Replace complete rear fender

AR63.50-P-1400ELX

Replace complete rear fender

14.05.2019

Model

218.9

1

Fender



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

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

Topical note

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

AH00.00-N-0005-01A

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

 Commercially available devices/tools
Weld protection blanket

4

Cut off rear wheel well section

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

AR63.10-P-0662-01CW

 Commercially available devices/tools

Wet and dry vacuum cleaner
Body jig saw
Glass removal

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

5.1

Separate fender (1)

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

AR63.50-P-1400-02ELX

 Commercially available devices/tools
Rotary wire brush
Body jig saw
Heat gun
Wet and dry vacuum cleaner
Metal needle template
Spot weld milling machine
Glass removal

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

 Spot weld milling cutter

*201589005100

5.2

Partially separate fender (1)

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

AR63.50-P-1450-01ELX

 Commercially available devices/tools
Rotary wire brush
Body jig saw
Heat gun
Wet and dry vacuum cleaner
Metal needle template
Spot weld milling machine
Glass removal

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

 Spot weld milling cutter

*201589005100

6

Prepare rear wheel well section for installation

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

AR63.10-P-0662-02CW

 Commercially available devices/tools
Body jig saw

7.1

Prepare fender (1) for installation

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

AR63.50-P-1400-03ELX

 Commercially available devices/tools

Spot weld milling machine
Rotary wire brush
Metal needle template

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

 Spot weld milling cutter

*201589005100

7.2

Partially prepare fender (1) for installation

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

AR63.50-P-1450-02ELX

 Commercially available devices/tools
Spot weld milling machine
Rotary wire brush
Metal needle template

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

 Spot weld milling cutter

*201589005100



Install

8

Install rear wheel well section

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

AR63.10-P-0662-03CW

 Commercially available devices/tools
Blind rivet tool
Wet and dry vacuum cleaner
Clamping pliers
Manual temporary fasteners

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

9.1

Install fender (1), fit and weld in

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

General information on riveting

AH60.00-P-0003-01N

AR63.50-P-1400-04ELX

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

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

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

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

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

Gap dimension

*BE60.00-P-1002-01O

Gap dimension

*BE60.00-P-1003-01O

Gap dimension

*BE60.00-P-1004-01O

 Feeler gauge

*129589032100

9.2

Partially install fender (1), fit and weld in

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

General information on riveting

AH60.00-P-0003-01N

AR63.50-P-1450-03ELX

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

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

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

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

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

Gap dimension

*BE60.00-P-1002-01O

Gap dimension

*BE60.00-P-1003-01O

Gap dimension

*BE60.00-P-1004-01O

 Feeler gauge

*129589032100

10

Adjust gap dimensions on cover, bumper and lamp units

Gap dimension

*BE60.00-P-1002-01O

Gap dimension

*BE60.00-P-1003-01O

Gap dimension

*BE60.00-P-1004-01O

 Feeler gauge

*129589032100

11

Clean weld joints and sheet metal flanges with rotary wire brush

 Commercially available devices/tools
Rotary wire brush

12

Clean repair areas

 Commercially available devices/tools
Wet and dry vacuum cleaner

 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

13

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

14

Seal seam following repairs

AR97.10-P-4000EL

 Supplement standard sealant with sealant.

 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

15

Paint repair areas and adjacent surfaces

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

16

Add cavity preserving agent

AR97.20-P-1500EL

17

Remove welding protection blankets

 On all covered parts remaining in vehicle.

18

Install all detachable parts in area to be repaired

Test values for gap dimensions on hoods, doors and lids

Number

Designation

Model 218.9

BE60.00-P-1002-01O

Gap dimension

Fender to A-pillar

Dimension "D"

mm

3,5 (1)

Front door to fender

Dimension "E"

mm

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

Front door to rear door

Dimension "F"

mm

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

B-pillar cover to front window

Dimension "G"

mm

10 (1)

B-pillar cover to rear window

Dimension "H"

mm

10 (1)

Rear door to side piece, bottom

Dimension "I"

mm

4,5 (1)

Fixed window on rear door to fixed window on rear side window

Dimension "O"

mm

7,5 (1)

Picture

AR60.00-P-0700-01EL

Test values for gap dimensions on hoods, doors and lids

Number

Designation

Model 218.9

BE60.00-P-1003-01O

Gap dimension

Trunk lid to rear fender, top

Dimension "J"

mm

–

Trunk lid to rear lamp unit

Dimension "K"

mm

–

Trunk lid to bumper

Dimension "L"

mm

–

Rear fender to lamp unit

Dimension "M"

mm

2,5 (-1,5/+1)

Picture

AR60.00-P-0700-01EL

Test values for gap dimensions on hoods, doors and lids

Number

Designation

Model 218.9

BE60.00-P-1004-01O

Gap dimension

Fuel filler flap

Dimension "N"

mm

3,0 (-0,5/+1)

Picture

AR60.00-P-0700-01EL

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-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-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-1092-02A

Adhesive kit, body, 2-component adhesive

A 012 989 17 71