Replace complete rear fender

AR63.50-P-1400R

Replace complete rear fender

27.7.10

4.12.08

Validity in document on model 230 without code (P99) Special model "AMG Black Series limited



Removing

 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 spatter 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 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 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



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

AH00.00-N-0005-01A



General information on repairs to body

AH60.00-N-0001-01A



Guidelines for removing fuel tank when performing welding work on bodies

AH60.00-P-3000-01Z



Notes on paintwork repairs

AH98.00-P-9408-02A



General information on MB materials

AH98.00-P-9409-03A

1

Remove detachable parts on outer side of rear fender

2

Remove trunk lid with tubular frame

AR88.50-P-5001R

3

Remove detachable body components in the luggage compartment in the area of the rear fender and rear end center assembly

4

Remove detachable parts in vehicle interior (repair area)

5

Cover all detachable parts remaining vehicle with fireproof tarpaulin

 When replacing right rear fender, the standard tank lock must be installed and the filler neck must be covered with fire-resitant tarp.

6

Separate rear fender

AR63.50-P-1400-02R

 Spot weld milling cutter

*201589005100

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

7

Prepare new rear fender part

AR63.50-P-1400-03R

 Feeler gauge

*129589032100

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

8

Install rear fender and weld in

AR63.50-P-1400-04R

Gap dimension

*BE60.00-P-1002-01A

Gap dimension

*BE60.00-P-1003-01A

Gap dimension

*BE60.00-P-1005-01A

 Bending iron

*129589002700

 Feeler gauge

*129589032100

 Protective mat

*230589009800

 Welding bead catcher

*230589019800

Pneumatic/hydraulic blind rivet tool

gotis://K_68-80_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Rivet

*BR00.45-Z-1001-13A

Sealant

*BR00.45-Z-1003-01A

Preservation agent

*BR00.45-Z-1003-05A

Rivet

*BR00.45-Z-1005-13A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A



General information on riveting

AH60.00-P-0003-01N

9

Adjust gaps on hoods, doors and lids

AR60.00-P-0700-01R

Gap dimension

*BE60.00-P-1002-01A

Gap dimension

*BE60.00-P-1003-01A

Gap dimension

*BE60.00-P-1005-01A

Feeler gauge

*129589032100

10

Clean repair areas

11

Prime area to be repaired using primer filler

12

Carry out seam sealing after repairs

 Supplement standard seals with MB body sealant.

AR97.10-P-4000R

Sealant

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

13

Paint repair areas and adjacent surfaces

14

Apply additional cavity preservation

AR97.20-P-1500R

Cavity preservation gun

gotis://K_91-97_01.0

Preservation agent

*BR00.45-Z-1003-05A



Notes on cavity preservation

AH97.20-P-0001-01B

15

Remove tarp

 On all covered parts remaining in vehicle.

16

Install all removed detachable body components

Number

Designation

Model
230 without code P99

BE60.00-P-1002-01A

Gap dimension

Front door to A-pillar

Dimension "B"

mm

-

Front door to fender

Dimension "H"

mm

3.0 (0.8)

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

2.0 (+1.5/-0.5)

Front door to rear fender

Dimension "P"

mm

3.0 (+0.8)

See picture

AR60.00-P-0700-01R

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

-

Trunk lid to rear fender

Dimension "F"

mm

3.0 (+1.2)

Trunk lid to rear lamp unit

Dimension "M"

mm

4.0 (+1.6/-0.8)

Trunk lid to bumper

Dimension "V"

mm

5.0 (+1.5/-1.0)

Rear fender to rear lamp unit

Dimension "U"

mm

2.50.5

See picture

AR60.00-P-0700-01R

BE60.00-P-1005-01A

Gap dimension

Fuel filler flap

Dimension "K"

mm

3.0 (+0.8)

Dimension "L"

mm

-

See picture

AR60.00-P-0700-01R

Number

Designation

Order number

BR00.45-Z-1003-01A

Sealant, white, 310 ml, DB supply specification 6069.20

A 001 989 63 20

BR00.45-Z-1041-01A

Seam sealant, sprayable 310 ml

A 002 989 84 20

BR00.45-Z-1003-05A

Cavity preservation, solvent-free (1 l container)

A 000 986 72 70 05

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42

BR00.45-Z-1001-13A

Blind rivet 6.414

A 003 990 35 97

BR00.45-Z-1005-13A

Blind rivet, 5 x 10

A 003 990 75 97