Replace complete rear fender

AR63.50-P-1400Y

Replace complete rear fender

18.11.11



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.

AS00.00-Z-0007-01A

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 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

All models

AH00.00-N-0005-01A



General information on body repair

All models

AH60.00-N-0001-01A



Notes on paintwork repairs

Model 124, 126, 129, 140, 163, 168, 169, 170, 171, 199, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 240, 414, 463, 639

AH98.00-P-9408-02A



General information on MB materials

Model 124, 126, 129, 140, 163, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 240, 414, 463, 639

AH98.00-P-9409-03A

1

Remove rear door sill molding

AR68.30-P-4100TX

2

Remove rear wall window

AR67.20-P-2000Y

3

Remove taillamps

AR82.10-P-4905TX

4

Remove rear bumper

AR88.20-P-2200TX

5

Remove detachable parts in trunk, in area of rear fender

6.1

Install filler neck covering

When replacing right rear fender with deeper damage.

AR63.50-P-1400-01Y

 Set of covers

*211589009100

7

Cover all detachable parts remaining in vehicle

Tarp (fire-resistant)

8

Separate rear fender (1)

AR63.50-P-1400-02Y



Sheet metal crimping pliers for areas not easily accessible

WF58.50-P-6350-01Y

 Spot weld milling cutter

*201589005100

 Set of cutting templates

*219589012300

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

Drill
gotis://K_58.1_04.0

Body jig saw
gotis://K_58.1_01.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

9

Prepare new rear fender (1)

AR63.50-P-1400-03Y

 Set of cutting templates

*219589012300

Round wire brush, braided, dia. 70 mm

Drill
gotis://K_58.1_04.0

Body jig saw
gotis://K_58.1_01.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

10

Install rear fender (1) and weld in

AR63.50-P-1400-04Y



General information on riveting

Model 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639, 903

AH60.00-P-0003-01N

Rear door to side piece, bottom

*BE60.00-P-1002-01O

Trunk lid to rear fender, top

*BE60.00-P-1003-01O

Trunk lid to rear lamp unit

*BE60.00-P-1003-01O

Rear fender to lamp unit

*BE60.00-P-1003-01O

Fuel filler flap

*BE60.00-P-1004-01O

 Feeler gauge

*129589032100

 Bending iron

*129589002700

Electrode miller

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
gotis://K_68-80_06.0

MIG MAG gas welder (steel, brazing, aluminum)
gotis://K_60-65_17.1

Inverter spot welder
gotis://K_60-65_16.0

Drill
gotis://K_58.1_04.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Polygrip flat round head rivet, 6.414

*BR00.45-Z-1001-13A

Sealant

*BR00.45-Z-1003-01A

11

Adjust gap dimensions on hoods, doors and lids

AR60.00-P-0700-01Y

Feeler gauge

*129589032100

Rear door to side piece, bottom

*BE60.00-P-1002-01O

Trunk lid to rear fender, top

*BE60.00-P-1003-01O

Trunk lid to rear lamp unit

*BE60.00-P-1003-01O

Rear fender to lamp unit

*BE60.00-P-1003-01O

Fuel filler flap

*BE60.00-P-1004-01O

12

Remove covers for filler neck

When replacing right rear fender with deeper damage.

AR63.50-P-1400-01Y

 Set of covers

*211589009100

13

Clean weld joints and sheet metal flange with round wire brush

Round wire brush, braided, dia. 70 mm

Drill
gotis://K_58.1_04.0

14

Clean repair areas

15

Prime repair area using primer filler

16

Carry out seam sealing after repairs

 Supplement standard sealants with MB body sealant.

AR97.10-P-4000Y

Sealant

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

17

Paint repair areas and adjacent surfaces

18

Apply additional cavity preservation

AR97.20-P-1500Y



Notes on cavity preservation

Model 124, 126, 129, 140, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 240, 463, 639, 671, 690.6, 901, 902, 903, 904, 905

Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7

AH97.20-P-0001-01B

Combination pressure spray gun (corrosion protection)
gotis://K_91-97_01.0

MB cavity wax preservation, 1 l

*BR00.45-Z-1003-05A

19

Remove tarp

 On all covered parts remaining in vehicle.

20

Install detachable parts in luggage compartment, in area of rear fender

21

Install rear wall window

AR67.20-P-2000Y

22

Install taillamps

AR82.10-P-4905TX

23

Install rear bumper

AR88.20-P-2200TX

24

Install rear door sill molding

AR68.30-P-4100TX

Number

Designation

Model
219

BE60.00-P-1002-01O

Gap dimension

Fender to A-pillar

Dim. "D"

mm

3.0 (1)

Front door to fender

Dim. "E"

mm

4.0 (-0.5/+1)

Front door to rear door

Dim. "F"

mm

5.0 (-1/+0.5)

B-pillar cover to front window

Dim. "G"

mm

10 (1)

B-pillar cover to rear window

Dim. "H"

mm

10 (1)

Rear door to side piece, bottom

Dim. "I"

mm

3.5 (-0.5/+1)

See picture

AR60.00-P-0700-01Y

BE60.00-P-1003-01O

Gap dimension

Trunk lid to rear fender, top

Dim. "J"

mm

4.0 (0.5)

Trunk lid to rear lamp unit

Dim. "K"

mm

2.5 (0.5)

Trunk lid to bumper

Dim. "L"

mm

7.0 (1)

Rear fender to lamp unit

Dim. "M"

mm

2.5 (0.5)

See picture

AR60.00-P-0700-01Y

BE60.00-P-1004-01O

Gap dimension

Fuel filler flap

Dim. "N"

mm

3.5 (0.5)

See picture

AR60.00-P-0700-01Y

Number

Designation

Order number

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 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 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-1001-13A

Blind rivet 6.414

A 003 990 35 97