Replace complete rear fender

AR63.50-L-1400VB

Replace complete rear fender

11.11.11



Removing

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 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.

AS00.00-Z-0017-01A



General information on body repair

All models

AH60.00-N-0001-01A



Guidelines for removing fuel tank when performing welding work on bodies

All models

AH60.00-P-3000-01Z



General information on riveting

AH60.00-P-0003-01N

1

Remove detachable parts on outer side of rear fender

2

Remove detachable parts in vehicle interior (repair area)

3

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

 Use fire-resistant tarp

4

Separate rear fender

AR63.50-L-1400-02VB

 Spot weld milling cutter

*201589005100

Vario Drill WS 91 spot weld removing tool

Hot air gun - 3000 W

Ball cutter, 12 mm

Round wire brush, braided,  70 mm

Cutting disk,  65 mm, 80 m/s (max.

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

Tarp (fire-resistant)

Drill
gotis://K_58.1_04.0

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

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

Sealant

*BR00.45-Z-1003-01A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

5

Prepare new rear fender part

AR63.50-L-1400-03VB

 Spot weld milling cutter

*201589005100

Round wire brush, braided,  70 mm

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

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

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

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

Drill
gotis://K_58.1_04.0

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

 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

6

Install rear fender

Observe fire protection measures!

AR63.50-L-1400-04VB

Polygrip aluminum/steel countersunk head rivet

dia. 410mm (approx. 10 each)

 Feeler gauge

*129589032100

 Spacer blocks

*414589012300

 Flange crimping pliers

*168589023700

Pop rivet gun, model HN 1

Electrode miller

C-clamps

Clamping pliers

Round wire brush, braided,  70 mm

Abrasive disk,  115 mm, 80 m/s (max.

Tarp (fire-resistant)

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

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

Drill
gotis://K_58.1_04.0

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

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



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

All models

AH00.00-N-0005-01A

7

Adjust gap dimensions on hoods, doors and lids

 Feeler gauge

*129589032100

8

Clean welds and metal flanges with wire brush. Clean repair areas.





General information on MB materials

All models

AH98.00-P-9409-03A

9

Prime areas to be repaired with MB-2K primer filler.



Notes on paintwork repairs

All models

AH98.00-P-9408-02A

10

Supplement standard sealant using MB body sealant

Seam sealing after repairs

AR97.10-L-4000VA



General information on MB materials

All models

AH98.00-P-9409-03A

11

Supplement standard underfloor protection with MB permanent underbody sealant

Permanent underfloor protection

AR97.20-P-0500-03A



General information on MB materials

All models

AH98.00-P-9409-03A

12

Paint rear fender and adjoining surfaces



Notes on paintwork repairs

AH98.00-P-9408-02A

13

Apply additional cavity preservation



Preservation

AP97.20-P-0640A

14

Reinstall all removed assembly parts

Number

Designation

Model
414.700

BE60.00-P-1005-01A

Gap dimension

Fuel filler flap

Dimension "K"

mm

4.0 (0.5)

Dimension "L"

mm

-

See picture

-

BE60.00-P-1010-01A

Gap dimension

Sliding door to front door

Dimension "C"

mm

5.0 (0.5)

Sliding door to outer rocker panel cover

Dimension "D"

mm

5.0 (0.5)

Sliding door to rear fender

Dimension "E"

mm

8.0 (0.5)

Sliding door to roof edge

Dimension "F"

mm

5.0 (0.5)

See picture

-

BE60.00-P-1011-01A

Gap dimension

Liftgate to taillamp unit

Dimension "G"

mm

5.0 (0.5)

Rear-end door to bumper

Dimension "I"

mm

7.0 (0.5)

Liftgate to liftgate

Dimension "L"

mm

7.0 (0.5)

Liftgate to rear spoiler

Dimension "M"

mm

5.0 (0.5)

Rear spoiler to roof

Dimension "T"

mm

7.0 (0.5)

See picture

-

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-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42