Replace complete rear fender

AR63.50-P-1400CX

Replace complete rear fender

27.7.10

19.3.08

Gap dimension, front door to fender

Model 204.0/2

*BE60.00-P-1002-01U

Gap dimension, front door to rear door

Model 204.0/2

*BE60.00-P-1002-01U

Gap dimension, front door to roof frame

Model 204.0/2

*BE60.00-P-1002-01U

Gap dimension, rear door and roof frame

Model 204.0/2

*BE60.00-P-1002-01U

Gap dimension, rear door to side piece, bottom

Model 204.0/2

*BE60.00-P-1002-01U



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 spatter 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 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

 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



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

AH00.00-N-0005-01A



General information on repairs to body

AH60.00-N-0001-01A



Pretreatment of bonding surfaces

AH60.00-P-0008-01SX



Notes on paintwork repairs

AH98.00-P-9408-02A



General information on riveting

AH60.00-P-0003-01N



General information on MB materials

AH98.00-P-9409-03A

1

Prepare required workshop equipment and commercially available tools for repair

2

Remove all detachable body components in area to be repaired.

3

Cover all detachable parts remaining vehicle with fireproof tarpaulin

 When replacing right rear fender (1), the tank lock must be installed and the filler neck must be covered by a tarp (fire-resistant).

4

Separate rear fender (1)

AR63.50-P-1400-02CX

 Spot weld milling cutter

*201589005100

Beading pliers

gotis://K_58.3_04.1

Needle template

gotis://K_58.3_09.0

Weld-spot milling machine

gotis://K_58.1_02.0

Hot-air gun

gotis://K_60-65_11.0

Hand drill (with chuck up to 16 mm dia.)

gotis://G_58.0_00.1

Angle grinder up to 125 mm

gotis://G_58.0_06.0

Keyhole saw

gotis://K_58.1_01.0

Glass removal device

gotis://K_67.0_01.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

5

Prepare rear fender (1) for installation

AR63.50-P-1400-03CX

 Spot weld milling cutter

*201589005100

Needle template

gotis://K_58.3_09.0

Round wire brush

gotis://K_58.3_06.0

Hand drill (with chuck up to 16 mm dia.)

gotis://G_58.0_00.1

Keyhole saw

gotis://K_58.1_01.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

6

Install rear fender (1), fit and weld in

AR63.50-P-1400-04CX

 Feeler gauge

*129589032100

Round wire brush

gotis://K_58.3_06.0

Vice grip pliers (standard)

gotis://K_58.3_04.2

Vice grip pliers (special, small)

gotis://K_58.3_04.3

Manual temporary fastener

gotis://K_58.3_10.0

Hand riveting tool (for blind pop rivets)

gotis://K_68-80_06.0

Inert gas welder

gotis://K_60-65_17.0

Multifunction device (spot welding)

gotis://K_60-65_15.0

Hand drill (with chuck up to 16 mm dia.)

gotis://G_58.0_00.1

Angle grinder up to 125 mm

gotis://G_58.0_06.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

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

Rear door to side section, bottom

*BE60.00-P-1002-01U

Rear fender to rear lamp unit

*BE60.00-P-1003-01U

Taillamp to bumper

*BE60.00-P-1003-01U

Fuel filler flap

*BE60.00-P-1004-01U

Liftgate to rear fender

*BE60.00-P-1005-01U

Liftgate to taillamp

*BE60.00-P-1005-01U

Liftgate to bumper

*BE60.00-P-1005-01U

Liftgate to D-pillar

*BE60.00-P-1005-01U

Sealant

*BR00.45-Z-1003-01A

Adhesive

*BR00.45-Z-1092-02A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Polygrip countersunk head rivet, 6.414

*BR00.45-Z-1002-13A

7

Adjust gap dimensions on hoods, doors and lids

AR60.00-P-0700-01CW

 Feeler gauge

*129589032100

Rear door to side section, bottom

*BE60.00-P-1002-01U

Rear fender to rear lamp unit

*BE60.00-P-1003-01U

Taillamp to bumper

*BE60.00-P-1003-01U

Fuel filler flap

*BE60.00-P-1004-01U

Liftgate to rear fender

*BE60.00-P-1005-01U

Liftgate to taillamp

*BE60.00-P-1005-01U

Liftgate to bumper

*BE60.00-P-1005-01U

Liftgate to D-pillar

*BE60.00-P-1005-01U

8

Shape body flange for taillamp with embossing tool

AR63.50-P-1400-09CW

 Embossing tool

*164589003900

9

Clean weld joints and sheet metal flange with round wire brush

10

Clean repair areas

11

Prime area to be repaired using primer filler

12

Carry out seam sealing after repairs

 Supplement standard sealant with sealant.

AR97.10-P-4000CW

Sealant

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

13

Paint repair areas and adjacent surfaces

14

Apply additional cavity preservation

AR97.20-P-1500CW



Notes on cavity preservation

AH97.20-P-0001-01B

Preservation agent

*BR00.45-Z-1003-05A

15

Remove tarp

 On all covered parts remaining in vehicle.

16

Install all detachable body components in area to be repaired.

Number

Designation

Model 204.2

BE60.00-P-1002-01U

Gap dimension

Front door to fender

Dim. "G"

mm

4 (+1/-0.5)

Front door to rear door

Dim. "H"

mm

4 (+1/-0.5)

Front door to roof frame

Dim. "I"

mm

15 (+0.5/-1)

Rear door to roof frame

Dim. "J"

mm

15.5 (+1/-0.5)

Rear door to side section, bottom

Dim. "K"

mm

4 (+1/-0.5)

Driver door cover to rear door cover

Dim. "W"

mm

4 (+1.5)

See picture

AR60.00-P-0700-01CW

BE60.00-P-1003-01U

Gap dimension

Trunk lid to rear fender, top

Dim. "L"

mm

-

Trunk lid to rear lamp unit

Dim. "M"

mm

-

Trunk lid to bumper

Dim. "N"

mm

-

Rear fender to rear lamp unit

Dim. "O"

mm

1 (1)

Taillamp to bumper

Dim. "P"

mm

2 (0.5)

Taillamp, trunk lid to taillamp

Dim. "M1"

mm

-

See picture

-

BE60.00-P-1004-01U

Gap dimension

Fuel filler flap (around)

Dim. "Q"

mm

3.0 (0.5)

See picture

-

BE60.00-P-1005-01U

Gap dimension

Liftgate to roof

Dim. "R"

mm

4.5 (1)

Liftgate to roof (spoiler removed)

Dim. "R1"

mm

-

Spoiler to roof

Dim. "R2"

mm

-

Liftgate to rear fender

Dim. "S"

mm

4.2 (1)

Liftgate to taillamp

Dim. "T"

mm

4 (1)

Liftgate to bumper

Dim. "U"

mm

4 (1)

Liftgate to D-pillar

Dim. "V"

mm

4.2 (1)

Rear window and D-pillar

Dim. "X"

mm

-

Top sliding roof to roof

Dim. "Y"

mm

-

Rear window to liftgate, bottom

Dim. "Z"

mm

-

See picture

-

Number

Designation

Order number

BR00.45-Z-1003-01A

Sealant, white, 310 ml, DB supply specification 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-1092-02A

Adhesive kit, body, 2-component adhesive

A 009 989 36 71

BR00.45-Z-1003-05A

Cavity preservation, 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-1002-13A

Polygrip countersunk head rivet, 6.414

A 003 990 86 97 05