Replace complete rear fender

AR63.50-P-1400RQA

Replace complete rear fender

07.05.2020

Model

197.4

1

Rear fender



Remove

 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

 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

 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

 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 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

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

AH60.00-P-0001-02A

Topical note

General information on crack diagnosis of aluminum parts

AH60.00-P-0014-01N

Topical note

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

General information on repair of vehicles with ultra-strength steels.

AH60.00-P-0024-01N

General notes on welding

AH60.00-P-0005-01N

General information on MB materials

AH98.00-P-9409-03A

General information on riveting

AH60.00-P-0003-01N

Note on working on aluminum components and vehicles

AH60.00-P-0034-01N

1

Remove detachable parts in area of repair point.

2

Cover all detachable parts that remain in the vehicle with fire-resistant welding protection blankets.

 Commercially available devices/tools
Welding protection blanket

3

Cut off rear fender (1).

AR63.50-P-1400-02RQ

 Commercially available devices/tools
Heat gun
Glass removal
Aluminum tools

4

Prepare rear fender (1).

AR63.50-P-1400-03RQ



Install

5

Install rear fender (1).

AR63.50-P-1400-04RQ

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

AH60.00-P-0033-01RQ

Gap dimension

*BE60.00-P-1002-01X

Gap dimension

*BE60.00-P-1003-01X

Gap dimension

*BE60.00-P-1004-01X

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

2K-component filler foam

*BR00.45-Z-1090-01A

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)

*BR00.45-Z-1001-13A

Self-tapping fillister head screw M5, replaced by: A 011 990 32 04

*BR00.45-Z-1022-13A

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

*BR00.45-Z-1026-13A

Flow-form rivet structure 4 mm up to 5.15 mm clamping range (S3)

*BR00.45-Z-1028-13A

 Feeler gauge

*129589032100

6

Adjust gap dimension on front door, on trunk lid, and on fuel filler flap.

AR60.00-P-0700-01RQ

Gap dimension

*BE60.00-P-1002-01X

Gap dimension

*BE60.00-P-1003-01X

Gap dimension

*BE60.00-P-1004-01X

 Feeler gauge

*129589032100

7

Clean weld joints and sheet metal flanges with rotary wire brush.

8

Reestablish and smooth transition area to outer A-pillar.

 Use only filler materials approved by Daimler AG.

9

Remove welding protection blankets.

10

Clean repair area.

 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

11

Treat repair areas with primer filler.

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

 Use only primer filler approved by Daimler AG.

12

Seal seam after repair.

AR97.10-P-4000RQ

 Supplement standard seals with sealant.

 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

13

Paint repair areas and adjacent surfaces.

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

 Use only paints approved by Daimler AG.

14

Supplement cavity preservation.

AR97.20-P-1500RQ

15

Install all detachable parts in area of repair point.

Check values for gaps

Number

Designation

Model 197.4

BE60.00-P-1002-01X

Gap dimension

Front door to fender

Dimension "D"

mm

4,5 (1)

Front door to longitudinal member panel

Dimension "E"

mm

5 (1)

Front door to rear fender

Dimension "F"

mm

4,5 (1)

Picture

AR60.00-P-0700-01RQ

Check values for gaps

Number

Designation

Model 197.4

BE60.00-P-1003-01X

Gap dimension

Trunk lid to rear fender, top

Dimension "G"

mm

4 (1)

Trunk lid to bumper

Dimension "H"

mm

6,5 (1,5)

Rear fender to taillamp

Dimension "I"

mm

2,5 (0,5)

Picture

AR60.00-P-0700-01RQ

Check values for gaps

Number

Designation

Model 197.4

BE60.00-P-1004-01X

Gap dimension

Fuel filler flap (around)

Dimension "J"

mm

2 (1)

Picture

AR60.00-P-0700-01RQ

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-13A

Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)

A 003 990 35 97

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1022-13A

Self-tapping fillister head screw M5, replaced by: A 011 990 32 04

A 000 990 60 11

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-1028-13A

Flow-form rivet structure 4 mm up to 5.15 mm clamping range (S3)

A 000 991 12 33

BR00.45-Z-1090-01A

2K-component filler foam

A 000 989 35 73

BR00.45-Z-1092-02A

Adhesive kit, body, 2-component adhesive

A 012 989 17 71