Replace complete rear fender

AR63.50-P-1400EW

Replace complete rear fender

19.12.11



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 splatter 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 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 components when performing electric welding and soldering work

AH60.00-P-0001-02A



General information on body repair

AH60.00-N-0001-01A



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 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

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

4.2

Separate rear fender (1)

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

AR63.50-P-1400-02EW



Sheet metal crimping pliers for areas not easily accessible

WF58.50-P-6350-01SC

 Spot weld milling cutter

*201589005100

Beading pliers

gotis://K_58.3_04.1

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

*BR00.45-Z-1001-07A

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-1400-03EW

 Spot weld milling cutter

*201589005100

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

*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

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.

AR63.50-P-1400-04EW



General information on riveting

AH60.00-P-0003-01N

 Feeler gauge

*129589032100

*BE60.00-P-1002-01U

*BE60.00-P-1003-01U

*BE60.00-P-1004-01U

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

*BR00.45-Z-1003-01A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Rivet

*BR00.45-Z-1001-13A

Polygrip countersunk-head rivet, 6.414

*BR00.45-Z-1002-13A

7

Adjust gap dimensions on hoods, doors and lids

AR60.00-P-0700-01EW

 Feeler gauge

*129589032100

*BE60.00-P-1002-01U

*BE60.00-P-1003-01U

*BE60.00-P-1004-01U

8

Clean weld joints and sheet metal flanges with rotary 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 fire! Use respiratory protection, protective clothing, gloves, safety glasses and skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

10

Prime repair area 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

11

Carry out seam sealing after repairs

 Supplement standard sealant with sealant.

AR97.10-P-4000EW

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

AS98.00-Z-0002-01A

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

AH98.00-P-9408-02A

13

Apply additional cavity preservation

AR97.20-P-1500EW



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

14

Remove welding protection blankets

 On all covered parts remaining in vehicle.

15

Install all detachable body components in area to be repaired.

Number

Designation

Model 212.0/1

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 piece, bottom

Dimension "K"

mm

4 (+1/-0.5)

Driver door cover to rear door cover

Dimension "W"

mm

4 (1)

See picture

AR60.00-P-0700-01EW

BE60.00-P-1003-01U

Gap dimension

Trunk lid to rear fender, top

Dimension "L"

mm

4 (1)

Trunk lid to rear lamp unit

Dimension "M"

mm

-

Trunk lid to bumper

Dimension "N"

mm

6.5 (1)

Rear fender to 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

4 (1.5)

See picture

AR60.00-P-0700-01EW

BE60.00-P-1004-01U

Gap dimension

Fuel filler flap (around)

Dimension "Q"

mm

3 (+1/-0.5)

See picture

AR60.00-P-0700-01EW

Number

Designation

Order number

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 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-1003-05A

Cavity sealant, 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-1001-13A

Blind rivet 6.414

A 003 990 35 97

BR00.45-Z-1002-13A

Polygrip countersunk-head rivet, 6.414

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