Replace complete rear fender

AR63.50-P-1400N

Replace complete rear fender

22.11.2019

Model

215



Remove

 Danger

Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust

Wear dust filter mask, safety glasses and protective gloves.
Use a suitable, grounded dust extraction system.

AS60.00-Z-0007-01N

 Danger

Risk of explosion from pressurized spray cans

Protect cans from direct sunlight and temperatures above 50 °C

AS00.00-Z-0015-01A

 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

 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

Topical note

General information on crack diagnosis of aluminum parts

AH60.00-P-0014-01N

Topical note

General information on body repair

AH60.00-N-0001-01A

General information on workshop and repair concept on vehicles with newly introduced materials and joining technology

AH60.00-P-0016-01N

General notes on jointing techniques in bodywork

AH60.00-P-0015-01SX

General information on dent removal and straightening aluminum parts

AH60.00-P-0012-01N

Notes on different body materials

AH60.00-P-0011-01SX

1

Remove trunk lid

AR88.50-P-5000M

2

Remove rear wall window

Model 215.375/378

AR67.20-P-2000N

3

Remove rear side window glass

AR67.30-P-4000N

4

Remove detachable parts from the outside of the rear fender

5

Remove detachable parts in the trunk, rear fender area, and rear-end center section

6

Remove rear bumper

AR82.10-P-4905M

7

Remove additional detachable parts in the vehicle interior (repair area)

8

Cover all detachable parts that remain in the vehicle (repair area)

 Tarp (fire-resistant)

9

Cut off rear fender

AR63.50-P-1400-02N

 When removing the right fender, bore self-piercing riveting of the battery frame on the fender.

 Spot weld milling cutter

*201589005100

 Spot-weld cutter

*215589005100

10

Prepare new rear fender part

AR63.50-P-1400-03N

 Inspection and welding gage

*220589052300

 Gauge adapter

*215589012300



Install

Topical note

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

Notes on bonded and foam-lined body areas

AH60.00-P-0010-01N

General information on riveting

AH60.00-P-0003-01N

General notes on spot welding of aluminum parts

AH60.00-P-0017-01N

11

Adjust gap dimensions on hoods, doors and lids

AR60.00-P-0700-01N

Gap dimension

*BE60.00-P-1002-01A

Gap dimension

*BE60.00-P-1003-01A

Gap dimension

*BE60.00-P-1005-01A

 Feeler gauge

*129589032100

12

Install rear fender

AR63.50-P-1400-04N


Use PolyGrip aluminum/steel panhead rivet
Diameter of 4 x 10 mm (approx. 45 pcs.)
Use PolyGrip aluminum/steel panhead rivet
Diameter of 6.4 x 14 mm (approx. 30 pcs.)
Use PolyGrip aluminum/steel countersunk-head rivet
Diameter of 4 x 10 mm (approx. 35 pcs.)
to be used.

 Feeler gauge

*129589032100

 Inspection and welding gage

*220589052300

 Gauge adapter

*215589012300

 Flange crimping pliers

*168589023700

13

Clean repair areas and prime using primer filler

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

14

Supplement standard sealants with MB body sealant

AR97.10-P-4000N

 Seam sealing following repair

15

Supplement standard underfloor protection with MB permanent underbody sealant

AR97.20-P-0500-03A

16

Paint rear fender and adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

17

Add cavity preserving agent

Topical note

Notes on cavity preservation

AH97.20-P-0001-01B



Model 215

AP97.20-P-0640A

18

Install trunk lid

AR88.50-P-5000M

19

Install rear window

Model 215.375/378

AR67.20-P-2000N

20

Install rear side window

AR67.30-P-4000N

21

Install taillamp

AR82.10-P-4905M

22

Reinstall additional assembly parts and thus complete vehicle.

Test and adjustment values for gap dimensions at hoods, doors and covers

Number

Designation

Model 215

BE60.00-P-1002-01A

Gap dimension

Front door to A-pillar

Dimension "B"

mm

–

Front door to fender

Dimension "H"

mm

4,5 (0,5)

Front door to rear door

Dimension "I"

mm

–

Front door to roof

Dimension "C"

mm

–

Rear door to side section, top

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

4,5 (0,5)

For picture, see

AR60.00-P-0700-01N

Test and adjustment values for gap dimensions at hoods, doors and covers

Number

Designation

Model 215

BE60.00-P-1003-01A

Gap dimension

Trunk lid to rear fender, top

Dimension "F"

mm

4,0 (0,5)

Trunk lid to rear fender, bottom

Dimension "M"

mm

–

Trunk lid to rear fender

Dimension "F"

mm

4,0 (0,5)

Trunk lid to taillamp

Dimension "M"

mm

4,0 (1,2)

Trunk lid to bumper

Dimension "V"

mm

–

Rear fender to taillamp

Dimension "U"

mm

–

For picture, see

AR60.00-P-0700-01N

Test and adjustment values for gap dimensions at hoods, doors and covers

Number

Designation

Model 215

BE60.00-P-1005-01A

Gap dimension

Fuel filler flap

Dimension "K"

mm

–

For picture, see

AR60.00-P-0700-01N

Dimension "L"

mm

3,0 (0,5)