P63.50-0319-05
| Remove | ||
Danger! | Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel. | No fire, sparks, open flames or smoking. Wear protective clothing when handling fuel. | |
| General information on body repair | All models | |
1 | Remove/install fuel tank | ||
| Guidelines for removing fuel tank when performing welding work on bodies | All models | |
2 | Remove detachable parts on outside of rear fender | ||
3 | Remove detachable body components in trunk, in area of rear fender and bottom rear center section | ||
4 | Remove detachable body components from vehicle interior (area to be repaired) | ||
5 | Cover all attached parts remaining in vehicle (area to be repaired) | Lay down roof and cover with protective foil. | |
6 | Separate rear fender | | |
7 | Prepare new rear fender part | | |
| Install | ||
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. | |
| Measures for preventing damage to vehicles or components when performing arc welding work | All models | |
8 | Install rear fender and weld in | When spot welding put down roof and protect with weld spatter catcher. | |
9 | Adjust gap dimensions on hoods, doors and lids | Dimensions | |
Gap dimensions on hoods, doors and lids | |||
10 | Clean repair areas and primer with MB-2K primer/filler | Paintwork, general Survey of materials Primers and fillers | |
11 | Supplement standard seals with MB body sealant | Seam sealing following repair | |
12 | Supplement standard underbody protection with MB permanent underbody sealant | ||
13 | Paint rear fender and adjoining surfaces | Paintwork, general Survey of materials | |
14 | Apply additional cavity preservation | Cavity preservation after repair work | |
15 | Reinstall all removed assembly parts |
Test and adjustment values, gap dimensions at hoods, doors and covers
Number | Designation | Model | |||
BE60.00-P-1002-01A | Gap dimension | Front door to A-pillar | Dimension "B" | mm | - |
Front door to fender | Dimension "H" | mm | 4.0 (0.5) | ||
Front door to rear door | Dimension "I" | mm | - | ||
Front door to roof | Dimension"C" | mm | - | ||
Rear door to top of side section | Dimension "D" | mm | - | ||
Rear door to side section, bottom | Dimension "J" | mm | - | ||
Fender to A-pillar | Dimension "Q" | mm | 4.0 (1.6) | ||
Front door to rear fender | Dimension"P" | mm | 4.0 (0.5) | ||
See picture in | |||||
BE60.00-P-1003-01A | Gap dimension | Trunk lid to rear fender, top | Dimension"F" | mm | - |
Trunk lid to bottom of rear fender | Dimension "M" | mm | - | ||
Trunk lid to rear fender | Dimension"F" | mm | 5.0 (+1/-0) | ||
Trunk lid to taillamp | Dimension "M" | mm | 5.0 (+1/-0) | ||
Trunk lid to bumper | Dimension "V" | mm | 8.0 (0.5) | ||
Rear fender to taillamp | Dimension "U" | mm | 3.0 (0.5) | ||
See picture in | |||||
BE60.00-P-1005-01A | Gap dimension | Fuel filler flap | Dimension "K" | mm | 3.5 (0.5) |
Dimension"L" | mm | - | |||
See picture in | |||||
129 589 09 23 00
201 589 00 51 00
129 589 03 21 00
170 589 01 23 00
Portal bracket set
Set of welding gauges for rear fender
Feeler gauge
Spot weld milling cutter
129 589 00 98 00
129 589 01 98 00
Welding bead catcher
Protective cover
Commercially available tools
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-1002-02A | Hole punching pliers, dia. 7 mm | |
WH58.30-Z-1003-02A | Clamping pliers | |
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) |
Workshop equipment
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 |
Referenced documents
- ah0000n000501a Measures for preventing damage to vehicles or components when performing electric welding work
- ah6000n000101a General information on body repair
- ah6000p300001z Guidelines for removing fuel tank when performing welding work on bodies
- ar4710p4100g Remove/install fuel tank
- ar6000p070001g Gap dimensions at hoods, doors and covers
- ar6350p140002g Cutting out rear fender
- ar6350p140003g Preparing new rear fender
- ar6350p140004g Installing rear mud guard
- ar9710p4000g Sealing joints following repairs
- ar9720p1500g Preserving hollow cavities 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
- as4700z000101a Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.