC
		1K-zinc dust paint	*BR00.45-Z-1056-07A
19	Install rear-end center section (5).		AR64.20-P-1000-08MFC
	000 588 13 84 00 Welder	Commercially available devices/tools  Wet/dry vacuum cleaner Round wire brush Blind rivet gun (minimum pull-off force 19 kN)	WS60.00-P-0437K
		Outside of taillamp to inside of taillamp	*BE60.00-P-1019-01NA
		Liftgate/trunk lid to bumper at rear	*BE60.00-P-1016-01NA
		Liftgate/trunk lid to side wall	*BE60.00-P-1015-01NA
		Countersunk-head blind rivet Z1 6.4x14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN)	*BR00.45-Z-1043-13A
		1K-zinc dust paint	*BR00.45-Z-1056-07A
		Parts kit for 2-component adhesive for body	*BR00.45-Z-1162-02A
		Feeler gauge	Fig 2
20	Clean weld joints and sheet metal flange.	Commercially available devices/tools  Round wire brush
21	Remove spark protection blankets.	Commercially available devices/tools  Spark-proof blanket
22	Clean repair areas.	Commercially available devices/tools  Wet/dry vacuum cleaner
23	Treat repair areas with primer filler.
Notice	Notes on paintwork repairs		AH98.00-P-9408-02A
	General information on operation items and work procedures for painting	Use only primer filler approved by Daimler AG: http://xentryportal.mercedes-benz.com	AH98.00-P-0003-01A
24	Seal seam after repair.		AR97.10-P-4000MFA
		White sealing compound, 310 ml, DBL 6069.20	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
25	Paint repair areas and adjacent surfaces.
Notice	Notes on paintwork repairs		AH98.00-P-9408-02A
General information on operation items and work procedures for painting	Use only paints approved by Daimler AG	http://xentryportal.mercedes-benz.com	AH98.00-P-0003-01A
26	Supplement cavity preservation.	Commercially available devices/tools  Pressure spray gun	AR97.20-P-1500MFA
		Cavity preservation (free of solvents), 1 liter	*BR00.45-Z-1003-05A
27	Install detachable parts in the area of the repair point.

GAP DIMENSIONS

Number	Designation			Model 118.3
BE60.00-P-1011-01NA	Rear door to side wall	Dimension "I"	mm	3, 5 (±0, 5)
		For picture, see		AR60.00-P-0700-01MFC

GAP DIMENSIONS

Number	Designation			Model 118.3
BE60.00-P-1012-01NA	Fuel filler flap/fuel filler flap hybrid to side wall (circumferential)	Dimension "J"	mm	2 (±0, 5)
		For picture, see		AR60.00-P-0700-01MFC

GAP DIMENSIONS

Number	Designation			Model 118.3
BE60.00-P-1015-01NA	Liftgate/trunk lid to side wall	Dimension "M"	mm	3, 5 (±1)
		For picture, see		AR60.00-P-0700-01MFC

GAP DIMENSIONS

Number	Designation			Model 118.3
BE60.00-P-1016-01NA	Liftgate/trunk lid to bumper at rear	Dimension "N"	mm	6 (±1)
		For picture, see		AR60.00-P-0700-01MFC

GAP DIMENSIONS

Number	Designation			Model 118.3
BE60.00-P-1017-01NA	Outer tail lamp to side wall	Dimension "O"	mm	1, 5 (±0, 5)

GAP DIMENSIONS

Number	Designation			Model 118.3
BE60.00-P-1019-01NA	Outside of taillamp to inside of taillamp	Dimension "Q"	mm	3, 5 (-0.5/+1)
	For picture, see			AR60.00-P-0700-01MFC

GAP DIMENSIONS

Number	Designation			Model 118.3
BE60.00-P-1022-01NA	Bumper at rear to side wall	Dimension "T"	mm	0 (+0, 5)
		For picture, see		AR60.00-P-0700-01MFC

Fig 1: Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	White sealing compound, 310 ml, DBL 6069.20	A 001 989 63 20
BR00.45-Z-1003-05A	Cavity preservation (free of solvents), 1 liter	A 000 986 72 70 10
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
BR00.45-Z-1016-13A	Blind rivet Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)	A 004 990 17 97
BR00.45-Z-1041-01A	Seam sealant, sprayable 310 ml	A 002 989 84 20
BR00.45-Z-1043-13A	Countersunk-head blind rivet Z1 6.4x14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN)	A 000 991 82 32
BR00.45-Z-1055-13A	Countersunk-head blind rivet Z3 6.4x17.0 (clamping area 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN)	A 000 991 86 32
BR00.45-Z-1056-07A	1K-zinc dust paint	A 000 986 28 00
BR00.45-Z-1057-07A	Basic body filler	A 012 989 29 71
BR00.45-Z-1162-02A	Parts kit for 2-component adhesive for body	A 012 989 17 71