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Home >> Mercedes Benz >> 2021 >> S63 AMG 2D Convertible >> Repair and Diagnosis >> Collision >> General Collision Information >> Collision - Rear Wall And Rear End (217 Chassis) >> Rear Wall And Rear End Body Repair >> Install Rear Longitudinal Member - Ar64.20-P-1200-24LF

Install Rear Longitudinal Member - Ar64.20-P-1200-24LF

Model 217.3 

Model 222 

except code Z07 (B7 armoring on special protection version) 

IMPORTANT The following steps are shown on the left side of the vehicle and must be accomplished analogously on the right side in the event of damage.

G15300492Courtesy of MERCEDES-BENZ USA

Shown on MODEL 222 with CODE Z07 (Top protection) 

  1. Install rear longitudinal member (1) with straightening tool, fit and fix in place.

    IMPORTANT Helper required.

  2. Drill Ø 6.7 mm rivet holes in rear longitudinal member (1) (areas A).
  3. Drill Ø 6.7 mm rivet holes in rear longitudinal member (1) through present holes in body (area B).

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    G15300493Courtesy of MERCEDES-BENZ USA
    G15300494Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  4. Drill Ø 6.7 mm rivet holes in rear longitudinal member (1) (area C).
  5. Mark separating point (1.1) for window cutout on outer rear wheel well and cut.

    NOTES Do not cut too deeply.

    Otherwise the components below can be damaged and weakened.

    IMPORTANT It is necessary to cut out a window in the outer rear wheel well for access to bolts. Weld sheet metal cut out back in.

  6. Transfer position of bolt holes through present holes in outer rear wheel well to rear longitudinal member (1) (area D).
    G15300495Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  7. Install section of front crossmember (4), fit and fix in place.
  8. Drill Ø 6.7 mm rivet holes in rear longitudinal member (1) and front crossmember (4) (areas H).
  9. Remove rear longitudinal member (1) and front crossmember (4).

    IMPORTANT Helper required.

  10. Deburr rivet holes on rear longitudinal member (1), front crossmember (4) and body on both sides.
  11. Remove drilling chips.
  12. Coat insides of riveted joints with zinc dust paint.

    NOTES Do not coat insides of riveted joints, to which 2-component adhesive is to be applied, with zinc dust paint.

    Otherwise adhesion problems may occur.

    G15300496Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  13. Apply 2-component adhesive to body in crosshatched areas.

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

    G15300497Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  14. Apply 2-component adhesive to body in crosshatched areas.

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

    G15300498Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  15. Install rear longitudinal member (1) and front crossmember (4) with straightening tool and fix in place.

    IMPORTANT Helper required.

  16. Rivet rear longitudinal member (1) with Ø 6.5x12.5 blind rivets (areas E).
  17. Rear longitudinal member (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas F).
  18. Rivet rear longitudinal member (1) with Ø 6.5x12.5 blind rivets (area G1 ).
  19. Rivet rear longitudinal member (1) with Ø 6.4x12 blind rivets (area G2).

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    G15300499Courtesy of MERCEDES-BENZ USA
  20. Rear longitudinal member (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas S).

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    G15300500Courtesy of MERCEDES-BENZ USA
    G15300501Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  21. Rivet rear longitudinal member (1) with Ø 6.5x14.5 rivets (area H1 ).
  22. Rivet rear longitudinal member (1) with Ø 6.5x12.5 rivets (area H2).
  23. Screw rear longitudinal member (1) with hexalobular bolts M6x16 and nuts M6 (area H3 ).
    G15300502Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  24. Rivet rear longitudinal member (1) and front crossmember (4) with Ø 6.5x12.5 rivets (areas I).
  25. Rear longitudinal member (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area J).
  26. Rear longitudinal member (1) SHIELDED GAS SEAM WELD (area K).

    IMPORTANT Inert gas weld in intervals and allow welding area to cool down in between. Reduces heat distortion.

  27. Grind contact surfaces on floor of front crossmember (4) down flat (area K).
  28. Install center closing panel (10), fit and fix in place.
  29. Drill Ø 6.7 mm rivet holes in center closing panel (10) (area L).
  30. Remove center closing panel (10).
  31. Deburr rivet holes on center closing panel (10) and body on both sides.
  32. Remove drilling chips.
  33. Coat insides of riveted joints with zinc dust paint.
    G15300503Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  34. Install center closing panel (10) and fix in place.
  35. Rivet center closing panel (10) with Ø 6.4x12 blind rivets (area M).
  36. Center closing panel (10) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area N).
  37. Center closing panel (10) SHIELDED GAS SEAM WELD (area O).

    IMPORTANT Inert gas weld in intervals and allow welding area to cool down in between. Reduces heat distortion.

  38. Grind inert gas weld down flat (area O).
    G15300504Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    G15300505Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  39. Install floor (3), fit and fix in place.
  40. Mark positions of rivet holes on floor (3).

