Partially replace outer rear wheel well

AR63.10-P-0660QA

Partially replace outer rear wheel well

18.11.11



Removing

 Danger!

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 death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding splatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes.

Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system.

AS00.00-Z-0007-01A

 Danger!

Risk of explosion as fuel vapors can ignite. Risk of poisoning from inhaling fuel vapors and exposed handling of fuel. Risk of injury if fuel splashes hit the eyes.

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A



General information on body repair

All models

AH60.00-N-0001-01A



Measures for preventing damage to vehicles or components when performing electric welding work

All models

AH00.00-N-0005-01A



Notes on paintwork repairs

All models

AH98.00-P-9408-02A



General information on MB materials

All models

AH98.00-P-9409-03A

1

Remove detachable parts in area to be repaired

2

Cover all detachable body components remaining in vehicle (area to be repaired)

Tarp (fire-resistant)

3

Remove rear fender

AR63.50-P-1400QA

4

Remove outer rear wheel well

AR63.10-P-0660-01QA

 Welding spot miller cutter

*201589005100

Ball cutter, dia. 12 mm

Round wire brush, braided, dia. 70 mm

Vario Drill WS 91 spot weld removing tool

Abrasive disk, dia. 115 mm, 80m/s (max. 13,250 rpm)

Cutting disk, 65 mm dia., 80 m/s (max. 23,500 rpm)

Drill
gotis://K_58.1_04.0

Straight grinder
gotis://K_58.0_03.0

Angle grinder
gotis://K_58.1_07.0

Body jig saw
gotis://K_58.1_01.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

5

Prepare outer rear wheel well for installation

AR63.10-P-0670-05QA

Round wire brush, braided, dia. 70 mm

Abrasive disk, dia. 115 mm, 80m/s (max. 13,250 rpm)

Drill
gotis://K_58.1_04.0

Angle grinder
gotis://K_58.1_07.0

Body jig saw
gotis://K_58.1_01.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

6

Install outer rear wheel well

AR63.10-P-0670-06QA



General information on riveting

AH60.00-P-0003-01N

 Spacer

*000589876300

 Feeler gauge

*129589032100

Round wire brush, braided, dia. 70 mm

Electrode miller

Clamping pliers

Hand riveter

Blind rivet/punch riveting method
gotis://K_68-80_06.0

Manual temporary fastener, dia. 6.4 mm - clamping range 0 - 15 mm, identification color silver

MIG MAG gas welder (steel, brazing, aluminum)
gotis://K_60-65_17.1

Drill
gotis://K_58.1_04.0

Inverter spot welder
gotis://K_60-65_16.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Polygrip flat round head rivet, 6.4 x 14 mm

*BR00.45-Z-1001-13A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

7

Adjust gap dimensions on hoods, doors and covers

Rear fender to lamp unit

*BE60.00-P-1003-01G

Trunk lid to rear fender, top

*BE60.00-P-1003-01G

Trunk lid license plate panel to rear lamp unit

*BE60.00-P-1003-01G

Front door to rear fender

*BE60.00-P-1002-01G

Fuel filler flap

*BE60.00-P-1004-01G

8

Install rear fender

AR63.50-P-1400QA

9

Clean weld joints and metal flanges with wire brush

10

Clean repair areas and prime using primer filler

11

Seam sealing following repair

Supplement standard sealant using MB preservative.

Sealant

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

12

Paint repair areas and adjacent surfaces

13

Cavity preservation following repair work



Notes on cavity preservation

Model 209

AH97.20-P-0001-01B

14

Install all removed assembly parts

Number

Designation

Model
209.4

BE60.00-P-1002-01G

Gap dimension

Front door to A-pillar

Dimension "D"

mm

1

Front door to fender

Dimension "E"

mm

3.5 (-0.5/+1)

Front door to rear fender

Dimension "F"

mm

3.5 (-0.5/+1)

See picture

AR60.00-P-0700-01QA

BE60.00-P-1003-01G

Gap dimension

Trunk lid to rear fender, top

Dimension "G"

mm

3.5 (1)

Trunk lid to rear lamp unit

Dimension "H"

mm

3.5 (0.5/+1)

Trunk lid to bumper

Dimension "I"

mm

6.5 (+1)

Rear fender to lamp unit

Dimension "J"

mm

3 (1)

Trunk lid license plate panel to rear lamp unit

Dimension "K"

mm

2.5 (0.5)

See picture

AR60.00-P-0700-01QA

BE60.00-P-1004-01G

Gap dimension

Fuel filler flap

Dimension "L"

mm

3.2 (+0.5)

See picture

AR60.00-P-0700-01QA

BE60.00-P-1007-01G

Gap dimension

Soft top compartment cover/
rear fender

Dimension "O"

mm

3 (0.5)

Soft top compartment cover to trunk lid

Dimension "P"

mm

4.5 (1)

See picture

AR60.00-P-0700-01QA

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-1041-01A

Seam sealant, sprayable 310 ml

A 002 989 84 20

BR00.45-Z-1003-05A

Cavity sealant, solvent-free (1 l container)

A 000 986 72 70 05

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14

A 003 990 35 97