Replace complete rear fender

AR63.50-P-1400F

Replace complete rear fender

23.1.95



Remove

 Danger!

Risk of explosion as fuel vapors can ignite. Risk of poisoning from inhaling fuel vapors and exposed handling of fuel. Risk of injury if fuel splashes hit the eyes.

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



Guidelines for removing fuel tank when performing welding work on bodies

AH60.00-P-3000-01Z

1

Remove fuel tank

2

Remove detachable body components on outer side of rear fender

3

Remove detachable body components from trunk, rear fender area and rear end center assembly

4

Remove detachable parts in vehicle interior (area to be repaired)

5

Cover all detachable body components remaining in vehicle (area to be repaired)

6

Separate rear fender

AR63.50-P-1400-02F

Spot weld cutter

*201589005100

Template for left upper rear fender

*210589072300

Template for right upper rear fender

*210589082300

 Template for front bottom left rear fender

*210589092300

Template for front bottom right rear fender

*210589102300

7

Prepare new rear fender part

AR63.50-P-1400-03F



Install



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

All models

AH00.00-N-0005-01A

 Danger!

Risk of death caused by high voltage used for arc welding. Risk of explosion caused by welding in the area of highly inflammable materials. Injury hazard from 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 danger zone. Use air extractor.

AS00.00-Z-0007-01A

8

Install rear fender and weld in

AR63.50-P-1400-04F

Feeler gauge

*129589032100

 Gauge for left taillamp cutout

*210589112300

 Gauge for right taillamp cutout

*210589122300

 Bending iron

*129589002700

 Cross-shaped straightener

*201589002700

9.1

Crimp edge on rear fender

Model 210.072/074, E 50 and E55 AMG and vehicles with AMG disk wheels
9 J18 H2 ET 35

AR63.50-P-1400-05F

10

Adjust gap dimensions on hoods, doors and lids

AR60.00-P-0700-01F

Gap dimensions

*BE60.00-P-1002-01A

Gap dimensions

*BE60.00-P-1003-01A

Gap dimensions

*BE60.00-P-1005-01A

Feeler gauge

*129589032100

11

Clean areas to be repaired and prime with priming filler

Notes on paintwork repairs

AH98.00-P-9408-02A

12

Supplement standard seals with MB body sealant

Seam sealing after repairs

AR97.10-P-4000F

13

Supplement standard underbody protection with MB permanent underbody sealant

Permanent underfloor protection

AR97.20-P-0500-03A

14

Paint rear fender and adjoining surfaces

Notes on paintwork repairs

AH98.00-P-9408-02A

15

Apply additional cavity preservation

Preservation

AP97.20-P-0640A

16

Reinstall all removed assembly parts

Number

Designation

Model
210.0

BE60.00-P-1002-01A

Gap dimension

Front door to A-pillar

Dimension "B"

mm

6.5 (0.5)

Front door to fender

Dimension "H"

mm

4.5 (0.5)

Front door to rear door

Dimension "I"

mm

5.5 (0.5)

Front door to roof

Dimension"C"

mm

6.5 (0.5)

Rear door to top of side section

Dimension "D"

mm

6.5 (0.5)

Rear door to side section, bottom

Dimension "J"

mm

4.0 (0.5)

Fender to A-pillar

Dimension "Q"

mm

-

Front door to rear fender

Dimension"P"

mm

-

See picture in

AR60.00-P-0700-01F

BE60.00-P-1003-01A

Gap dimension

Trunk lid to rear fender, top

Dimension"F"

mm

4.5 (0.5)

Trunk lid to bottom of rear fender

Dimension "M"

mm

4.5 (0.5)

Trunk lid to rear fender

Dimension"F"

mm

-

Trunk lid to taillamp

Dimension "M"

mm

-

Trunk lid to bumper

Dimension "V"

mm

-

Rear fender to taillamp

Dimension "U"

mm

-

See picture in

AR60.00-P-0700-01F

BE60.00-P-1005-01A

Gap dimension

Fuel filler flap

Dimension "K"

mm

4.0

Dimension"L"

mm

4.5

See picture in

AR60.00-P-0700-01F

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-1010-02A

Sheet metal crimping shears

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

WE58.40-Z-1001-05A

Two-post lifting platform