    IMPORTANTDimensions: 

    t1 = approx. 9 mm

    t2 = approx. 49 mm

    t3 = approx. 75 mm

    t4 = approx. 152 mm

    t5 = approx. 187 mm

    t6 = approx. 16 mm

    t7 = approx. 151 mm

    IMPORTANT Dimensions measured from end of floor component (3) t1 up to t5 .

    G15300506Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  41. Drill Ø 6.7 mm rivet holes in floor (3) (areas P).
  42. Remove floor (3).
  43. Deburr rivet holes on floor (3) and body on both sides.
  44. Remove drilling chips.
  45. Coat insides of riveted joints with zinc dust paint.

    NOTES Do not coat insides of riveted joints, to which 2-component adhesive is to be applied, with zinc dust paint.

    Otherwise adhesion problems may occur.

  46. Apply 2-component adhesive to rear longitudinal member (1) and front crossmember (4).

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

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    G15300507Courtesy of MERCEDES-BENZ USA
    G15300508Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  47. Install floor (3) and fix in place.
  48. Rivet floor (3) with Ø 6.5x12.5 blind rivets (areas Q1 ).
  49. Rivet floor (3) with Ø 6, 4x12. blind rivets (areas Q2 ).
  50. Floor (3) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area R1 ).
  51. Floor (3) SHIELDED GAS SEAM WELD (areas R2 ).

    IMPORTANT Inert gas weld in intervals and allow welding area to cool down in between. Reduces heat distortion.

  52. Grind inert gas weld down flat (areas R2 ).
    G15300509Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  53. Install rear crossmember (2) with straightening tool, fit and fix in place.
  54. Bend back sheet metal flange (area U2 ).
  55. Drill Ø 6.7 mm rivet holes in rear crossmember (2) (areas U1 and U 2 ).

    IMPORTANT Transfer present rivet holes in rear crossmember (2) (areas U1 ).

    IMPORTANT Drill rivet holes through present holes in body (area U1).

  56. Remove rear crossmember (2).
  57. Deburr rivet holes on rear crossmember (2) and body on both sides.
  58. Remove drilling chips.
    G15300510Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  59. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Apply 2-component adhesive to inside (area U3 ).

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

    G15300511Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  60. Install rear crossmember (2) and fix in place.
  61. Rivet rear crossmember (2) with Ø 6.5x14.5 rivets (areas U4 ).
  62. Rear crossmember (2) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas U5 ).
  63. Model 217.3

    Grind crosshatched areas on rear longitudinal member down to bare metal.

    IMPORTANT Sand down spot weld flanges to bare metal on both sides.

  64. Model 217.3

    Remove grinding dust.

  65. Model 217.3

    Coat insides of spot weld flanges with zinc dust paint.

    NOTES Do not coat bonding surfaces with zinc dust paint (area Z10 ).

    Otherwise adhesion problems may occur.

    IMPORTANT Observe pretreatment of bonding surfaces.

    G15300512Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 217.3 

  66. Model 217.3

    Apply 2-component adhesive to body in crosshatched areas.

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

    Shown on MODEL 217.3 

    G15300513Courtesy of MERCEDES-BENZ USA
    G15300514Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 217.3 

  67. Model 217.3

    Install longitudinal member inner panel (12), fit and fix in place.

  68. Model 217.3

    Longitudinal member inner panel (12) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas Z2 ).

  69. Model 217.3

    Longitudinal member inner panel (12) SHIELDED GAS PLUG WELD (areas Z3 and Z5 ).

    IMPORTANT Use holes (area Z4) only after installing B-pillar.

  70. Model 217.3

    Grind MIG plug welding down flat (area Z3 ).

  71. Model 217.3

    Longitudinal member inner panel (12) BRAZING (area Z1 ).

    G15300515Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 217.3 

  72. Model 217.3

    Offset reinforcement (14) SHIELDED GAS SEAM WELD (area Z9 ).

    IMPORTANT Grind insert gas weld on offset reinforcement (14) down flat (area Z9 ).

  73. Model 217.3

    Offset reinforcement (14) SHIELDED GAS SEAM WELD (areas Z7 and Z8 ).

    G15300239Courtesy of MERCEDES-BENZ USA
  74. Model 217.3

    Install duplicator (15), fit and fix in place.

    IMPORTANT Center duplicator (15) above inert gas weld on offset reinforcement (14).

  75. Model 217.3

    Drill Ø 6.7 mm rivet holes on duplicator (15) (areas X1 ).

  76. Model 217.3

    Remove duplicator (15).

  77. Model 217.3

    Deburr rivet holes on duplicator (15), offset reinforcement (14) and body on both sides.

  78. Model 217.3

    Remove drilling chips.

  79. Model 217.3

    Grind mating surface down to bare metal in cross-hatched area.

  80. Model 217.3

    Remove grinding dust.

  81. Model 217.3

    Apply 2-component adhesive to offset reinforcement (14) and body in crosshatched areas.

