Replace complete rear fender

AR63.50-P-1400GH

Replace complete rear fender

18.1.10



Remove

Danger!

Explosion hazard when ignited, risk of poisoning when fuel vapors are inhaled as well as injury hazard from eye contact with fuel.

No fire, sparks, open flames or smoking. Avoid sparks.

Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A



Guidelines for removing fuel tank when performing welding work on bodies

All models

AH60.00-P-3000-01Z



General information on repairs to body

All models

AH60.00-N-0001-01A

1

Remove fuel tank

 When replacing left rear paneling

AR47.10-P-4100GH

2

Remove rear bumper

Model without spare tire carriers installed at rear

AR88.20-P-2200GH

Model with spare tire carriers installed at rear

AR88.20-P-2200GI

3

Remove detachable body components from outside of rear fender

4

Remove inner paneling from rear fender

AR68.30-P-4490GH

5

Remove rear side window

Fixed pane

AR67.30-P-2301GH

Electric vent window

AR67.30-P-2301GI

6

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

Tarp (fire-resistant)

7

Separate rear fender

AR63.50-P-1400-02GH

 Scribing template

*163589092300

 Scribing template

*163589102300

 Scribing template

*163589112300

 Scribing template

*163589122300

 Scribing template

*163589132300

 Scribing template

*163589002300

 Spot weld milling cutter

*201589005100

8

Prepare new rear fender part



AR63.50-P-1400-03GH

 Scribing template

*163589092300

 Scribing template

*163589102300

 Scribing template

*163589112300

 Scribing template

*163589122300

 Scribing template

*163589132300

 Scribing template

*163589002300

 Spot weld milling cutter

*201589005100



Install

 Danger!

The high voltage used for electric welding presents a lethal hazard. 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.

AS00.00-Z-0007-01A

9

Install rear fender and weld in

 For this purpose see also

AR63.50-P-1400-04GH

Gap dimensions on hoods, doors and lids

AR60.00-P-0700-01GH

Gap dimensions

*BE60.00-P-1002-01D

Gap dimensions

*BE60.00-P-1003-01D

Gap dimensions

*BE60.00-P-1004-01D

 Feeler gauge

*129589032100

 Template for left taillamp cutout

*163589062300

 Template for right taillamp cutout

*163589142300



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

All models

AH00.00-N-0005-01A

10

Clean area repaired and prime with MB
-2K primer filler

 See Paintwork Manual

11

Supplement standard sealing with
MB body sealant

Seam sealing after repairs

12

Supplement standard underfloor protection with MB permanent underbody sealant

Permanent underfloor protection

13

Paint rear fender and adjoining surfaces

 See Paintwork Manual

14

Apply additional cavity preservation

15

Install rear side window

Fixed pane

AR67.30-P-2301GH

Electric vent window

AR67.30-P-2301GI

16

Install rear fender inner paneling

AR68.30-P-4490GH

17

Install detachable body components on outside of rear fender

18

Install rear bumper

Model without spare tire carriers installed at rear

AR88.20-P-2200GH

Model with spare tire carriers installed at rear

AR88.20-P-2200GI

19

Install fuel tank

 When replacing left rear paneling

AR47.10-P-4100GH

Number

Designation

Model 163

BE60.00-P-1002-01D

Gap dimension

Front door to A-pillar

Dimension "B"

mm

5.0 (0.5)

Front door to fender

Dimension "H"

mm

5.0 (0.5)

Front door to rear door

Dimension "I"

mm

5.0 (0.5)

Front door to roof

Dimension "C"

mm

5.0 (0.5)

Rear door to top of side section

Dimension "D"

mm

5.0 (0.5)

Rear door to side section, bottom

Dimension "J"

mm

5.0 (0.5)

Fender to A-pillar

Dimension "Q"

5.0 (0.5)

Front door to rear fender

Dimension "P"

-

See picture

AR60.00-P-0700-01GH

BE60.00-P-1003-01D

Gap dimension

Rear-end door to roof

Dimension "E"

mm

9.5 (0.5)

Rear-end door to D-pillar

Dimension "F"

mm

5.0 (0.5)

Rear-end door to D-pillar

Dimension "G"

mm

5.0 (0.5)

Rear-end door to rear fender

Dimension "M"

mm

5.0 (0.5)

See picture

AR60.00-P-0700-01GH

BE60.00-P-1004-01D

Gap dimension

Fuel filler flap

Dimension "K"

mm

4.0 (0.5)

Dimension "L"

mm

4.0 (0.5)

See picture

AR60.00-P-0700-01GH