Replace complete rear fender

AR63.50-P-1400GQ

Replace complete rear fender

14.05.2019

Model

166.0

1

Rear fender



Remove

 Danger

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 inhaling welding gases

Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system.

AS00.00-Z-0007-01A

 Warning

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

 Caution

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

Topical note

General information on body repair

AH60.00-N-0001-01A

Topical note

Measures for preventing damage to components when performing electric welding and soldering work

AH60.00-P-0001-02A

Notes on avoiding damage to windows installed in special high-security vehicles

Model 166.0
with code Z04 (Light armoring)
Model 166.0
with code Z05 (B5 armoring on special protection version)

AH67.00-P-0003-01FB

1

Remove all detachable parts in repair area

2

Cover all detachable parts remaining in vehicle with welding protection blankets

 When replacing right rear fender (1), the standard tank lock must be installed and the filler neck must be covered by a welding protection blanket (fire-resistant).

3.1

Cut off rear wheel well section

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

AR63.10-P-0662-01CW

 Commercially available devices/tools
Glass removal

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

3.2

Separate rear fender (1)

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

Model 166.0
except code Z04 (Light armoring)
except code Z05 (B5 armoring on special protection version)

AR63.50-P-1400-02GQ

Model 166.0
with code Z04 (Light armoring)

AR63.50-P-1400-02GQS



Sheet metal crimping pliers for areas not easily accessible

WF58.50-P-6350-01SC

 Commercially available devices/tools
Glass removal

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

4.1

Prepare rear wheel well section for installation

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

AR63.10-P-0662-02CW

4.2

Prepare rear fender (1) for installation

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

Model 166.0
except code Z04 (Light armoring)
except code Z05 (B5 armoring on special protection version)

AR63.50-P-1400-03GQ

Model 166.0
with code Z04 (Light armoring)

AR63.50-P-1400-03GQS

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

5.1

Install rear wheel well section

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

General information on riveting

AH60.00-P-0003-01N

AR63.10-P-0662-03CW

 Commercially available devices/tools
Blind rivet tool
Tools for disassembly/assembly

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Blind rivet for power window to left door 4.88 (clamping range 1.5 mm to 4 mm, draw-off strength min. 8 kN)

*BR00.45-Z-1008-13A

5.2

Install rear fender (1), fit and weld in

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

General information on riveting

AH60.00-P-0003-01N

Model 166.0
except code Z04 (Light armoring)
except code Z05 (B5 armoring on special protection version)

AR63.50-P-1400-04GQ

Model 166.0
with code Z04 (Light armoring)

AR63.50-P-1400-04GQS



000 588 02 84 00 Welder

WS60.00-P-0022K

 Commercially available devices/tools
Blind rivet tool
Tools for disassembly/assembly

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

Gap dimension

*BE60.00-P-1003-01Z

Gap dimension

*BE60.00-P-1004-01Z

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Blind rivet with polygrip countersunk head 6.414 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)

*BR00.45-Z-1002-13A

 Feeler gauge

*129589032100

6

Adjust gap dimensions on hoods, doors and lids

AR60.00-P-0700-01GQ

Gap dimension

*BE60.00-P-1003-01Z

Gap dimension

*BE60.00-P-1004-01Z

 Feeler gauge

*129589032100

7

Remove welding protection blankets

 On all covered parts remaining in vehicle.

8

Clean repair areas

 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 protective skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

9

Prime repair area using primer filler

Use only primer filler approved by Daimler AG.



See http://aftersales.mercedes-benz.com

10

Seal seam following repairs

AR97.10-P-4000GQ

 Supplement standard sealant with sealant.

 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 protective skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

11

Paint repair areas and adjacent surfaces

Use only paints approved by Daimler AG.



See http://aftersales.mercedes-benz.com

12

Add cavity preserving agent

AR97.20-P-1500GQ

13

Install all detachable parts in area to be repaired

Test and adjustment values for gap dimensions

Number

Designation

Model 166

BE60.00-P-1003-01Z

Gap dimension

Liftgate to bumper at bottom

Dimension "L"

mm

5,5 (1,5)

Liftgate to rear fender

Dimension "J"

mm

4,8 (1)

Liftgate to bumper at side

Dimension "K"

mm

4,9 (1,3)

Liftgate to roof

Dimension "W"

mm

5,5 (1,5)

Liftgate to rear window

Dimension "O"

mm

4,0 (1,0)

Rear fender to backup lamp

Dimension "M"

mm

1,4 (0,7)

D-pillar to rear window

Dimension "V"

mm

-

For picture, see

AR60.00-P-0700-01GQ

Test and adjustment values for gap dimensions

Number

Designation

Model 166

BE60.00-P-1004-01Z

Gap dimension

Fuel filler flap

Dimension "N"

mm

2,7 (0,3)

For picture, see

AR60.00-P-0700-01GQ

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42

BR00.45-Z-1002-13A

Blind rivet with polygrip countersunk head 6.414 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)

A 003 990 86 97 05

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1008-13A

Blind rivet for power window to left door 4.88 (clamping range 1.5 mm to 4 mm, draw-off strength min. 8 kN)

A 003 990 24 97