P63.50-0004-05
| Remove | ||
Danger! | Risk of explosion if ignition takes place, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel. | No fire, sparks, open flames or smoking. Wear protective clothing when handling fuel. | |
| General information on body repair | All models | |
| Notes on rear fender repair | Model 202 | |
1 | Disconnect battery | ||
2.1 | Remove battery | When replacing right rear fender | |
3.1 | Install fuel filler neck covering | When replacing right rear fender | |
Set of covers | |||
4 | Remove rear bumper | ||
5 | Remove rear bumper | ||
5 | Remove trunk lid | ||
6 | Remove trunk lid | ||
7 | Remove detachable parts on outside of rear fender | ||
8 | Remove attached parts on outside of rear fender | Area of rear fender and rear center section | |
9 | Remove attached parts in trunk, area of rear fender and rear center piece | In area to be repaired | |
10 | Cover all attached parts remaining in vehicle | ||
11 | Raise vehicle. | ||
12 | Remove rear wheel | ||
13 | Separate rear fender | ||
Template | |||
Template | |||
Template | |||
Template | |||
Spot weld milling cutter | |||
14 | Prepare new rear fender | ||
| Install | ||
Danger! | Risk of death caused by high voltage used for arc welding. Risk of explosion caused by welding in the area of high combustible materials. Risk of injury caused by welding spatter and UV-light while welding. Risk of poisoning caused by inhaling welding vapors. | Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor. | |
15 | Install rear fender and weld in | Before welding sheet metal part check gaps and adjust. Refer to | |
Gap dimensions at hoods, doors and covers | |||
Gap dimensions | |||
Gap dimensions | |||
Feeler gage | |||
Template for left taillamp cutout | |||
Template for right taillamp cutout | |||
Bending jig | |||
Cross-shape straightener | |||
Bending pliers | |||
| Measures for preventing damage to vehicles or components when performing arc welding work | All models | |
16 | Clean areas to be repaired and prime with MB 2-component primer/filler | ||
17 | Supplement standard sealing with MB body sealant | ||
18 | Supplement standard underfloor protection with MB permanent underfloor protection agent | ||
19 | Paint rear fender and adjoining surfaces | ||
20 | Apply additional cavity preservation | ||
21 | Install detachable body components removed |
Test and adjustment values, gap dimensions at hoods, doors and covers
Number | Designation | Model 202.01/02/033/ | |||
BE60.00-P-1002-01A | Gap dimension | Front door to A-pillar | Dimension "B" | mm | 6.0 (+1) |
Front door to fender | Dimension "H" | mm | 5.0 (+1) | ||
Front door to rear door | Dimension "I" | mm | 6.0 (+1) | ||
Front door to roof | Dimension "C" | mm | 6.0 (+1) | ||
Rear door to upper side section | Dimension "D" | mm | 6.0 (+1) | ||
Rear door to lower side section | Dimension "J" | mm | 5.0 (0.5) | ||
Fender to A-pillar | Dimension "Q" | mm | - | ||
Front door to rear fender | Dimension "P" | mm | - | ||
Fig., see | |||||
BE60.00-P-1003-01A | Gap dimension | Trunk lid to top of rear fender | Dimension "F" | mm | 4.5 (0.5) |
Trunk lid to bottom of rear fender | Dimension "M" | mm | 5.0 (0.5) | ||
Trunk lid to rear fender | Dimension "F" | mm | - | ||
Trunk lid to taillamp | Dimension "M" | mm | - | ||
Trunk lid to bumper | Dimension "V" | mm | - | ||
Rear fender to taillamp | Dimension "U" | mm | - | ||
Fig., see | |||||
Special tools
129 589 03 21 00
201 589 00 27 00
Cross-shape straightener
Feeler gage
202 589 04 23 00
Marking template, top left
202 589 05 23 00
Marking template, top right
202 589 07 23 00
202 589 10 23 00
202 589 06 23 00
Template
Template
Template for left taillamp cutout
202 589 11 23 00
Template for right taillamp cutout
202 589 00 37 00
201 589 00 51 00
129 589 00 27 00
Bending pliers
Bending jig
Spot weld milling cutter
202 589 00 91 00
Set of covers
Commercially available tools
Number | Designation | |
WH58.30-Z-1002-01A | Ball cutter, dia. 12 mm | |
WH58.30-Z-1006-01A | Vario Drill WS 91 spot weld removing tool | |
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-1001-02A | Inert gas welder |
WE58.40-Z-1002-02A | Spot welder |
WE58.40-Z-1003-03A | Angle grinder (electric/pneumatic) |
WE58.40-Z-1004-03A | Body saw (electric/pneumatic) |
Parts ordering notes
Part no. | Designation | Quantity |
000 986 34 42 | MB zinc dust paint |
Referenced documents
- ah0000n000501a Measures for preventing damage to vehicles or components when performing electric welding work
- ah6000n000101a General information on body repair
- ah6350p140001e Repair method for rear fender
- ar5410p0005ea Removing and installing battery
- ar6000p070001e Gap dimensions at hoods, doors and covers
- ar6350p140001e Removing and installing cover for filler neck
- ar6350p140002e Separating rear fender
- ar6350p140003e Preparing new rear fender
- ar6350p140004e Install rear fender
- ar6720p2000e Remove/install rear window
- ar8210p4905ea Removing and installing tail lamp
- ar8820p2200e Removing and installing rear bumper
- ar8850p5000e Removing and installing trunk lid
- ar9720p1500e Preserving hollow cavities following repair
- 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
- 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.