Replace complete rear fender

AR63.50-P-1400GZ

Replace complete rear fender

2.11.11



Removing

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 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



General information on body repair

All models

AH60.00-N-0001-01A

1

Remove detachable parts in the repair area

2

Cover detachable parts remaining in vehicle (area to be repaired).

Tarp (fire-resistant)

3

Separate rear fender

AR63.50-P-1400-02GZ

 Set of cutting templates

*164589042300

 Cutting template

*164589092300

 Spot weld milling cutter

*201589005100

Vario Drill WS 91 spot weld removing tool

Round wire brush, braided, dia. 70 mm

Cutting disk, dia. 50 mm, 80 m/s (max. 30,600 rpm)

Drill
gotis://K_58.1_04.0

Straight grinder
gotis://K_58.0_03.0

Body jig saw
gotis://K_58.1_01.0

Hot-air gun

4

Prepare connection points on body in area of rear fender

AR63.50-P-1400-06GZ

Round wire brush, braided, dia. 70 mm

Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 rpm)

Drill
gotis://K_58.1_04.0

Angle grinder
gotis://K_58.1_07.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

5

Prepare new rear fender part

AR63.50-P-1400-03GZ

Hole punching pliers, dia. 7 mm

Round wire brush, braided, dia. 70 mm

Drill
gotis://K_58.1_04.0

Body jig saw
gotis://K_58.1_01.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

 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

6

Install rear fender

AR63.50-P-1400-04GZ



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

All models

AH00.00-N-0005-01A

 Embossing tool

*164589003900

Clamping pliers

Round wire brush, braided, dia. 70 mm

Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 rpm)

Abrasive disk, dia. 50 mm, 80 m/s (max. 23,000 rpm)

Blind rivet/punch riveting method
gotis://K_68-80_06.0

MIG MAG gas welder (steel, brazing, aluminum)
gotis://K_60-65_17.1

Inverter spot welder
gotis://K_60-65_16.0

Drill
gotis://K_58.1_04.0

Straight grinder
gotis://K_58.0_03.0

Angle grinder
gotis://K_58.1_07.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Rivet

*BR00.45-Z-1001-13A

7

Clean repair areas

8

Prime repair area using primer filler

 See Paintwork Manual.

9

Perform seam sealing after repair

AR97.10-P-4000GZ

10

Paint repair areas and adjacent surfaces

 See Paintwork Manual.

11

Apply additional cavity preservation

AR97.20-P-1500GZ

12

Reinstall all detachable parts removed

Number

Designation

Order number

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