Replace complete rear fender

AR63.50-P-1400ECA

Replace complete rear fender

27.7.10



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 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.

AS00.00-Z-0010-01A

 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



General information on MB materials

AH98.00-P-9409-03A



General information on riveting

AH60.00-P-0003-01N

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 in vehicle with welding protection blanket

Welding protective blanket

gotis://K_60-65_23.0

4.1

Cut off rear wheel well section

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

AR63.10-P-0662-01CW

Body jig saw

gotis://K_58.1_01.0

Window glazing device, FSC 1.6

gotis://K_67.0_01.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

Touch-up pencil

*BR00.45-Z-1012-07A

4.2

Separate rear fender (1)

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

AR63.50-P-1400-02ECA

 Spot weld milling cutter

*201589005100

Weld-spot milling machine

gotis://K_58.1_02.0

Window glazing device, FSC 1.6

gotis://K_67.0_01.0

Round wire brush

gotis://K_58.3_06.0

Hot-air gun

gotis://K_60-65_11.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Touch-up pencil

*BR00.45-Z-1012-07A

5.1

Prepare rear wheel well section for installation

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

AR63.10-P-0662-02CW

Body jig saw

gotis://K_58.1_01.0

5.2

Prepare rear fender (1) for installation

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

AR63.50-P-1400-03ECA

Round wire brush

gotis://K_58.3_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

6.1

Install rear wheel well section

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

AR63.10-P-0662-03CW



General information on riveting

AH60.00-P-0003-01N

Hand riveting tool (for blind pop rivets)

gotis://K_68-80_06.0

Manual temporary fastener, 4.1 mm

gotis://K_58.3_10.0

Vice grip pliers (standard)

gotis://K_58.3_04.2

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

Sealant

*BR00.45-Z-1003-01A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Rivet

*BR00.45-Z-1008-13A

6.2

Install rear fender (1), fit and weld in

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

 For measuring points of gap dimensions on body see:



AR63.50-P-1400-04ECA

Adjust gap dimensions on doors and covers.

AR60.00-P-0700-01EC

 Feeler gauge

*129589032100

*BE60.00-P-1002-01W

*BE60.00-P-1003-01W

*BE60.00-P-1004-01W

*BE60.00-P-1005-01W

Multifunction device (spot welding)

gotis://K_60-65_15.0

Vice grip pliers (standard)

gotis://K_58.3_04.2

Hand riveting tool (for blind pop rivets)

gotis://K_68-80_06.0

Round wire brush

gotis://K_58.3_06.0

Adhesive

*BR00.45-Z-1092-02A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Rivet

*BR00.45-Z-1001-13A

7

Clean weld joints and sheet metal flanges with round wire brush

Round wire brush

gotis://K_58.3_06.0

8

Clean area to be repaired

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

 Danger!

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

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

AS98.00-Z-0002-01A

9

Prime area to be repaired using primer filler

 Use only primer filler approved by Daimler AG. Refer to:



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



Notes on paintwork repairs

AH98.00-P-9408-02A

10

Carry out seam sealing after repairs

 Supplement standard sealant with sealant.

AR97.10-P-4000EC

Sealant

*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 flames! Use respiratory protection, protective clothing, gloves, safety goggles and skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

11

Paint repair areas and adjacent surfaces

 Use only paints approved by Daimler AG. Refer to:



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



Notes on paintwork repairs

AH98.00-P-9408-02A

12

Apply additional cavity preservation

AR97.20-P-1500EC



Notes on cavity preservation

AH97.20-P-0001-01B

Cavity preservation gun

gotis://K_91-97_01.0

Preservation agent

*BR00.45-Z-1003-05A

13

Remove welding protection blanket

 On all covered parts remaining in vehicle.

14

Install all detachable body components in area to be repaired.

Number

Designation

Model 207.4

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)

See picture

AR60.00-P-0700-01EC

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 rear lamp unit

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)

See picture

AR60.00-P-0700-01EC

BE60.00-P-1004-01W

Gap dimension

Fuel filler flap (around)

Dimension "M"

mm

3 (+1/-0.5)

See picture

AR60.00-P-0700-01EC

BE60.00-P-1005-01W

Gap dimension

Soft top compartment lid to rear fender

Dimension "N"

mm

4 (1)

Soft top compartment cover to trunk lid

Dimension "O"

mm

4 (+1.5/-0.5)

Wind deflector to A-pillar

Dimension "P"

mm

3.5 (1.5)

Wind deflector to water deflector

Dimension "Q"

mm

2,1 (1)

See picture

AR60.00-P-0700-01EC

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-1012-07A

Primer stick

A 000 986 27 50

BR00.45-Z-1001-13A

Blind rivet 6.414

A 003 990 35 97

BR00.45-Z-1008-13A

Blind rivet, power window at left door 4.8X8

A 003 990 24 97