Replace rear fender complete

AR63.50-P-1401LWR

Replace rear fender complete

14.05.2019

Model

205.4

1

Rear fender

 Danger

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

 Caution

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

 Danger

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 contactwith 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

Topical note

General information on body repair

AH60.00-N-0001-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

Notes on acoustic foam and structural foam in the vehicle

AH60.00-P-0039-01LW

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 blankets

 When replacing the right rear fender (1), the standard tank lock must be installed and the filler neck covered with a welding protection blanket.

3

Separate rear fender (1)

AR63.50-P-1401-01LWR



000 588 00 84 00 Heat gun

WS54.00-P-0049B

 Commercially available devices/tools
Round wire brush
Spot weld milling machine
Wet/dry vacuum cleaner

Primer stick

*BR00.45-Z-1012-07A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

4

Prepare rear fender (1)

AR63.50-P-1401-02LWR

 Commercially available devices/tools
Round wire brush

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

 Danger

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

Topical note

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

5

Install rear fender (1)

AR63.50-P-1401-03LWR



000 588 01 84 00 Welder

WS60.00-P-0021K



000 588 02 84 00 Welder

WS60.00-P-0022K

Gap dimensions on hoods, doors and lids

AR60.00-P-0700-01LW

 Commercially available devices/tools
Round wire brush
Manual temporary fastener 6.35 mm
Blind rivet gun (minimum pull-off force 19 kN)
Wet/dry vacuum cleaner

Soft top compartment lid to rear fender

*BE60.00-P-1034-01BB

Trunk lid to fender at rear, top

*BE60.00-P-1012-01BB

Rear fender to taillamp

*BE60.00-P-1015-01BB

Front door to sidewall

*BE60.00-P-1007-01BB

Soft top compartment lid to trunk lid

*BE60.00-P-1035-01BB

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Blind rivet 6.512.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)

*BR00.45-Z-1012-13A

Blind rivet 6.514.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)

*BR00.45-Z-1016-13A

 Feeler gauge

*129589032100

6

Clean welds and sheet metal flanges

 Commercially available devices/tools
Round wire brush

7

Remove spark protection blankets

8

Clean repair area

 Commercially available devices/tools
Wet/dry vacuum cleaner

9

Prime repair area using primer filler

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

 Use only primer filler approved by Daimler AG:
http://xentryportal.mercedes-benz.com

10

Seal seam following repairs

AR97.10-P-4000LW

11

Paint repair areas and adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

 Use only paints approved by Daimler AG:
http://xentryportal.mercedes-benz.com

12

Add cavity preserving agent

AR97.20-P-1500LW

13

Install all detachable body components in area to be repaired

Check values for gap dimensions

Number

Designation

Model 205.4

BE60.00-P-1007-01BB

Front door to sidewall

Dimension "H1"

mm

3,5 (0,5)

For picture, see

AR60.00-P-0700-01LW

Check values for gap dimensions

Number

Designation

Model 205.4

BE60.00-P-1012-01BB

Trunk lid to fender at rear, top

Dimension "K"

mm

3,5 (0,5)

Dimension "K1"

mm

-

For picture, see

AR60.00-P-0700-01LW

Check values for gap dimensions

Number

Designation

Model 205.4

BE60.00-P-1015-01BB

Rear fender to taillamp

Dimension "N"

mm

1 (1)

For picture, see

AR60.00-P-0700-01LW

Check values for gap dimensions

Number

Designation

Model 205.4

BE60.00-P-1034-01BB

Soft top compartment lid to rear fender

Dimension "Z3"

mm

3 (+1/-0,5)

For picture, see

AR60.00-P-0700-01LW

Check values for gap dimensions

Number

Designation

Model 205.4

BE60.00-P-1035-01BB

Soft top compartment lid to trunk lid

Dimension "Z4"

mm

5 (0,5)

For picture, see

AR60.00-P-0700-01LW

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-1012-07A

Primer stick

A 000 986 27 50

BR00.45-Z-1012-13A

Blind rivet 6.512.5 (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 6.514.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)

A 004 990 17 97

BR00.45-Z-1162-02A

Parts kit for 2-component adhesive for body

A 012 989 17 71