Replace complete rear end - AR64.20-P-1020ES
WARNING: This page does not describe the selected car, but rather 33 other vehicles, including the 2016 Mercedes-Benz E63 S AMG, 2016 Mercedes-Benz E400, 2016 Mercedes-Benz E350, 2016 Mercedes-Benz E300, and 2016 Mercedes-Benz E250. However, it is still accessible from the selected car via links, so may be relevant.
MODEL 212.2
MODEL 218.9
Shown on model 212.2
| 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 | |
| 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 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 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 | |
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-N-0005-01A | ||
| General information on body repair | AH60.00-N-0001-01A | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| Remove | |||
| 1 | Prepare all workshop equipment and commercially available tools required for repair | ||
| 2 | Remove all detachable parts in area to be repaired | ||
| 3 | Cover all detachable parts remaining in vehicle with welding protection blankets | Welding protective blanket | |
| 4.1 | Remove rear end (1) | Version without reinforcements (2) | |
| AR64.20-P-1020-01ES | |||
| Zinc dust paint suitable for spot welding Weld-spot milling machine Round wire brush Electric hot-air blower for plastics Wet and dry vacuum cleaner |
*BR00.45-Z-1001-07A | ||
| Fig 3 | |||
| 4.2 | Remove rear end (1) | Version with reinforcements (2) | |
| AR64.20-P-1020-01ESA | |||
| Zinc dust paint suitable for spot welding Weld-spot milling machine Round wire brush Electric hot-air blower for plastics Wet and dry vacuum cleaner |
*BR00.45-Z-1001-07A | ||
| Fig 3 | |||
| 5.1 | Prepare rear end (1) for installation | Version without reinforcements (2) | |
| AR64.20-P-1020-05ES | |||
| Zinc dust paint suitable for spot welding Round wire brush |
*BR00.45-Z-1001-07A | ||
| 5.2 | Prepare rear end (1) for installation | Version with reinforcements (2) | |
| AR64.20-P-1020-05ESA | |||
| Zinc dust paint suitable for spot welding Round wire brush |
*BR00.45-Z-1001-07A | ||
| Install | |||
| 6.1 | Install rear end (1) | Version without reinforcements (2) | |
| General information on riveting | AH60.00-P-0003-01N | ||
| AR64.20-P-1020-06ES | |||
| MODEL 212.2 | *BE60.00-P-1003-01U | ||
| MODEL 212.2 | *BE60.00-P-1005-01U | ||
| MODEL 218.9 | *BE60.00-P-1003-01O | ||
| MODEL 218.9 | *BE60.00-P-1005-01O | ||
| Blind rivet, 6.4 x 14 | *BR00.45-Z-1001-13A | ||
| Body adhesive kit, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Vice grip pliers (standard) Round wire brush Blind/self-piercing riveting Multifunction device (spot welding) |
|||
| Fig 2 | |||
| 6.2 | Install rear end (1) | Version with reinforcements (2) | |
| General information on riveting | AH60.00-P-0003-01N | ||
| AR64.20-P-1020-06ESA | |||
| MODEL 212.2 | *BE60.00-P-1003-01U | ||
| MODEL 212.2 | *BE60.00-P-1005-01U | ||
| MODEL 218.9 Type without reinforcements |
*BE60.00-P-1003-01O | ||
| MODEL 218.9 Type without reinforcements |
*BE60.00-P-1005-01O | ||
| Blind rivet, 6.4 x 14 | *BR00.45-Z-1001-13A | ||
| Body adhesive kit, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Vice grip pliers (standard) Round wire brush Blind/self-piercing riveting Multifunction device (spot welding) |
|||
| Fig 2 | |||
| 7 | Adjust gap dimensions on hoods, doors and lids | MODEL 212.2 | AR60.00-P-0700-01EW |
| MODEL 218.9 | AR60.00-P-0700-01EL | ||
| MODEL 212.2 | *BE60.00-P-1005-01U | ||
| MODEL 212.2 | *BE60.00-P-1003-01O | ||
| MODEL 218.9 Type without reinforcements |
*BE60.00-P-1005-01O | ||
| MODEL 218.9 Type without reinforcements |
*BE60.00-P-1003-01U | ||
| Fig 2 | |||
