LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 2021 >> S580 >> Repair and Diagnosis >> Collision >> Body Panels >> Collision - Rear Wall And Rear End (223 Chassis) >> Rear Wall And Rear End Body Repair >> Lower Rear-End Center Section Installation - Ar64.20-P-1000-13S

Lower Rear-End Center Section Installation - Ar64.20-P-1000-13S

REFER TO SPECIAL TOOLS 000 588 04 39 00 Rivet press tool   WS60.00-P-0440B
REFER TO SPECIAL TOOLS 000 588 03 39 00 Rivet die   WS60.00-P-0386K

Model 223.0/1 

Model 223.9 

Fig 1: Feeler Gauge (129 589 03 21 00)
G07469060Courtesy of MERCEDES-BENZ USA
G16228192Courtesy of MERCEDES-BENZ USA

Countersunk-head rivet (Z) 

  1. Z1 = countersunk-head rivet 6.4x14.0
  2. Z2 = countersunk-head rivet 6.4x15.5
  3. Z3 = countersunk-head rivet 6.4x17.0
  4. Z4 = countersunk-head rivet 6.4x19.0
  5. Z5 = countersunk-head rivet 6.4x21.0

Blind rivet (Y) 

  1. Y1 = rivet 6.4x12
  2. Y2 = rivet 6.5x12.5
  3. Y3 = rivet 6.5x14.5
  4. Y4 = Rivet 6.4M6
  5. Y5 = Rivet 6.4
  6. Y6 = rivet 6.5x13.5
  7. Y7 = rivet 6.4x14
  8. Y8 = rivet 6.4x17
  9. Y9 = rivet 6.4x20

Flow-form rivet with countersunk head (X) 

Flow-form rivet (W) 

  1. W1 = Flow-form rivet structure with 3.5 mm clamping range
  2. W3 = Flow-form rivet structure 3.35 mm up to 4.1 mm clamping range
  3. W4 = Flow-form rivet structure 4 mm up to 5.15 mm clamping range
  4. W5 = Flow-form rivet structure 5.0 mm up to 6.1 mm clamping range
  5. W6 = Flow-form rivet structure 6.0 mm up to 7.2 mm clamping range
  6. W7 = Flow-form rivet structure 7.1 mm up to 8.3 mm clamping range

Blind rivet (V) 

  1. V1 = rivet 3.2x4.5
  2. V2 = rivet 3.2x6.5

Blind rivet (U) 

  1. U1 = rivet 3.2x9.5

Blind rivet with countersunk head (T) 

  1. T1 = blind rivet with countersunk head 3.0 mm to 5.0 mm clamping range
  2. T2 = blind rivet with countersunk head 1.5 mm to 3.0 mm clamping range
  3. X1 = Flow-form rivet with countersunk head 1.3 mm to 2.5 mm clamping range
  4. X2 = Flow-form rivet with countersunk head 2.3 mm to 3.5 mm clamping range
  5. X3 = Flow-form rivet with countersunk head 3.35 mm to 4.1 mm clamping range
  6. X4 = Flow-form rivet with countersunk head 4 mm to 5.15 mm clamping range
  7. X5 = Flow-form rivet with countersunk head 5.0 mm to 6.1 mm clamping range
  8. X6 = Flow-form rivet with countersunk head 6.0 mm to 7.2 mm clamping range
  9. X7 = Flow-form rivet with countersunk head 7.1 mm to 8.3 mm clamping range

IMPORTANT The following operation steps are shown on model 223.1.

The superordinate service document as well as the safety information in the service document must be observed.

The graphics show the vehicle from the mechanic's perspective. At the same time, this perspective also specifies the direction in which the rivets must be placed.

G16228716Courtesy of MERCEDES-BENZ USA
  1. Install and fit bottom rear-end center section (2) and rear-end center section paneling (1).
  2. Install the rear bumper and fit it in place.
  3. Install taillamps and fit them in place.
  4. Install seal and fit it in place.
  5. Install striker eye and fit it in place.
  6. Check gaps using SPECIAL TOOL feeler gauge and adjust.
  7. Fix bottom rear-end center section (2) and rear-end center section paneling (1) in place.
  8. Remove striker eye.
  9. Remove seal.
  10. Remove taillamps.
  11. Remove rear bumper.
  12. Bend connecting flange on the rear lamp reinforcements back (arrows).
  13. Drill rivet holes in rear-end center section paneling (1) and bottom rear-end center section (2) with ø 6.7 mm (areas A1 , A2 , A3 ).

