P63.50-3290-06
1 Rear fender
| 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 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. | |
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. | |
Danger! | Risk of explosion from pressurized spray cans | Protect cans from direct sunlight and temperatures above 50 °C | |
Danger! | 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. | |
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. | |
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. Wear protective clothing when handling fuel. | |
Danger! | Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust | Wear protective respiratory mask, protective gloves and safety glasses. Use suitable, grounded vacuum cleaner | |
| General information on repair of vehicles with ultra-strength steels. | Failure to observe instructions when straightening/repairing, separating, preparing adhesive points, joining/connecting, resistance spot welding, MIG welding, MIG brazing can lead to considerable damage to ultra-strength steels and their joints. | |
| Measures for preventing damage to vehicles or components when performing electric welding work | ||
| General information on body repair | ||
| Pretreatment of bonding surfaces | ||
| Notes on paintwork repairs | ||
| General information on riveting | ||
| Notes on various body materials | ||
| General information on dent removal and straightening aluminum parts | ||
| General information on body connection techniques | ||
1 | Remove rear door sill molding | ||
2 | Remove headliner | Only loosen headliner in repair area. | |
3 | Remove rear wall window | ||
4 | Remove taillamps | ||
5 | Remove rear bumper | ||
6 | Remove trim in trunk | ||
7 | Cover all detachable parts remaining in vehicle | Tarp (fire-resistant) | |
8 | Separate rear fender (1) | ||
| Sheet metal crimping pliers for areas not easily accessible | ||
| Recycle aluminum parts | ||
Spot weld milling cutter | |||
Spot weld milling cutter | |||
Set of cutting templates | |||
Ball cutter, dia. 12 mm | |||
Vario Drill WS 91 spot weld removing tool | |||
Beading pliers | |||
Round wire brush, braided, dia. 70 mm | |||
Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm) | |||
Hot air gun - 3000 W | |||
Aluminum workshop vehicle | |||
Drill | |||
Angle grinder | |||
Body jig saw | |||
Wet/dry vacuum cleaner | |||
Zinc dust paint suitable for spot welding | |||
9 | Prepare new rear fender (1) | ||
Set of cutting templates | |||
Round wire brush, braided, dia. 70 mm | |||
Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm) | |||
Aluminum workshop vehicle | |||
Drill | |||
Angle grinder | |||
Body jig saw | |||
Zinc dust paint suitable for spot welding | |||
| Install | ||
10 | Install rear fender (1) and weld in | ||
| General information on riveting | ||
Rear door to side piece, bottom | |||
Trunk lid to rear lamp unit | |||
Rear fender to lamp unit | |||
Trunk lid license plate panel to rear lamp unit | |||
Fuel filler flap | |||
Welding bead catcher | |||
Feeler gauge | |||
Bending iron | |||
Electrode miller | |||
BTR Usibor drill bit, dia. 6.7 mm | |||
Clamping pliers | |||
Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver | |||
Round wire brush, braided, dia. 70 mm | |||
Taurus 3 blind rivet tool with 100 mm extension unit | Blind rivet/punch riveting method | ||
Aluminum workshop vehicle | |||
MIG MAG gas welder (steel, brazing, aluminum) | |||
Inverter spot welder | |||
Drill | |||
Wet/dry vacuum cleaner | |||
Zinc dust paint suitable for spot welding | |||
Polygrip flat round head rivet, 6.414 | |||
Polygrip countersunk-head rivet, 6.414 | |||
Adhesive | |||
11 | Adjust gap dimensions on hoods, doors and lids | ||
Feeler gauge | |||
Rear door to side piece, bottom | |||
Trunk lid to rear lamp unit | |||
Rear fender to lamp unit | |||
Trunk lid license plate panel to rear lamp unit | |||
Fuel filler flap | |||
12 | Clean weld joints and sheet metal flange with round wire brush | Round wire brush, braided, dia. 70 mm | |
Drill | |||
13 | Clean repair areas | ||
14 | Prime repair area using primer filler | ||
15 | Carry out seam sealing after repairs | Supplement standard sealants with MB body sealant. | |
Sealant | |||
Seam sealant, sprayable 310 ml | |||
16 | Paint repair areas and adjacent surfaces | ||
| General information on MB materials | ||
