Replace complete rear fender

AR63.50-P-1400H

Replace complete rear fender

09.03.2020

Model

240.078



Remove

 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

 Danger

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

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

AS00.00-Z-0010-01A

 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

 Danger

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.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 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

Topical note

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

AH00.00-N-0005-01A

Topical note

General information on body repair

Typ 240.078

AH60.00-N-0001-01A

Topical note

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

Topical note

Guidelines for removing fuel tank when performing welding work on bodies

AH60.00-P-3000-01Z

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

General information on MB materials

AH98.00-P-9409-03A

1

Remove taillamp

AR82.10-P-4905H

2

Remove rear bumper

AR88.20-P-2200H

3

Remove trunk lid

AR88.50-P-5000H

4

Remove detachable parts in area to be repaired

5

Cover all detachable parts remaining in the vehicle (repair area)

 Tarp (fire-resistant)

6

Cut off rear fender

AR63.50-P-1400-02H

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

 Spot weld milling cutter

*201589005100

7

Prepare new rear fender part

AR63.50-P-1400-03H

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

8

Install rear fender and fit

AR63.50-P-1400-04H

9

Install tail lamp and fit

AR82.10-P-4905H

10

Install trunk lid and fit

AR88.50-P-5000H

11

Adjust gap dimensions on hoods, doors and lids

AR60.00-P-0700-01X

Gap dimension

*BE60.00-P-1003-01I

Gap dimension

*BE60.00-P-1003-01I

Gap dimension

*BE60.00-P-1003-01I

Gap dimension

*BE60.00-P-1003-01I

Gap dimension

*BE60.00-P-1003-01I

 Feeler gauge

*129589032100

 Spacers

*000589876300

 Set of feeler gauges

*240589032300

12

Remove taillamp

AR82.10-P-4905H

13

Remove trunk lid

AR88.50-P-5000H

14

Mount standard fuel filler cap and mask off gap

 Only when installing a new right rear fender.

Gap dimension

*BE60.00-P-1004-01I

15

Install and weld in rear fender

AR63.50-P-1400-04H

General information on riveting

AH60.00-P-0003-01N

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

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

Blind rivet

*BR00.45-Z-1003-13A

 Crimping iron

*129589002700

16

Clean weld joints and metal flanges with wire brush

17

Clean repair areas

18

Prime repair area using primer filler

19

Seam sealing following repair

AR97.10-P-4000H

 Supplement standard sealants with MB body sealant.

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

20

Paint repair areas and adjacent surfaces

21

Cavity preservation following repair work

AR97.20-P-1500H

Topical note

Notes on cavity preservation

AH97.20-P-0001-01B

Cavity preservation (free of solvents), 1 liter

*BR00.45-Z-1003-05A

22

Install trunk lid

AR88.50-P-5000H

23

Install taillamp

AR82.10-P-4905H

24

Install rear bumper

AR88.20-P-2200H

25

Remove tarp

 On all covered parts remaining in vehicle.

26

Install all removed detachable parts

Test and adjustment values for gap dimensions

Number

Designation

Model 240

BE60.00-P-1003-01I

Gap dimension

Rear fender to C-pillar

Dimension "H"

mm

4 (0,5)

Rear fender to trunk lid

Dimension "J"

mm

4 (0,5)

Rear fender to rear door

Dimension "K"

mm

4 (0,5)

Rear fender to bumper

Dimension "L"

mm

2,8 (0,5)

Rear fender to taillamp

Dimension "M"

mm

2 (0,5)

Bumper to taillamp

Dimension "O"

mm

2 (0,5)

Trunk lid to taillamp, bottom

Dimension "P"

mm

5 (0,5)

For picture, see

AR60.00-P-0700-01X

Test and adjustment values for gap dimensions

Number

Designation

Model 240

BE60.00-P-1004-01I

Gap dimension

Fuel filler flap

Dimension "R"

mm

3,5 (1)

For picture, see

AR60.00-P-0700-01X

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-1003-05A

Cavity preservation (free of solvents), 1 liter

A 000 986 72 70 10

BR00.45-Z-1003-13A

Blind rivet

A 003 990 98 97

BR00.45-Z-1092-02A

Adhesive kit, body, 2-component adhesive

A 012 989 17 71