    IMPORTANT The following operation steps 14, 15 and 16 are shown on the left side of the vehicle and must be performed in the same way on the right side of the vehicle.

  14. Mark position of the rivet holes on bottom rear-end center section (2).

    IMPORTANTDimensions: 

    x1 = approx. 17 mm

    x2 = approx. 7 mm

    y1 = approx. 10 mm

    y2 = approx. 22 mm

  15. Drill rivet holes in bottom rear-end center section (2) with ø 6.7 mm (areas B1 , B2 , B3 ).
  16. Punch rivet holes in bottom rear-end center section (2) with ø 6.0 mm using rivet press tool (area C).
    G16228717Courtesy of MERCEDES-BENZ USA
    G16228718Courtesy of MERCEDES-BENZ USA
  17. Countersink rivet holes in bottom rear-end center section (2) and in the body (areas K).

    IMPORTANT Counter sink rivet hole to form level surface to allow adjustment of the bumper crossmember, if required.

  18. Remove rear-end center section paneling (1) and rear-end center section lower part (2).
  19. Deburr rivet holes in the rear-end center section paneling (1), bottom rear-end center section (2) and in the body on both sides.
  20. Remove drilling chips.
    G16228709Courtesy of MERCEDES-BENZ USA
  21. Apply 2-component adhesive to body in cross-hatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

  22. Apply 2-component adhesive to body in cross-hatched areas.

    The operation step is shown on the left side of the vehicle and must be performed in the same way on the right side of the vehicle.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G16228710Courtesy of MERCEDES-BENZ USA
    G16228721Courtesy of MERCEDES-BENZ USA
  23. Install bottom rear-end center section (2) and fix in place.
  24. Apply 2-component adhesive to bottom rear-end center section (2) in the cross-hatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G16228722Courtesy of MERCEDES-BENZ USA
  25. Install rear-end center section paneling (1) and fix in place.
  26. Rivet lower rear-end center section (2) with countersunk-head rivets ø 6.4x14.0 (areas Z1 ).
  27. Rivet lower rear-end center section (2) and rear-end center section paneling (1) with countersunk-head rivets ø 6.4x15.5 (areas Z2 ).
  28. Rivet lower rear-end center section (2) and rear-end center section paneling (1) with countersunk-head rivets ø 6.4x17.0 (areas Z3 ).
  29. Rivet lower rear-end center section (2) and rear-end center section paneling (1) with rivets ø 6.5x12.5 (areas Y2 ).
  30. Rivet lower rear-end center section (2) and rear-end center section paneling (1) with rivets ø 6.5x14.5 (areas Y3 ).
  31. Rivet bottom rear-end center section (2) from outside with flow-form rivet structure 2.3 to 3.5 mm clamping range (areas W1 ).
    G16228723Courtesy of MERCEDES-BENZ USA
  32. Rivet lower rear-end center section (2) and rear-end center section paneling (1) with rivets ø 6.5x12.5 (areas Y2 ).
  33. Rivet lower rear-end center section (2) and rear-end center section paneling (1) with rivets ø 6.5x14.5 (areas Y3 ).
  34. Rivet lower rear-end center section (2) and rear-end center section paneling (1) with rivets ø 6.4x12 (areas Y1 ).
  35. Insert new screws (3) with sealing compound.

    IMPORTANT The following operation steps 36, 37 are shown on the left side of the vehicle and must be similarly performed on the right side of the vehicle.

  36. Rivet lower rear-end center section (2) with rivets ø 6.5x12.5 (area Y2 ).
  37. Rivet lower rear-end center section (2) with rivets ø 6.4x12 (area Y1 ).
    G16228724Courtesy of MERCEDES-BENZ USA
scientia non olet · About LEMON Manuals