Replace complete rear fender

AR63.50-P-1400M

Replace complete rear fender

11.11.11



Removing

 Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with 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

 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

Danger!

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

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by 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



Guidelines for removing fuel tank when performing welding work on bodies

All models

AH60.00-P-3000-01Z



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

All models

AH00.00-N-0005-01A



General information on body repair

All models

AH60.00-N-0001-01A



Notes on paintwork repairs

Model 124, 126, 129, 140, 163, 168, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463, 639

AH98.00-P-9408-02A



General information on MB materials

Model 124, 126, 129, 140, 163, 168, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463, 639

AH98.00-P-9409-03A

1

Remove rear bumper

AR88.20-P-2200M

Model 220
with trailer hitch, code 550, except AMG optical package - front spoiler, side skirts and rear apron, code 772,

Trailer hitch with removable ball neck

Model 220
with trailer hitch, code 550, except AMG optical package - front spoiler, side skirts and rear apron, code 772,

Mechanical swing-away trailer hitch

AR88.20-P-2200MA

2

Remove rear bumper

AR82.10-P-4905M

3

Remove trunk lid

AR88.50-P-5000M

4

Remove fuel tank

Model 220.025/125/126/163/178 with ski bag (through-loading feature), code 282a, with refrigerator compartment in rear center backrest, code 308

Model 220.025/125/126/163/176/178 except ski bag (through-loading feature), code 282a, except refrigerator compartment in rear center backrest, code 308

Model 220.026/028/063/065/067/070/

075/083/084/087/128/165/167/170/175/

176/179/183/184/187/875/878

with ski bag (through-loading feature), code 282a, with refrigerator compartment in rear center backrest, code 308

AR47.10-P-4100I

Model 220.026/028/063/065/067/070/

073/074/075/083/084/087/128/165/167/
170/173/174/175/179/183/184/187/
875/878 except ski bag (through-loading feature), code 282a, with refrigerator compartment in rear center backrest, code 308

AR47.10-P-4100IA

5

Remove rear seat backrest

Model 220 875/878 with electrically adjustable rear bench seat, code 223b

Model 220 875/878 except electrically adjustable rear bench seats, code (223b),
except electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c

Model 220 875/878 electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c

Model 220 0/1
with electrically adjustable rear bench seat, code 223b

AR91.12-P-1620M

Model 220. 0/1
except electrically adjustable rear bench seat, code 223b,
except electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c

AR91.12-P-1620MA

Model 220 0/1
with electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c

AR91.12-P-1620MB

Model 220.875/878
with Vis-à-vis seats

AR91.12-P-1620MP

6

Remove floor mats

7

Remove detachable parts in area to be repaired

8

Cover all detachable parts remaining in vehicle

Tarp (fire-resistant)

9

Separate rear fender

AR63.50-P-1400-02M

Spot weld cutter

*201589005100

Template

*220589072300

Template

*220589082300

Vario Drill WS 91 spot weld removing tool

Ball cutter, dia. 12 mm

Round wire brush, braided, dia. 70 mm

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

Cutting disk, Ø 65 mm, 80 m/s (max. 23,500 rpm)

Sheet metal crimping pliers
gotis://K_58.3_04.1

Drill
gotis://K_58.1_04.0

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

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

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

Two-post lifting platform 3.0-3.5 t, electromechanical
gotis://H_00.1_01.0

Tarp (fire-resistant)

10

Prepare new rear fender part

AR63.50-P-1400-03M

Template

*220589072300

Template

*220589082300

Round wire brush, braided, dia. 70 mm

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

Drill
gotis://K_58.1_04.0

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



Install

11

Install rear fender and weld in

 Bumper bracket must be modified on model 220.8.

AR63.50-P-1400-04M

Feeler gauge

*129589032100

 Bending iron

*129589002700

 Check and welding gage

*220589052300

Electrode miller

Round wire brush, braided, dia. 70 mm

Clamping pliers

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

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

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

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

Two-post lifting platform 3.0-3.5 t, electromechanical
gotis://H_00.1_01.0

Tarp (fire-resistant)

12

Adjust gap dimensions on hoods, doors and lids

AR60.00-P-0700-01M

Feeler gauge

*129589032100

Rear door to top of side section

*BE60.00-P-1002-01A

Rear door to side piece, bottom

*BE60.00-P-1002-01A

Trunk lid to rear fender, top

*BE60.00-P-1003-01A

Trunk lid to bottom of rear fender

*BE60.00-P-1003-01A

Trunk lid to rear lamp unit

*BE60.00-P-1003-01A

Rear fender to lamp unit

*BE60.00-P-1003-01A

Fuel filler flap

*BE60.00-P-1005-01A

13

Clean weld joints and sheet metal flange with round wire brush

Round wire brush, braided, dia. 70 mm

14

Clean repair areas

15

Prime repair area using primer filler

16

Carry out seam sealing after repairs

 Supplement standard sealants with MB body sealant.

