Replace complete rear fender

AR63.50-P-1400RG

Replace complete rear fender

02.05.2019

Model

190.3

Modification notes

21.02.2017

Gap dimension, longitudinal member panel to fender/sidewall panel

Model 190.3

BE60.00-P-1009-01EA

1

Rear fender

 Caution

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 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

Topical note

General information on body repair

AH60.00-N-0001-01A

Topical note

General information on crack diagnosis of aluminum parts

AH60.00-P-0014-01N

Note on working on aluminum components and vehicles

AH60.00-P-0034-01RG



Remove

1

Prepare all workshop equipment and commercially available devices/tools required for repair

2

Remove detachable parts in areas to be repaired

3

Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket

4

Completely remove outer side longitudinal member

AR63.30-P-1000RG

5

Separate rear fender (1)

AR63.50-P-1400-02RG



000 588 00 84 00 Heat gun

WS54.00-P-0049B



000 588 02 39 00 Rivet press tool

WS60.00-P-0010B

 Commercially available devices/tools
Vacuum unit suitable for aluminum dusts
Round wire brush
Spot weld milling machine
Drill bit and milling cutter for ultra-high-strength steels
Hand drill
Body saw
Wet/dry vacuum cleaner

Preparation

Topical note

Notes on processing of 2-K structural foam adhesive during body repairs

AH60.00-P-0040-01A

Topical note

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

6

Prepare new rear fender (1)

AR63.50-P-1400-03RG

 Commercially available devices/tools
Vacuum unit suitable for aluminum dusts
Round wire brush
Hand drill
Wet/dry vacuum cleaner



Install

 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

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 inhaling welding gases

Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system.

AS00.00-Z-0007-01A

Topical note

Measures for preventing damage to components when performing electric welding and soldering work

AH60.00-P-0001-02A

General notes on welding

AH60.00-P-0005-01N

General information on riveting

AH60.00-P-0003-01N

7

Install rear fender (1)

AR63.50-P-1400-04RG

Gap dimensions on hoods, doors and lids

AR60.00-P-0700-01RG



000 588 02 39 00 Rivet press tool

WS60.00-P-0010B



000 588 02 84 00 Welder

WS60.00-P-0022K

 Commercially available devices/tools
Vacuum unit suitable for aluminum dusts
Round wire brush
Drill bit for ultra-high-strength steels
Hand drill
Manual temporary fastener 6.35 mm
Wet/dry vacuum cleaner

Gap dimension, sidewall panel to door paneling

*BE60.00-P-1008-01EA

Gap dimension, longitudinal member panel to fender/sidewall panel

*BE60.00-P-1009-01EA

Gap dimension, side wall paneling to tailgate/trunk lid/rear spoiler

*BE60.00-P-1020-01EA

Gap dimension, sidewall panel to taillamp

*BE60.00-P-1021-01EA

Gap dimension, tank cap

*BE60.00-P-1023-01EA

Gap dimension, sidewall panel to bumper

*BE60.00-P-1026-01EA

Blind rivet 6.512.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)

*BR00.45-Z-1012-13A

Flow-form rivet structure 1.3 mm up to 2.5 mm clamping range (S08)

*BR00.45-Z-1048-13A

Flow-form rivet structure up to 3.5 mm clamping range (S1)

*BR00.45-Z-1026-13A

Parts kit for 2-component adhesive for body

*BR00.45-Z-1162-02A

 Feeler gauge

*129589032100

8

Completely install outer side longitudinal member

AR63.30-P-1000RG



Clean

9

Clean welds and sheet metal flanges

 Commercially available devices/tools
Vacuum unit suitable for aluminum dusts
Round wire brush
Hand drill
Wet/dry vacuum cleaner

10

Remove fire-resistant welding blankets

11

Clean repair area

 Commercially available devices/tools
Wet/dry vacuum cleaner

Paint

 Danger

Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.

No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

 Danger

Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents

Never spray corrosion protection on flames or hot, glowing objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection.

AS97.00-Z-0001-01A

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

Topical note

Notes on sprayable joint sealant

AH97.10-P-0002-01A

Topical note

Notes on cavity preservation

AH97.20-P-0001-01B

General note on use of 2-component acoustic filler foam following repairs

AH60.00-P-0033-01RQ

Notes on seam seal

AH97.10-P-0002-02A

General information on MB materials

AH98.00-P-9409-03A

12

Prime repair area using primer filler

 Use only primer filler approved by Daimler AG. Guidelines for paint technology are available at: https://xentryportal.i.daimler.com/wps/portal.

13

Seal seam following repairs

AR97.10-P-4000RG

 Supplement standard seals with sealant.

14

Paint repair areas and adjacent surfaces

 Use only paints approved by Daimler AG. Guidelines for paint technology are available at: https://xentryportal.i.daimler.com/wps/portal.

15

Add cavity preserving agent

AR97.20-P-1500RG



Assemble

16

Install detachable parts in area to be repaired

Gap dimensions

Number

Designation

Model 190.3

BE60.00-P-1008-01EA

Gap dimension, sidewall panel to door paneling

Dimension "H"

mm

3,5 (0,5)

See

AR60.00-P-0700-01RG

Gap dimensions

Number

Designation

Model 190.3

BE60.00-P-1009-01EA

Gap dimension, longitudinal member panel to fender/sidewall panel

Dimension "I"

mm

0 (+0,5)

See

AR60.00-P-0700-01RG

Gap dimensions

Number

Designation

Model 190.3

BE60.00-P-1020-01EA

Gap dimension, side wall paneling to tailgate/trunk lid/rear spoiler

Dimension "T"

mm

3,5 (0,5)

See

AR60.00-P-0700-01RG

Gap dimensions

Number

Designation

Model 190.3

BE60.00-P-1021-01EA

Gap dimension, sidewall panel to taillamp

Dimension "U"

mm

1 (1)

See

AR60.00-P-0700-01RG

Gap dimensions

Number

Designation

Model 190.3

BE60.00-P-1023-01EA

Gap dimension, tank cap

Dimension "W"

mm

2,5 (0,5)

See

AR60.00-P-0700-01RG

Gap dimensions

Number

Designation

Model 190.3

BE60.00-P-1026-01EA

Gap dimension, sidewall panel to bumper

Dimension "Z"

mm

0,5 (0,5)

See

AR60.00-P-0700-01RG

Repair materials

Number

Designation

Order number

BR00.45-Z-1012-13A

Blind rivet 6.512.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)

A 004 990 16 97

BR00.45-Z-1026-13A

Flow-form rivet structure up to 3.5 mm clamping range (S1)

A 000 991 11 33

BR00.45-Z-1048-13A

Flow-form rivet structure 1.3 mm up to 2.5 mm clamping range (S08)

A 000 991 23 33

BR00.45-Z-1162-02A

Parts kit for 2-component adhesive for body

A 012 989 17 71