| 8 | Clean weld joints and sheet metal flanges with rotary wire brush | Round wire brush | |
| 9 | Clean repair area | 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 | |
| 10 | Prime repair area with primer filler | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 11 | Carry out seam sealing after repairs | MODEL 212.2 | AR97.10-P-4000EW |
| MODEL 218.9 | AR97.10-P-4000EL | ||
| White sealing compound, 310 ml, DBL 6069.20 | BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | BR00.45-Z-1041-01A | ||
| 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 | |
| 12 | Paint repair area adjacent surfaces | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 13 | Apply additional cavity preservation | ||
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Cavity preservation, solvent-free (1 l container) | *BR00.45-Z-1003-05A | ||
| 14 | Remove welding protection blankets | ||
| 15 | Install all detachable body components in area to be repaired |
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS
| Number | Designation | MODEL 218.9 | |||
|---|---|---|---|---|---|
| BE60.00-P-1003-01O | Gap dimension | Trunk lid to rear fender, top | Dimension "J" | mm | - |
| Trunk lid to rear lamp unit | Dimension "K" | mm | - | ||
| Trunk lid to bumper | Dimension "L" | mm | - | ||
| Rear fender to lamp unit | Dimension "M" | mm | 2, 5 (-1, 5/+1) | ||
| AR60.00-P-0700-01EL | |||||
CHECK VALUES FOR GAP DIMENSIONS
| Number | Designation | MODEL 212.2 | |||
|---|---|---|---|---|---|
| BE60.00-P-1003-01U | Gap dimension | Trunk lid to rear fender, top | Dimension "L" | mm | - |
| Trunk lid to taillamp | Dimension "M" | mm | - | ||
| Trunk lid to bumper | Dimension "N" | mm | - | ||
| Rear fender to taillamp | Dimension "O" | mm | 2 (+1, 5/-1) | ||
| Taillamp to bumper | Dimension "P" | mm | 2 (±1) | ||
| Trunk lid taillamp to taillamp | Dimension "M1" | mm | - | ||
| AR60.00-P-0700-01E W | |||||
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS
| Number | Designation | MODEL 218.9 | |||
|---|---|---|---|---|---|
| BE60.00-P-1005-01O | Gap dimensions | Liftgate to roof (spoiler removed) | Dimension "R1" | mm | 10 (±1, 5) |
| Spoiler to roof | Dimension "R2" | mm | 5, 0 (±1, 5) | ||
| Liftgate to rear fender | Dimension "P" | mm | 4, 5 (±1) | ||
| Liftgate to taillamp | Dimension "V" | mm | 5, 0 (±1) | ||
| Liftgate to bumper | Dimension "W" | mm | 6, 0 (±1, 5) | ||
| Rear window and D-pillar | Dimension "X" | mm | 4, 5 (±1, 5) | ||
| Rear window to liftgate, bottom | Dimension "Y" | mm | 3, 0 (±0, 5) | ||
CHECK VALUES FOR GAP DIMENSIONS
| Number | Designation | MODEL 212.2 | |||
|---|---|---|---|---|---|
| BE60.00-P-1005-01U | Gap dimension | Liftgate to roof | Dimension "R" | mm | - |
| Liftgate to roof (spoiler removed) | Dimension "R1" | mm | 9, 5 (±1, 5) | ||
| Spoiler to roof | Dimension "R2" | mm | 5 (±1, 5) | ||
| Liftgate to rear fender | Dimension "S" | mm | 4 (+1, 5/-1) | ||
| Liftgate to taillamp | Dimension "T" | mm | - | ||
| Liftgate to bumper | Dimension "U" | mm | 6 (±1, 5) | ||
| Liftgate to D-pillar | Dimension "V" | mm | - | ||
| Rear window and D-pillar | Dimension "X" | mm | - | ||
| Top sliding roof to roof | Dimension "Y" | mm | 5 (±1, 5) | ||
| Rear window to liftgate, bottom | Dimension "Z" | mm | 3 (±1, 5) | ||
| - | |||||
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-1001-13A | Blind rivet, 6.4 x 14 | A 003 990 35 97 |
| 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, solvent-free (1 l container) | A 000 986 72 70 05 |
| BR00.45-Z-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 20 |
| BR00.45-Z-1092-02A | Body adhesive kit, 2-component adhesive | A 009 989 36 71 |