P63.50-3658-09
1 Rear fender
| 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. | |
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. | |
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. | |
| Measures for preventing damage to vehicles or components when performing electric welding work | ||
| General information on repairs to body | ||
| Pretreatment of bonding surfaces | ||
| General information on MB materials | ||
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 | When replacing right rear fender (1), the tank lock must be installed and the filler neck must be covered by a welding protection blanket (fire-resistant). | |
Welding protective blanket gotis://K_60-65_23.0 | |||
4.1 | Partially cut off rear wheel well | Only if rear fender (1) is repaired and not replaced. | |
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 | |||
Zinc dust paint suitable for spot welding | |||
4.2 | Separate rear fender (1) | Only if rear fender (1) is repaired and not replaced. | |
Spot weld milling cutter | |||
Weld-spot milling machine gotis://K_58.1_02.0 | |||
Metal needle template gotis://K_58.3_09.0 | |||
Body jig saw gotis://K_58.1_01.0. | |||
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 | |||
5.1 | Partially prepare rear wheel well for installation | Only if rear fender (1) is repaired and not replaced. | |
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. | |
Spot weld milling cutter | |||
Weld-spot milling machine gotis://K_58.1_02.0 | |||
Metal needle template gotis://K_58.3_09.0 | |||
Round wire brush gotis://K_58.3_06.0 | |||
Zinc dust paint suitable for spot welding | |||
| Install | ||
6.1 | Partially install rear wheel well | Only if rear fender (1) is repaired and not replaced. | |
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 | |||
Zinc dust paint suitable for spot welding | |||
Rivet | |||
6.2 | Install rear fender (1), fit and weld in | Only if rear fender (1) is repaired and not replaced. | |
| General information on riveting | ||
Feeler gauge | |||
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 | |||
Sealant | |||
Adhesive | |||
Zinc dust paint suitable for spot welding | |||
Polygrip countersunk head rivet, 6.414 | |||
7 | Adjust gap dimensions on hoods, doors and lids | ||
Feeler gauge | |||
8 | Clean weld joints and sheet metal flanges with round wire brush | Round wire brush gotis://K_58.3_06.0 | |
9 | Clean repair areas | 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. | |
10 | 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 | ||
11 | Carry out seam sealing after repairs | Supplement standard sealant with sealant. | |
Sealant | |||
Seam sealant, sprayable 310 ml | |||
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. | |
12 | 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 | ||
13 | Apply additional cavity preservation | ||
| Notes on cavity preservation | ||
Cavity preservation gun gotis://K_91-97_01.0 | |||
Preservation agent | |||
14 | Remove welding protection blanket | On all covered parts remaining in vehicle. | |
15 | Install all detachable body components in area to be repaired. |
Check values for gaps
Number | Designation | Model 212.2 | |||
BE60.00-P-1002-01U | Gap dimension | Front door to fender | Dimension "G" | mm | 4 (+1/-0.5) |
Front door to rear door | Dimension "H" | mm | 4.5 (+1/-0.5) | ||
Front door to roof frame | Dimension "I" | mm | 14 (1.5) | ||
Rear door to roof frame | Dimension "J" | mm | 13 (1.5) | ||
Rear door to side section, bottom | Dimension "K" | mm | 4 (+1/-0.5) | ||
Driver door cover to rear door cover | Dimension "W" | mm | 4 (1) | ||
See picture | |||||
BE60.00-P-1003-01U | Gap dimension | Trunk lid to rear fender, top | Dimension "L" | mm | - |
Trunk lid to rear lamp unit | Dimension "M" | mm | - | ||
Trunk lid to bumper | Dimension "N" | mm | - | ||
Rear fender to rear lamp unit | Dimension "O" | mm | 2 (+1.5/-1) | ||
Taillamp to bumper | Dimension "P" | mm | 2 (1) | ||
Taillamp, trunk lid to taillamp | Dimension "M1" | mm | - | ||
See picture | |||||
BE60.00-P-1004-01U | Gap dimension | Fuel filler flap (around) | Dimension "Q" | mm | 3 (+1/-0.5) |
See picture | |||||
BE60.00-P-1005-01U | Gap dimension | Liftgate to roof | Dimension "R" | mm | - |
Liftgate to roof (spoiler removed) | Dimension "R1" | mm | 9,5 (1.5) | ||
Spoiler to roof | Dimension "R2" | mm | 5 (1.5) | ||
Liftgate to rear fender | Dimension "S" | mm | 4 (+1.5/-1) | ||
Liftgate to taillamp | Dimension "T" | mm | - | ||
Liftgate to bumper | Dimension "U" | mm | 6 (1.5) | ||
Liftgate to D-pillar | Dimension "V" | mm | - | ||
Rear window and D-pillar | Dimension "X" | mm | - | ||
Top sliding roof to roof | Dimension "Y" | mm | 5 (1.5) | ||
Rear window to liftgate, bottom | Dimension "Z" | mm | 3 (1.5) | ||
See picture | - | ||||
201 589 00 51 00
Spot weld milling cutter
Feeler gauge
129 589 03 21 00
Repair materials
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, 6.414 | A 003 990 86 97 05 |
BR00.45-Z-1008-13A | Blind rivet, power window at left door 4.8X8 | A 003 990 24 97 |
Referenced documents
- ah0000n000501a Measures for preventing damage to vehicles or components when performing electric welding work
- ah6000n000101a General information on body repair
- ah6000p000301n General information on riveting
- ah6000p000801sx Pretreatment of bonding surfaces
- ah9720p000101b Notes on cavity preservation
- ah9800p940802a Notes on paintwork repairs
- ah9800p940903a General information on MB materials
- ar6000p070001ew Gap dimensions on hoods, doors and lids
- ar6310p066201cw Cut off rear wheel well section
- ar6310p066202cw Prepare rear wheel well section for installation
- ar6310p066203cw Install rear wheel well section
- ar6350p140002es Separate rear fender
- ar6350p140003es Prepare new rear fender part
- ar6350p140004es Install rear fender
- ar9710p4000ew Seam sealing 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
- as0000z001601a Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes
- as0000z001701a Risk of injury caused by scraping or cutting body parts on sharp vehicle parts
- as9800z000201a Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.