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

    G15300240Courtesy of MERCEDES-BENZ USA
    G15300241Courtesy of MERCEDES-BENZ USA
  82. Model 217.3

    Install duplicator (15) and fix in place.

  83. Model 217.3

    Rivet duplicator (15) and offset reinforcement (14) with Ø 6.5x12.5 blind rivets (areas X2 ).

  84. Model 222

    except code Z07 (B7 armoring on special protection version)

    Install longitudinal member inner panel (7), fit and fix in place.

  85. Model 222

    except code Z07 (B7 armoring on special protection version)

    Drill Ø 6.7 mm rivet hole in longitudinal member inner panel (7) (area U6 ).

  86. Model 222

    except code Z07 (B7 armoring on special protection version)

    Remove longitudinal member inner panel (7).

  87. Model 222

    except code Z07 (B7 armoring on special protection version)

    Deburr rivet hole on longitudinal member inner panel (7) and body on both sides.

  88. Model 222

    except code Z07 (B7 armoring on special protection version)

    Remove drilling chips.

  89. Model 222

    except code Z07 (B7 armoring on special protection version)

    Coat insides of riveted joint with zinc dust paint.

    G15300519Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  90. Model 222

    except code Z07 (B7 armoring on special protection version)

    Apply 2-component adhesive to body in crosshatched areas.

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

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    G15300520Courtesy of MERCEDES-BENZ USA
  91. Model 222

    except code Z07 (B7 armoring on special protection version)

    Install longitudinal member inner panel (7) and fix in place.

  92. Model 222

    except code Z07 (B7 armoring on special protection version)

    Rivet longitudinal member inner panel (7) with Ø 6.5x12.5 blind rivet (area U7 ).

  93. Model 222

    except code Z07 (B7 armoring on special protection version)

    Longitudinal member inner panel (7) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas U8 ).

    G15300521Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  94. Model 222

    except code Z07 (B7 armoring on special protection version)

    Install reinforcement (6), fit and fix in place.

  95. Model 222

    except code Z07 (B7 armoring on special protection version)

    Reinforcement (6) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area V1 ).

  96. Model 222

    except code Z07 (B7 armoring on special protection version)

    Reinforcement (6) SHIELDED GAS SEAM WELD (areas V2 ).

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    G15300522Courtesy of MERCEDES-BENZ USA
  97. Model 222

    except code Z07 (B7 armoring on special protection version)

    Apply 2-component adhesive to body in crosshatched areas.

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

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    G15300523Courtesy of MERCEDES-BENZ USA
  98. Model 222

    except code Z07 (B7 armoring on special protection version)

    Apply sealant to foam part in longitudinal member outer shell (5) in crosshatched area.

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    G15300524Courtesy of MERCEDES-BENZ USA
    G15300525Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  99. Model 222

    except code Z07 (B7 armoring on special protection version)

    Install longitudinal member outer shell (5) with straightening tool, fit and fix in place.

  100. Model 222

    except code Z07 (B7 armoring on special protection version)

    Longitudinal member outer shell (5) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas W1 ).

  101. Model 222

    except code Z07 (B7 armoring on special protection version)

    Longitudinal member outer shell (5) SHIELDED GAS SEAM WELD (areas W2 ).

    IMPORTANT Inert gas weld in intervals and allow welding area to cool down in between. Reduces heat distortion.

  102. Model 222

    except code Z07 (B7 armoring on special protection version)

    Clean contact surfaces on structured foam parts (8 and 9) on longitudinal member outer shell (5).

  103. Model 222

    except code Z07 (B7 armoring on special protection version)

    Apply 2-component adhesive for reinforcements on longitudinal member outer shell (5) and insert structured foam parts (8 and 9).

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

    G15300526Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  104. Install bottom rear longitudinal member (11), fit and fix in place.
  105. Drill Ø 6.7 mm rivet holes in bottom rear longitudinal member (11) (area X).
  106. Remove bottom rear longitudinal member (11).
  107. Deburr rivet holes on bottom rear longitudinal member (11) and rear crossmember on both sides.
  108. Remove drilling chips.

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    G15300527Courtesy of MERCEDES-BENZ USA
    G15300528Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

  109. Apply 2-component adhesive to rear longitudinal member (1) and front crossmember (2).

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

  110. Install rear bottom longitudinal member (11) and fix in place.
  111. Rivet bottom rear longitudinal member (11) with Ø 6.5x12.5 rivets (area Y1 ).
  112. Bottom rear longitudinal member (11) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas Y2 ).

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    G15300529Courtesy of MERCEDES-BENZ USA
  113. Apply 2-component adhesive to rear longitudinal member (1) crosshatched area.

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

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    G15300530Courtesy of MERCEDES-BENZ USA
  114. Install rear-end floor (12) and fix in place.
  115. Rear floor (12) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas Z).

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    G15300531Courtesy of MERCEDES-BENZ USA
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