Completely replace rear fender

AR63.50-P-1400EA

Completely replace rear fender

26.6.95



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.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A



General information on body repair

All models

AH60.00-N-0001-01A



Notes on rear fender repair

Model 202

AH63.50-P-1400-01E

1

Disconnect battery

2.1

Remove battery

When replacing right rear fender.

AR54.10-P-0005EA

3.1

Install cover for filler fitting

When replacing right rear fender.

AR63.50-P-1400-01E

 Set of covers

*202589009100

4

Remove rear bumper

AR88.20-P-2200EA

5

Remove rear bumper

AR82.10-P-4905EB

6

Remove side window in load space

7

Remove detachable body components on outer side 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

AR63.50-P-1400-02EA

 Template

*202589062300

 Template

*202589072300

Spot weld milling cutter

*201589005100

14

Prepare new rear fender

AR63.50-P-1400-03EA

 Template

*202589062300

 Template

*202589072300



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.

AS00.00-Z-0007-01A

15

Install rear fender and weld in

 Before welding sheet metal part check gaps and adjust. Refer to

AR63.50-P-1400-04EA

Gap dimensions at hoods, doors and covers

AR60.00-P-0700-01EA

Gap dimensions

*BE60.00-P-1002-01A

Gap dimensions

*BE60.00-P-1004-01A

Feeler gage

*129589032100

Bending jig

*129589002700

Bending pliers

*202589003700



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

All models

AH00.00-N-0005-01A

16

Clean areas to be repaired and prime with MB 2-component primer/filler

17

Process corrosion protection

materials before painting

AR97.20-P-0500A

18

Supplement standard seals with MB body sealant

 Seam sealing following repairs

AR97.10-P-4000E

19

Supplement standard underfloor protection with MB permanent underfloor protection agent

 Notes on processing permanent underbody protection

AH97.20-P-9409-01A

20

Paint area to be repaired and adjacent surfaces

21

Apply additional cavity preservation

 Cavity preservation following repairs

AR97.20-P-1500E

Processing instructions for cavity preservation

AP97.20-P-0640-01A

22

Install detachable body components removed

Number

Designation

Model 202.01/02/033/
12/13

Model 202.07/08/093/
18/19

BE60.00-P-1002-01A

Gap dimension

Front door to A-pillar

Dimension "B"

mm

6.0 (+1)

6.0 (+1)

Front door to fender

Dimension "H"

mm

5.0 (+1)

5.0 (+1)

Front door to rear door

Dimension "I"

mm

6.0 (+1)

6.0 (+1)

Front door to roof

Dimension "C"

mm

6.0 (+1)

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)

5.0 (0.5)

Fender to A-pillar

Dimension "Q"

mm

-

-

Front door to rear fender

Dimension "P"

mm

-

-

Fig., see

AR60.00-P-0700-01E

AR60.00-P-0700-01EA

BE60.00-P-1004-01A

Gap dimension

Tailgate to roof

Dimension "E"

mm

-

6.5 (0.5)

Tailgate to D-pillar

Dimension "F"

mm

-

13.0

Tailgate to D-pillar

Dimension "G"

mm

-

4.5 (1)

Tailgate to rear fender

Dimension "M"

mm

-

5.0 (0.5)

Fig., see

-

AR60.00-P-0700-01EA

Number

Designation

WH58.30-Z-1002-01A

Ball cutter, dia. 12 mm

WH58.30-Z-1003-01A

Electrode miller

WH58.30-Z-1006-01A

Vario Drill WS 91 spot weld removing tool

WH58.30-Z-1002-02A

Hole punching pliers, dia. 7 mm

WH58.30-Z-1001-03A

Round wire brush, braided, dia. 70 mm

WH58.30-Z-1021-04A

Cutting disk, dia. 65 mm, 80 m/s (max. 23,500 rpm)

WH58.30-Z-1024-04A

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

WH58.30-Z-1001-40A

Tarp (fire-resistant)

WE58.40-Z-1001-02A

Inert gas welder

WE58.40-Z-1002-02A

Spot welder

WE58.40-Z-1001-03A

Drill (electric/pneumatic)

WE58.40-Z-1002-03A

Straight grinder (electric/pneumatic)

WE58.40-Z-1003-03A

Angle grinder (electric/pneumatic)

WE58.40-Z-1004-03A

Body saw (electric/pneumatic)

WE58.40-Z-1005-03A

Wet/dry vacuum cleaner

Part no.

Designation

Quantity

000 986 34 42

MB zinc dust paint