Completely replace rear fender

AR63.50-P-1400KA

Completely replace rear fender

16.2.12



Remove



General information on body repair

All models

AH60.00-N-0001-01A

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect ground cable of battery

AR54.10-P-0003A

2.1

Remove battery

When replacing right rear fender

AR54.10-P-0005EA

Danger!

Risk of explosion if ignition takes place, 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.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

3.1

Install fuel filler neck covering

When replacing right rear fender

AR63.50-P-1400-01E

 Set of covers

*202589009100



Guidelines for removing fuel tank when performing welding work on bodies

All models

AH60.00-P-3000-01Z

4

Remove trunk lid

5

Remove soft top compartment cover

6

Remove detachable parts on outside of rear fender

7

Remove attached parts on outside of rear fender

 In vicinity of rear fender, soft top compartment and rear center assembly

8

Remove attached parts in trunk, area of rear fender and rear center piece

 In area to be repaired

9

Open soft top

When using protective cover  it is not necessary to remove the soft top.

 Installation:Insert protective cover into soft top compartment.Fold back soft top. Close protective cover.

 Protective cover

*129589009800

10

Cover all attached parts remaining in vehicle

11

Raise vehicle

12

Remove rear wheel

13

Separate rear fender

AR63.50-P-1400-02KA

Spot weld milling cutter

*201589005100



Install

 Danger!

Risk of death caused by high voltage used for arc welding. Risk of explosion caused by welding in the area of high combustible materials. Risk of injury caused by 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 hazard area. Use air extractor.

AS00.00-Z-0007-01A



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

All models

AH00.00-N-0005-01A

14

Prepare new rear fender

AR63.50-P-1400-03KA

15

Prepare joint surfaces on body for installation of rear fender

AR63.50-P-1400-06KA

16

Install rear fender and weld in

 Before welding sheet metal part check gaps and adjust. Refer to

AR63.50-P-1400-04KA

Gap dimensions at hoods, doors and covers

AR60.00-P-0700-01KA

Door gaps

*BE60.00-P-1002-01A

Trunk lid gaps

*BE60.00-P-1003-01A

Soft top compartment gaps

*BE60.00-P-1008-01A

Feeler gage

*129589032100

 Cross-shape straightener

*201589002700

 If the wheelhouse has also been replaced crimp edge of wheelhouse together with the edge of wheel flange after welding.

If the wheelhouse was not replaced at the same time, the edge of the rear fender must be shaped to fit the wheelhouse before welding. Refer to:

Crimp edge of rear fender

AR63.50-P-1400-05KA

 Bending jig

*129589002700

17

Clean areas to be repaired and prime with MB 2-component primer/filler

18

Supplement standard sealing with MB body sealant

AR97.10-P-4000K

19

Supplement standard underfloor protection with MB permanent underfloor protection agent

 General notes on underbody preservation

AH97.20-P-2000-01A

20

Paint rear fender and adjoining surfaces

 General notes on paintwork repairs

AH98.00-P-9408-02A

 General notes on MB materials

AH98.00-P-9409-03A

21

Apply additional cavity preservation

AR97.20-P-1500K

22

Install detachable body components removed

Number

Designation

Model
208.4

BE60.00-P-1002-01A

Gap dimension

Front door to A-pillar

Dimension "B"

mm

5.0 (1.0)

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 upper side section

Dimension "D"

mm

-

Rear door to lower side section

Dimension "J"

mm

-

Fender to A-pillar

Dimension "Q"

mm

-

Front door to rear fender

Dimension "P"

mm

4.0 (0.5)

Fig., see

AR60.00-P-0700-01KA

BE60.00-P-1003-01A

Gap dimension

Trunk lid to top of rear fender

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

-

Fig., see

AR60.00-P-0700-01KA

BE60.00-P-1008-01A

Gap dimension

Soft top compartment cover/
rear fender

Dimension "X"

mm

4.0 (0.5)

Soft top compartment cover to trunk lid

Dimension "Y"

mm

4.5 (0.5)

Fig., see

AR60.00-P-0700-01KA

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-1001-02A

Hole punching pliers, dia. 6 mm.

WH58.30-Z-1003-02A

Clamping pliers

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)

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)