Install rear fender complete

AR63.50-P-1401-03RG

Install rear fender complete



000 588 02 39 00 Rivet press tool

WS60.00-P-0010B



000 588 02 84 00 Welder

WS60.00-P-0022K

Model

190.4

Gap dimensions

Number

Designation

Model 190.4

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 190.4

BE60.00-P-1009-01EA

Gap dimension, longitudinal member panel to fender/sidewall panel

Dimension "I"

mm

0,5 (0,5)

See

AR60.00-P-0700-01RG

Gap dimensions

Number

Designation

Model 190.4

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 190.4

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 190.4

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 190.4

BE60.00-P-1026-01EA

Gap dimension, sidewall panel to bumper

Dimension "Z"

mm

0 (+0,5)

See

AR60.00-P-0700-01RG

Repair materials

Number

Designation

Order number

BR00.45-Z-1006-13A

Blind rivet mounting for cable, 3.29.5 K9.5

A 004 990 35 97

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-1016-13A

Blind rivet 6.514.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)

A 004 990 17 97

BR00.45-Z-1020-13A

Rivet 4.816

N 007337 004024

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-1049-13A

Flow-form rivet structure 2.3 mm up to 3.5 mm clamping range (S18)

A 000 991 24 33

BR00.45-Z-1162-02A

Parts kit for 2-component adhesive for body

A 012 989 17 71

1

Install and fit rear fender, lock striker, door, trunk lid, rear light units, rear bumper and seals.

2

Check gap dimensions with  feeler gauge             and adjust.

3

Fix in place rear fender.

4

Remove lock striker, door, trunk lid, rear light units, rear bumper and seals.

5

Drill rivet holes in rear fender (1) with drill bit Ø 6.7 mm (areas A1, B1 and B2).

 Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

6

Drill rivet holes in rear fender (1) with drill bit Ø 6.7 mm (areas H1 and H2).

 Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

7

Remove rear fender (1).

8

Deburr rivet holes on rear fender (1) and body on both sides.

 Observe pretreatment of bonding surfaces.

9

Remove shavings using wet/dry vacuum cleaner.

10

Apply 2-component adhesive on the body and rear fender in the cross-hatched areas.

 Observe manufacturer's specification for drying and processing time of 2-component adhesive.

11

Install rear fender (1), fit and fix in place.

12

Rivet the rear fender (1) with rivet press tool and blind rivets or blind rivets (unit A2).

 Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

13

Rivet the rear fender (1) with rivet press tool and blind rivets or blind rivets (areas B3 and B4).

 Replace self-piercing rivets installed in vehicle by high-strength blind rivets according to clamping range.

14

Rivet the rear fender (1) with rivet press tool and flow form rivets or flow-form rivets (areas C1 and C2).

 Use flow form rivets structure 1.3 mm to 2.5 mm clamping range (S08) or flow form rivets structure 2.3 mm to 3.5 mm clamping range (S18).

15

Rivet the rear fender (1) with rivet press tool and rivets (area D).

 Use rivets 4.816.

16

Rivet the rear fender (1) with rivet press tool and flow form rivets or flow-form rivets (areas E1 and E2).

 Use flow form rivets structure 1.3 mm to 2.5 mm clamping range (S08) or flow form rivets structure 2.3 mm to 3.5 mm clamping range (S18).

17

Rivet the rear fender (1) with rivet press tool and blind rivet (area G).

 Blind rivet mounting for cable 3.29.5 K9.5.

18

Tack weld rear fender (1) with welder (  ) (areas F1 and F2).

 When MIG welding ( ): Prepare welds by grinding down to bare metal with stainless steel brush directly before welding.
Tack weld seams at the start and at the end ( ).

19

Weld rear fender (1) with welder (   ) (area F1).

 When MIG welding ( ): Prepare welds by grinding down to bare metal with stainless steel brush directly before welding.

20

Rivet the rear fender (1) with rivet press tool and blind rivets or blind rivets (areas H3 and H4).

 Replace self-piercing rivets installed in vehicle by high-strength blind rivets according to clamping range.