Replace complete rear fender

AR63.50-P-1400V

Replace complete rear fender

22.11.2019

Model

171, 172

Modification notes

02.05.2011

Value changed: Gap dimension, dimension "T"

BE60.00-P-1005-01Y

Shown on model 171

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

 Danger

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.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

Topical note

General information on body repair

Typ 171, 172

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

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

1

Remove all detachable parts in area to be repaired

2

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

 When replacing right rear fender (1), the tank lock must be installed and the filler neck must be covered by a welding protection blanket (fire-resistant).

 Protective cover

*129589009800

3

Separate rear fender (1)

AR63.50-P-1400-02V

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

4

Prepare new rear fender (1)

AR63.50-P-1400-03V

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

5

Install rear fender (1)

AR63.50-P-1400-04V

General information on riveting

AH60.00-P-0003-01N

Model 171Gap dimension

*BE60.00-P-1002-01L

Model 171Gap dimension

*BE60.00-P-1003-01L

Model 171Gap dimension

*BE60.00-P-1004-01L

Model 171Gap dimension

*BE60.00-P-1005-01L

Model 172Gap dimension

*BE60.00-P-1002-01Y

Model 172Gap dimension

*BE60.00-P-1003-01Y

Model 172Gap dimension

*BE60.00-P-1004-01Y

Model 172Gap dimension

*BE60.00-P-1005-01Y

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

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

*BR00.45-Z-1012-13A

 Spacers

*000589876300

 Bending pliers

*202589003700

 Feeler gauge

*129589032100

6

Adjust gap dimensions on hoods, doors and lids

AR60.00-P-0700-01V

Model 171Gap dimension

*BE60.00-P-1002-01L

Model 171Gap dimension

*BE60.00-P-1003-01L

Model 171Gap dimension

*BE60.00-P-1004-01L

Model 171Gap dimension

*BE60.00-P-1005-01L

Model 172Gap dimension

*BE60.00-P-1002-01Y

Model 172Gap dimension

*BE60.00-P-1003-01Y

Model 172Gap dimension

*BE60.00-P-1004-01Y

Model 172Gap dimension

*BE60.00-P-1005-01Y

 Feeler gauge

*129589032100

7

Clean weld joints and metal flanges with wire brush

8

Remove welding protection blankets and protective cover

9

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

10

Prime repair area using primer filler

 Use only primer filler approved by Daimler AG.

Refer to:



https://xentryportal.i.daimler.com

11

Seal seam following repairs

Model 171

AR97.10-P-4000V

Model 172

AR97.10-P-4000W

 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

12

Paint repair areas and adjacent surfaces

 Use only paints approved by Daimler AG.

Refer to:



https://xentryportal.i.daimler.com

13

Add cavity preserving agent

Model 171

AR97.20-P-1500V

Model 172

AR97.20-P-1500W

14

Install all detachable body components in area to be repaired

Test and adjustment values for gap dimensions

Number

Designation

Model 171

BE60.00-P-1002-01L

Gap dimension

Front door to fender

Dimension "H"

mm

3,0 (+0,8)

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)

Picture

AR60.00-P-0700-01V

Test and adjustment values for gap dimensions

Number

Designation

Model 172

BE60.00-P-1002-01Y

Gap dimension

Front door to fender

Dimension "H"

mm

4,5 (+1/-0,5)

Fender to A-pillar

Dimension "Q"

mm

3,5 (1,5)

Front door to rear fender

Dimension "P"

mm

4,0 (1)

Picture

AR60.00-P-0700-01V

Test and adjustment values for gap dimensions

Number

Designation

Model 171

BE60.00-P-1003-01L

Gap dimension

Trunk lid to rear fender

Dimension "F"

mm

3,5 (+1,5)

Trunk lid to taillamp

Dimension "M"

mm

4,0 (+1,6/-0,5)

Trunk lid to bumper

Dimension "V"

mm

5,0 (+1,5/-1,0)

Rear fender to taillamp

Dimension "U"

mm

2,5 (0,5)

Trunk lid tip to rear fender

Dimension "E"

mm

5,0 (+1,5)

Picture

AR60.00-P-0700-01V

Test and adjustment values for gap dimensions

Number

Designation

Model 172

BE60.00-P-1003-01Y

Gap dimension

Trunk lid to rear fender

Dimension "F"

mm

4,5 (1)

Trunk lid to taillamp

Dimension "M"

mm

4,5 (+1,5/-0,5)

Trunk lid to bumper

Dimension "V"

mm

6,0 (1,5)

Rear fender to taillamp

Dimension "U"

mm

1,5 (1)

Trunk lid tip to rear fender

Dimension "E"

mm

6,5 (+1/-0,5)

Picture

AR60.00-P-0700-01V

Test and adjustment values for gap dimensions

Number

Designation

Model 171

BE60.00-P-1004-01L

Gap dimension

Fuel filler flap

Dimension "K"

mm

3,0 (0,5)

Picture

AR60.00-P-0700-01V

Test and adjustment values for gap dimensions

Number

Designation

Model 172

BE60.00-P-1004-01Y

Gap dimension

Fuel filler flap

Dimension "K"

mm

3,0 (+1,5/-0,5)

Picture

AR60.00-P-0700-01V

Test and adjustment values for gap dimensions

Number

Designation

Model 171

BE60.00-P-1005-01L

Gap dimension

Roof to windshield frame

Dimension "S"

mm

5,0 (+1,0)

Roof to rear window frame

Dimension "T"

mm

5,0 (0,5)

Picture

AR60.00-P-0700-01V

Test and adjustment values for gap dimensions

Number

Designation

Model 172

BE60.00-P-1005-01Y

Gap dimension

Roof to windshield frame

Dimension "S"

mm

7,0 (+1,0)

Roof to rear window frame

Dimension "T"

mm

5,0 (1,0)

Picture

AR60.00-P-0700-01V

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42

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-1092-02A

Adhesive kit, body, 2-component adhesive

A 012 989 17 71