P63.50-3196-06
1 Rear fender
2 Side wall reinforcement
| Removing | ||
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. | |
Danger! | Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. | |
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. | |
Danger! | Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel | No fire, sparks, open flames or smoking. Wear protective clothing when handling fuel. | |
| General information on body repair | ||
| Measures for preventing damage to components when performing electric welding and soldering work | ||
| General information on riveting | ||
1 | Remove all detachable parts in repair area. | ||
2 | Cover all detachable parts remaining in vehicle | Welding protective blanket gotis://K_60-65_23.0 | |
3 | Separate rear fender (1) | ||
Round wire brush gotis://K_58.3_06.0 | |||
Weld-spot milling machine gotis://K_58.1_02.0 | |||
Hot-air gun gotis://K_60-65_11.0 | |||
Body jig saw gotis://K_58.1_01.0 | |||
Beading pliers gotis://K_58.3_04.1 | |||
Wet and dry vacuum cleaner gotis://P_00.12_06.0 | |||
Set of cutting templates | |||
Zinc dust paint suitable for spot welding | |||
4 | Separate side wall reinforcement (2) | If rear fender (1) is damaged severely. | |
Round wire brush gotis://K_58.3_06.0 | |||
Weld-spot milling machine gotis://K_58.1_02.0 | |||
Body jig saw gotis://K_58.1_01.0 | |||
Wet and dry vacuum cleaner gotis://P_00.12_06.0 | |||
Zinc dust paint suitable for spot welding | |||
5 | Prepare new rear fender (1) | ||
Round wire brush gotis://K_58.3_06.0 | |||
Body jig saw gotis://K_58.1_01.0 | |||
Wet and dry vacuum cleaner gotis://P_00.12_06.0 | |||
Zinc dust paint suitable for spot welding | |||
6 | Prepare side wall reinforcement (2) for installation | If rear fender (1) is damaged severely. | |
Round wire brush gotis://K_58.3_06.0 | |||
Wet and dry vacuum cleaner gotis://P_00.12_06.0 | |||
Zinc dust paint suitable for spot welding | |||
| Install | ||
7 | Install protective cover for water drain hose | ||
Protective tube | |||
8 | Install side wall reinforcement (2) | If rear fender (1) is damaged severely. | |
Round wire brush gotis://K_58.3_06.0 | |||
Hand riveting tool (for blind pop rivets) gotis://K_68-80_06.0 | |||
Multifunction device (spot welding) gotis://K_60-65_15.0 | |||
Inert gas welder gotis://K_60-65_17.0 | |||
Wet and dry vacuum cleaner gotis://P_00.12_06.0 | |||
Zinc dust paint suitable for spot welding | |||
Polygrip flat round head rivet, 6.414 | |||
9 | Install rear fender (1) | ||
Bending iron | |||
Feeler gauge | |||
Round wire brush gotis://K_58.3_06.0 | |||
Hand riveting tool (for blind pop rivets) gotis://K_68-80_06.0 | |||
Multifunction device (spot welding) gotis://K_60-65_15.0 | |||
Inert gas welder gotis://K_60-65_17.0 | |||
Wet and dry vacuum cleaner gotis://P_00.12_06.0 | |||
Rear fender taillamp | |||
Rear fender to rear-end door | |||
Front fuel filler flap | |||
Rear fuel filler flap | |||
Rear-end door to taillamp | |||
Rear-end door to roof | |||
Front door to rear fender, bottom | |||
Sealant | |||
Zinc dust paint suitable for spot welding | |||
Polygrip flat round head rivet, 6.414 | |||
10 | Adjust gaps on hoods, doors and lids | ||
Feeler gauge | |||
Rear fender taillamp | |||
Rear fender to rear-end door | |||
Front fuel filler flap | |||
Rear fuel filler flap | |||
Rear-end door to taillamp | |||
Rear-end door to roof | |||
Front door to rear fender, bottom | |||
11 | Clean weld joints and sheet metal flanges with rotary wire brush | Round wire brush gotis://K_58.3_06.0 | |
12 | Remove welding protection blankets | ||
13 | Clean repair area | Wet and dry vacuum cleaner gotis://P_00.12_06.0 | |
14 | Prime repair area with primer filler | Only use approved primer filler from Daimler AG. Refer to: | |
http://portal.aftersales.i.daimler.com | |||
15 | Carry out seam sealing after repairs | Supplement standard seam seal. | |
16 | Paint repair area adjacent surfaces | Use only paints approved by Daimler AG. Refer to: | |
http://portal.aftersales.i.daimler.com | |||
17 | Apply additional cavity preservation | ||
18 | Install all removed detachable parts |
Test and adjustment values for gap dimensions
Number | Designation | Type | |||
BE60.00-P-1003-01N | Gap dimension | Rear door to side roof paneling | Dimension "L" | mm | - |
Rear door to rear fender | Dimension "M" | mm | - | ||
Rear door to rear side window | Dimension "N" | mm | - | ||
Rear fender to taillamp | Dimension "O" | mm | 2.5 (0.5) | ||
Rear fender to rear-end door | Dimension "P" | mm | 4.0 (1) | ||
See picture | |||||
BE60.00-P-1004-01N | Gap dimension | Front fuel filler flap | Dimension "Q" | mm | 4.5 (0.5) |
Rear fuel filler flap | Dimension "R" | mm | 4.0 (0.5) | ||
See picture | |||||
BE60.00-P-1005-01N | Gap dimension | Bumper to taillamp | Dimension "S" | mm | 2.5 (1) |
Rear-end door to taillamp | Dimension "T" | mm | 4.0(1.5) | ||
Rear-end door to bumper | Dimension "U" | mm | 5.0 (2) | ||
Rear-end door to roof | Dimension "V" | mm | 4.5 (1) | ||
See picture | |||||
BE60.00-P-1006-01N | Gap dimension | Front door to rear fender, bottom | Dimension "X" | mm | 4.0 (0.5) |
Front door to rear side window | Dimension "Y" | mm | 6.5 (-0.5/+1) | ||
See picture | |||||
169 589 04 23 00
Bending iron
Set of cutting templates
Feeler gauge
129 589 03 21 00
129 589 00 27 00
Repair materials
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 |
BR00.45-Z-1001-13A | Blind rivet 6.414 | A 003 990 35 97 |
BR00.45-Z-1003-15A | Protective tube | A 169 611 01 46 |
Referenced documents
- ah6000n000101a General information on body repair
- ah6000p000102a Measures for preventing damage to components when performing electric welding and soldering work
- ah6000p000301n General information on riveting
- ar6000p070001al Gap dimensions on hoods, doors and lids
- ar6320p086001al Separate side wall reinforcement
- ar6320p086003al Prepare side wall reinforcement for installation
- ar6320p086004al Install side wall reinforcement
- ar6350p140002al Separate rear fender
- ar6350p140003al Prepare new rear fender part
- ar6350p140004al Install rear fender
- ar6350p140008ak Install protective cover for water drain hose
- ar9710p4000ak Seam sealing following repair
- ar9720p1500ak Cavity preservation following repair work
- as0000z000701a 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
- as0000z001001a Risk of death caused by vehicle slipping or toppling off of the lifting platform.
- as0000z001701a Risk of injury caused by scraping or cutting body parts on sharp vehicle parts
- as4700z000101a 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.