17 | Apply additional cavity preservation | ||
| Notes on cavity preservation | ||
Combination pressure spray gun (corrosion protection) | |||
MB cavity wax preservation, 1 l | |||
18 | Remove tarp | On all covered parts remaining in vehicle. | |
19 | Install rear wall window | ||
20 | Install headliner | ||
21 | Install taillamps | ||
22 | Install rear bumper | ||
23 | Install paneling in trunk | ||
24 | Install rear door sill molding |
Check values for gaps
Number | Designation | Model 221 | |||
BE60.00-P-1002-01R | Gap dimension | Front door to A-pillar | Dimension "D" | mm | 4.5 (0.5) |
Front door to fender | Dimension "E" | mm | 4 (0.5) | ||
Front door to rear door | Dimension "F" | mm | 4.5 (0.5) | ||
Trim strip at front door to roof frame | Dimension "G" | mm | 4.5 (0.5) | ||
Trim strip at rear door to roof frame | Dimension "H" | mm | 4.5 (0.5) | ||
Rear door to side piece, bottom | Dimension "I" | mm | 4.5 (0.5) | ||
Front door cover to rear door cover | Dimension "S" | mm | 4.5 (0.5) | ||
See picture | |||||
BE60.00-P-1003-01R | Gap dimension | Trunk lid to rear fender, top | Dimension "J" | mm | 4 (0.5) |
Trunk lid to rear lamp unit | Dimension "K" | mm | 4 (0.5) | ||
Trunk lid to bumper | Dimension "L" | mm | 5.5 (1.5) | ||
Rear fender to lamp unit | Dimension "M" | mm | 2.5 (0.5) | ||
Trunk lid license plate panel to rear lamp unit | Dimension "N" | mm | 4 (0.5) | ||
See picture | |||||
BE60.00-P-1004-01R | Gap dimension | Fuel filler flap | Dimension "O" | mm | 3.5 (0.5) |
See picture | |||||
129 589 03 21 00
Spot weld milling cutter
Feeler gauge
Bending iron
Spot weld milling cutter
129 589 00 27 00
201 589 00 51 00
215 589 00 51 00
129 589 01 98 00
Welding bead catcher
Set of cutting templates
221 589 03 23 00
Repair materials
Number | Designation | Order number |
BR00.45-Z-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 20 |
BR00.45-Z-1003-01A | White sealing compound, 310 ml, DBL 6069.20 | A 001 989 63 20 |
BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |
BR00.45-Z-1003-05A | Cavity sealant, 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-1002-13A | Polygrip countersunk-head rivet, 6.414 | A 003 990 86 97 05 |
BR00.45-Z-1001-13A | Blind rivet 6.414 | A 003 990 35 97 |
Referenced documents
- ah0000n000501a Measures for preventing damage to vehicles or components when performing electric welding work
- ah6000n000101a General information on body repair
- ah6000p000301n General information on riveting
- ah6000p000801sx Pretreatment of bonding surfaces
- ah6000p001101sx Notes on different body materials
- ah6000p001201n General information on dent removal and straightening aluminum parts
- ah6000p001501sx General notes on jointing techniques in bodywork
- ah6000p002401n General information on repair of vehicles with ultra-strength steels.
- ah9720p000101b Notes on cavity preservation
- ah9800p940802a Notes on paintwork repairs
- ah9800p940903a General information on MB materials
- ar6000p070001sx Gap dimensions on hoods, doors and lids
- ar6350p140002sx Separate rear fender
- ar6350p140003sx Prepare new rear fender part
- ar6350p140004sx Install rear fender
- ar6720p2000sx Remove/install rear window
- ar6720p2000sxs Remove/install rear window
- ar6830p4100sx Remove/install door sill
- ar6830p4100sxs Remove/install door sill molding
- ar6830p4300sx Remove/install headliner
- ar6830p4300sxs Remove/install headliner
- ar6830p4600sx Remove paneling in trunk
- ar6830p4600sxs Remove/install paneling in trunk
- ar8210p4905sx Remove/install taillamp
- ar8820p2200sx Remove/install rear bumper
- ar8820p2200sxs Remove/install rear bumper
- ar9710p4000sx Seam sealing following repair
- ar9720p1500sx Cavity preservation following repair work
- as0000z000701a 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
- as0000z001001a Risk of death caused by vehicle slipping or toppling off of the lifting platform.
- as0000z001501a Risk of explosion from pressurized spray cans
- as0000z001601a Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes
- as0000z001701a Risk of injury caused by scraping or cutting body parts on sharp vehicle parts
- as4700z000101a Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.
- as6000z000701n Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust
- os6000p000101n Recycle aluminum parts
- wf5850p635001y Crimping pliers for areas not easily accessible