AR97.10-P-4000B

Sealant

*BR00.45-Z-1003-01A

17

Paint repair areas and adjacent surfaces

18

Apply additional cavity preservation

AR97.20-P-1500B



Notes on cavity preservation

Model 124, 126, 129, 140, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 463, 639, 671, 690.6, 901, 902, 903, 904, 905

Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7

AH97.20-P-0001-01B

Combination pressure spray gun (corrosion protection)
gotis://K_91-97_01.0

MB cavity wax preservation, 1 l

*BR00.45-Z-1003-05A

19

Remove tarp from all covered parts that remained in the vehicle.

Tarp (fire-resistant)

20

Install rear seat backrest

Model 220 875/878 with electrically adjustable rear bench seat, code 223b

Model 220.875/878 except electrically adjustable rear bench seat, code 223b,
except electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c

Model 220 875/878 with electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c

Model 220 0/1
with electrically adjustable rear bench seat, code 223b

AR91.12-P-1620M

Model 220 0/1
except electrically adjustable rear bench seat, code 223b,
except electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c

AR91.12-P-1620MA

Model 220 0/1
with electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c

AR91.12-P-1620MB

Model 220.875/878
with Vis-à-vis seats

AR91.12-P-1620MP

21

Install fuel tank

Model 220.025/125/126/163/178 with ski bag (through-loading feature), code 282a, with refrigerator compartment in rear center backrest, code 308

Model 220.025/125/126/163/176/178 except ski bag (through-loading feature), code 282a, except refrigerator compartment in rear center backrest, code 308

Model 220.026/028/063/065/067/070/

075/083/084/087/128/165/167/170/175/

176/179/183/184/187/875/878 with ski bag (through-loading feature), code 282a, with refrigerator compartment in rear center backrest, code 308

AR47.10-P-4100I

Model 220.026/028/063/065/067/070/

073/074/075/083/084/087/128/165/167/
170/173/174/175/179/183/184/187/
875/878 except ski bag (through-loading feature), code 282a, with refrigerator compartment in rear center backrest, code 308

AR47.10-P-4100IA

22

Install rear bumper

AR88.20-P-2200M

Model 220
with trailer hitch, code 550, except AMG optical package - front spoiler, side skirts and rear apron, code 772,

Trailer hitch with removable ball neck

Model 220
with trailer hitch, code 550, except AMG optical package - front spoiler, side skirts and rear apron, code 772,

Mechanical swing-away trailer hitch

AR88.20-P-2200MA

23

Install taillamp

AR82.10-P-4905M

24

Install trunk lid

AR88.50-P-5000M

25

Insert floor mat

26

Install all removed detachable parts

Number

Designation

Model
220.0/1

BE60.00-P-1002-01A

Gap dimension

Front door to A-pillar

Dimension "B"

mm

8.0 (0.5)

Front door to fender

Dimension "H"

mm

5.0 (0.5)

Front door to rear door

Dimension "I"

mm

5.0 (0.5)

Front door to roof

Dimension "C"

mm

8.0 (0.5)

Rear door to top of side section

Dimension "D"

mm

5.0 (0.5)

Rear door to side piece, bottom

Dimension "J"

mm

5.0 (0.5)

Fender to A-pillar

Dimension "Q"

mm

-

Front door to rear fender

Dimension "P"

mm

-

See picture

AR60.00-P-0700-01M

BE60.00-P-1003-01A

Gap dimension

Trunk lid to rear fender, top

Dimension "F"

mm

4.0 (0.5)

Trunk lid to bottom of rear fender

Dimension "M"

mm

-

Trunk lid to rear fender

Dimension "F"

mm

4.0 (0.5)

Trunk lid to rear lamp unit

Dimension "M"

mm

4.4 (0.5)

Trunk lid to bumper

Dimension "V"

mm

-

Rear fender to lamp unit

Dimension "U"

mm

-

See picture

AR60.00-P-0700-01M

BE60.00-P-1005-01A

Gap dimension

Fuel filler flap

Dimension "K"

mm

-

Dimension "L"

mm

4.0 (0.5)

See picture

AR60.00-P-0700-01M

Number

Designation

Model
220.875/878

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

5.0 (0.5)

Front door to rear door

Dimension "I"

mm

-

Front door to roof

Dimension "C"

mm

6.5 (0.5)

Rear door to top of side section

Dimension "D"

mm

5.0 (0.5)

Rear door to side piece, bottom

Dimension "J"

mm

5.0 (0.5)

Fender to A-pillar

Dimension "Q"

mm

-

Front door to rear fender

Dimension "P"

mm

-

See picture

AR60.00-P-0700-01MP

BE60.00-P-1003-01A

Gap dimension

Trunk lid to rear fender, top

Dimension "F"

mm

4.0 (0.5)

Trunk lid to bottom of rear fender

Dimension "M"

mm

-

Trunk lid to rear fender

Dimension "F"

mm

4.0 (0.5)

Trunk lid to rear lamp unit

Dimension "M"

mm

4.4 (0.5)

Trunk lid to bumper

Dimension "V"

mm

-

Rear fender to lamp unit

Dimension "U"

mm

-

See picture

AR60.00-P-0700-01MP

BE60.00-P-1005-01A

Gap dimension

Fuel filler flap

Dimension "K"

mm

-

Dimension "L"

mm

4.0 (0.5)

See picture

-

Number

Designation

Order number

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1003-05A

Cavity sealant, solvent-free (1 l container)

A 000 986 72 70 05