Replace complete rear fender

AR63.50-P-1400CC

Replace complete rear fender

09.03.2020

Model

204.3

1

Rear fender

2

Wheel well end plate (only with code (P98 ) Black Series)

3

Wheel well end plate (only with code (P98) Black Series)



Remove

 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

 Warning

Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes

Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only.

AS00.00-Z-0016-01A

 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

Topical note

General information on body repair

AH60.00-N-0001-01A

Topical note

Measures for preventing damage to components when performing electric welding and soldering work

AH60.00-P-0001-02A

Topical note

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

General information on MB materials

AH98.00-P-9409-03A

1

Prepare all workshop equipment and commercially available tools required for repair

2

Remove all detachable parts in repair area

3

Cover all detachable parts remaining in vehicle with welding protection blankets

 When replacing right rear fender (1), the standard tank cap must be installed and the filler neck must be covered by a welding protection blanket (fire-resistant).

4.1

Cut off rear wheel well section

Model 204.3
except code P98 (Black Series)
Only if rear fender (1) is repaired and not replaced.

AR63.10-P-0662-01CW

 Commercially available devices/tools
Glass removal
Wet and dry vacuum cleaner
Body jig saw

Primer stick

*BR00.45-Z-1012-07A

4.2

Separate rear fender (1)

Only if rear fender (1) is replaced and not repaired.

AR63.50-P-1400-02CC



000 588 00 84 00 Heat gun

WS54.00-P-0049B



Sheet metal crimping pliers for areas not easily accessible

WF58.50-P-6350-01SC

 Commercially available devices/tools
Glass removal
Wet and dry vacuum cleaner
Body jig saw
Rotary wire brush
Needle template
Hole punching pliers
Spot weld milling machine

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Primer stick

*BR00.45-Z-1012-07A

5.1

Prepare rear wheel well section for installation

Model 204.3
except code P98 (Black Series)
Only if rear fender (1) is repaired and not replaced.

AR63.10-P-0662-02CW

5.2

Prepare rear fender (1) for installation

Only if rear fender (1) is replaced and not repaired.

AR63.50-P-1400-03CC

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

6.1

Install rear wheel well section

Model 204.3
except code P98 (Black Series)
Only if rear fender (1) is repaired and not replaced.

General information on riveting

AH60.00-P-0003-01N

AR63.10-P-0662-03CW

 Commercially available devices/tools
Blind rivet tool
Wet and dry vacuum cleaner
Arresting pliers (standard)
Tools for disassembly/assembly

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Blind rivet for power window to left door 4.88 (clamping range 1.5 mm to 4 mm, draw-off strength min. 8 kN)

*BR00.45-Z-1008-13A

6.2

Install rear fender (1), fit and weld in

Only if rear fender (1) is replaced and not repaired.

General information on riveting

AH60.00-P-0003-01N

AR63.50-P-1400-04CC



000 588 02 84 00 Welder

WS60.00-P-0022K

 Commercially available devices/tools
Blind rivet tool
Rotary wire brush
Arresting pliers (standard)
Multifunction unit (spot welding)

Gap dimension

*BE60.00-P-1002-01W

Gap dimension

*BE60.00-P-1003-01W

Gap dimension

*BE60.00-P-1004-01W

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)

*BR00.45-Z-1001-13A

Blind rivet with polygrip countersunk head 6.414 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)

*BR00.45-Z-1002-13A

7

Adjust gap dimensions on hoods, doors and lids

AR60.00-P-0700-01CW

Gap dimension

*BE60.00-P-1002-01W

Gap dimension

*BE60.00-P-1003-01W

Gap dimension

*BE60.00-P-1004-01W

 Feeler gauge

*129589032100

8

Clean weld joints and sheet metal flanges with rotary wire brush

9

Clean repair areas

 Danger

Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.

No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

10

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. See http://portal.aftersales.i.daimler.com

11

Seal seam following repairs

Seam sealing following repair, rear end damage

AR97.10-P-4000-02CW

 Supplement standard seals with sealant.

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

 Danger

Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.

No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

12

Paint repair areas and adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

 Use only paints approved by Daimler AG. See http://portal.aftersales.i.daimler.com

 Danger

Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents

Never spray corrosion protection on flames or hot, glowing objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection.

AS97.00-Z-0001-01A

13

Add cavity preserving agent

AR97.20-P-1500CW

Topical note

Notes on cavity preservation

AH97.20-P-0001-01B



000 588 00 72 00 Sealing and corrosion protection gun

WS97.00-P-0001B

Cavity preservation (free of solvents), 1 liter

*BR00.45-Z-1003-05A

14

Remove welding protection blankets

 On all covered parts remaining in vehicle.

15

Install all detachable parts in area to be repaired

Check values for gaps

Number

Designation

Model 204.3

BE60.00-P-1002-01W

Gap dimension

Front door to fender

Dimension "F"

mm

4 (+1,5/-0,5)

Front door to rear fender

Dimension "G"

mm

4 (+1/-0,5)

Picture

AR60.00-P-0700-01CW

Check values for gaps

Number

Designation

Model 204.3

BE60.00-P-1003-01W

Gap dimension

Trunk lid to rear fender, top

Dimension "H"

mm

4 (1)

Trunk lid to bumper

Dimension "I"

mm

5,5 (2)

Rear fender to taillamp

Dimension "J"

mm

2 (+1,5/-1)

Taillamp to bumper

Dimension "K"

mm

2 (1)

Taillamp, trunk lid to taillamp

Dimension "L"

mm

4 (1)

Picture

AR60.00-P-0700-01CW

Check values for gaps

Number

Designation

Model 204.3

BE60.00-P-1004-01W

Gap dimension

Fuel filler flap (around)

Dimension "M"

mm

3 (+1/-0,5)

Picture

AR60.00-P-0700-01CW

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-1001-13A

Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)

A 003 990 35 97

BR00.45-Z-1002-13A

Blind rivet with polygrip countersunk head 6.414 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)

A 003 990 86 97 05

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1003-05A

Cavity preservation (free of solvents), 1 liter

A 000 986 72 70 10

BR00.45-Z-1008-13A

Blind rivet for power window to left door 4.88 (clamping range 1.5 mm to 4 mm, draw-off strength min. 8 kN)

A 003 990 24 97

BR00.45-Z-1012-07A

Primer stick

A 000 986 27 50

BR00.45-Z-1041-01A

Seam sealant, sprayable 310 ml

A 002 989 84 20

BR00.45-Z-1092-02A

Adhesive kit, body, 2-component adhesive

A 012 989 17 71