ar6350p140003k

Prepare new rear fender

Type ar · topic 63.50 · version 0109 · 2006-07-26

Applies to: MODEL 208.3

Where it sits

Function group 3 Body › 63 Side wall › 63.50 Rear fenders — Series 208 (models 3**)

EinPAS 35 Body/frame/detachable parts › 35.34 Sidewall › 35.34.35 Fender/sidewall — Series 208 (models 3**)

EinPAS 35 Body/frame/detachable parts › 35.37 Fender › 35.37.31 Rear fender — Series 208 (models 3**)

AR63.50-P-1400-03K

Prepare new rear fender

Test and adjustment values, gap dimensions at hoods, doors and covers

Number

Designation

Model
208.3

BE60.00-P-1002-01A

Gap dimension

Front door to A-pillar

Dim. "B"

mm

6.5 (0.5)

Front door to fender

Dim. "H"

mm

4.0 (0.5)

Front door to rear door

Dim. "I"

mm

-

Front door to roof

Dim. "C"

mm

-

Rear door to upper side section

Dim. "D"

mm

-

Rear door to lower side section

Dim. "J"

mm

-

Fender to A-pillar

Dim. "Q"

mm

-

Front door to rear fender

Dim. "P"

mm

4.0 (0.5)

Fig., see

AR60.00-P-0700-01K

BE60.00-P-1003-01A

Gap dimension

Trunk lid to top of rear fender

Dim. "F"

mm

-

Trunk lid to bottom of rear fender

Dim. "M"

mm

4.5 (0.5)

Trunk lid to rear fender

Dim. "F"

mm

4.5 (0.5)

Trunk lid to taillamp

Dim. "M"

mm

-

Trunk lid to bumper

Dim. "V"

mm

-

Rear fender to taillamp

Dim. "U"

mm

-

Fig., see

AR60.00-P-0700-01K

Commercially available tools

Number

Designation

WH58.30-Z-1002-02A

Hole punching pliers, dia. 7 mm

WH58.30-Z-1010-02A

Sheet metal crimping shears

WH58.30-Z-1001-03A

Round wire brush, braided, dia. 70 mm

Workshop equipment

WE58.40-Z-1001-03A

Drill (electric/pneumatic)

WE58.40-Z-1002-03A

Straight grinder (electric/pneumatic)

Prepare new rear fender

P63.50-0505-06

1 Separate rear fender with body saw in areas A and B.

Allow approx. 20 mm extension for cutting to fit.

2 Install rear fender, align and fasten with clamping pliers.

Observe gaps at front door and trunk lid.

3 Mark cuts in areas C and D and separate with body saw.

Prepare new rear fender

P63.50-0506-09

4 Mark cut (area A) according to separated rear fender.

Allow 12 mm for crimp.

5 Remove rear fender from vehicle

6 Cut crimping area on rear fender to size and crimp with crimping pliers.

7 Punch or drill 7 mm dia. holes in rear fender (areas B - F).

Prepare new rear fender

P63.50-0507-09

8 Grind connection surfaces down to bare metal in shaded areas A - C.

9 Sand spot weld flanges to bare metal on both sides

10 Coat insides of spot weld flanges with zinc dust paint.