P64.20-0717-05
| 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 | |
1.1 | Remove fuel tank | Depending on the scope of damage, the fuel tank can remain in the vehicle by making an additional cut. Refer to | |
Separate rear fender | |||
| Guidelines for removing fuel tank when performing welding work on bodies | All models | |
2 | Remove detachable body components on outer side of rear fender | ||
3 | Remove detachable body components in trunk, in area of rear fender and bottom rear center section. | ||
4 | Remove detachable parts in vehicle interior (area to be repaired) | ||
5 | Cover all attached parts remaining in vehicle (area to be repaired) | ||
6 | Separate rear fender | ||
Spot weld milling cutter | |||
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 | Before welding sheet metal part check gaps and adjust. Refer to | |
Gap dimensions on hoods, doors and lids | |||
Door gaps | |||
Gap dimension for covers | |||
Feeler gauge | |||
Inspection and welding gauge for side window | |||
Cross-shaped straightener | |||
Bending iron | |||
9 | Clean areas to be repaired and prime with MB-2K primer/filler | ||
10 | Supplement standard seals with MB body sealant | Seam sealing following repairs | |
11 | Supplement standard underbody protection with MB permanent underbody sealant | ||
12 | Paint rear fender and adjoining surfaces | ||
13 | Apply additional cavity preservation | Cavity preservation after repair work | |
14 | Install detachable body components removed |
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 | 6.5 (0.5) |
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 | - | ||
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 | 4.5 (0.5) | ||
Trunk lid to rear fender | Dimension"F" | mm | 4.5 (0.5) | ||
Trunk lid to taillamp | Dimension "M" | mm | - | ||
Trunk lid to bumper | Dimension "V" | mm | - | ||
Rear fender to taillamp | Dimension "U" | mm | - | ||
See picture in | |||||
201 589 00 27 00
208 589 02 23 00
129 589 03 21 00
201 589 00 51 00
Cross-shaped straightener
Spot weld milling cutter
Feeler gauge
Inspection and welding gauge for side window
129 589 00 27 00
Bending iron
Commercially available tools
Number | Designation | |
WH58.30-Z-1002-01A | Ball cutter, dia. 12 mm | |
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-1010-02A | Sheet metal crimping shears | |
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
- ar4710p4100e Remove/install fuel tank
- ar6000p070001k Gap dimensions at hoods, doors and covers
- ar6350p140002k Cutting out rear fender
- ar6350p140003k Prepare new rear fender
- ar6350p140004k Install rear fender
- ar9710p4000k Seam sealing following repair
- ar9720p1500k 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.