Partially remove/install rear fender

AR63.50-P-1450ES

Partially remove/install rear fender

09.03.2020

Model

212.2

1

Fender

 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

Topical note

General information on body repair

AH60.00-N-0001-01A

Topical note

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

General information on MB materials

AH98.00-P-9409-03A



Remove

1

Remove detachable parts in area to be repaired

2

Cover all detachable parts remaining on vehicle with spark protection blanket

 When replacing the right fender (1), the standard tank cap must be installed and the filler neck covered with a welding protection blanket.

3

Partially remove fender (1)

AR63.50-P-1450-01ELX

 Commercially available devices/tools
Round wire brush
Body jig saw
Spot weld milling machine
Glass removal
Wet and dry vacuum cleaner

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Primer stick

*BR00.45-Z-1012-07A

4

Prepare fender (1)

AR63.50-P-1450-02ELX

 Commercially available devices/tools
Round wire brush
Body jig saw
Spot weld milling machine

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

 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

 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

Topical note

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

AH60.00-P-0001-02A

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

AH60.00-P-0033-01RQ

General information on riveting

AH60.00-P-0003-01N

5

Partially install fender (1)

AR63.50-P-1450-03ELX



000 588 02 84 00 Welder

WS60.00-P-0022K

 Commercially available devices/tools
Blind rivet tool
Round wire brush
Manual temporary fastener 6.35 mm
Spot welder
Wet and dry vacuum cleaner

Gap dimension

*BE60.00-P-1002-01U

Gap dimension

*BE60.00-P-1003-01U

Gap dimension

*BE60.00-P-1004-01U

Gap dimension

*BE60.00-P-1005-01U

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Blind rivet with polygrip countersunk head 6.414 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)

*BR00.45-Z-1002-13A

 Feeler gauge

*129589032100

 Bending pliers

*202589003700

For measuring points of gap dimensions on body see:



Gap dimensions on hoods, doors and lids

AR60.00-P-0700-01EW

6

Clean weld joints and sheet metal flange with round wire brush

 Commercially available devices/tools
Round wire brush

7

Remove spark protection blankets

8

Clean repair area

 Commercially available devices/tools
Wet and dry vacuum cleaner

 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

9

Prime repair area using primer filler

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

 Use only primer filler approved by Daimler AG:
http://aftersales.mercedes-benz.com

10

Seal seam following repairs

AR97.10-P-4000EW

 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

Paint repair areas and adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

 Use only paints approved by Daimler AG:
http://aftersales.mercedes-benz.com

 Danger

Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents

Never spray corrosion protection on flames or hot, glowing objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection.

AS97.00-Z-0001-01A

12

Add cavity preserving agent

Topical note

Notes on cavity preservation

AH97.20-P-0001-01B

Cavity preservation (free of solvents), 1 liter

*BR00.45-Z-1003-05A

13

Install all detachable body components in area to be repaired

Check values for gap dimensions

Number

Designation

Model 212.2

BE60.00-P-1002-01U

Gap dimension

Front door to fender

Dimension "G"

mm

4 (+1/-0,5)

Front door to rear door

Dimension "H"

mm

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

Front door to roof frame

Dimension "I"

mm

14 (1,5)

Rear door to roof frame

Dimension "J"

mm

13 (1,5)

Rear door to side piece, bottom

Dimension "K"

mm

4 (+1/-0,5)

Driver door cover to rear door cover

Dimension "W"

mm

4 (1)

Picture

AR60.00-P-0700-01EW

Check values for gap dimensions

Number

Designation

Model 212.2

BE60.00-P-1003-01U

Gap dimension

Trunk lid to rear fender, top

Dimension "L"

mm

–

Trunk lid to taillamp

Dimension "M"

mm

–

Trunk lid to bumper

Dimension "N"

mm

–

Rear fender to taillamp

Dimension "O"

mm

2 (+1,5/-1)

Taillamp to bumper

Dimension "P"

mm

2 (1)

Trunk lid taillamp to taillamp

Dimension "M1"

mm

–

Picture

AR60.00-P-0700-01EW

Check values for gap dimensions

Number

Designation

Model 212.2

BE60.00-P-1004-01U

Gap dimension

Fuel filler flap (circumference)

Dimension "Q"

mm

3 (+1/-0,5)

Picture

AR60.00-P-0700-01EW

Check values for gap dimensions

Number

Designation

Model 212.2

BE60.00-P-1005-01U

Gap dimension

Liftgate to roof

Dimension "R"

mm

–

Liftgate to roof (spoiler removed)

Dimension "R1"

mm

9,5 (1,5)

Spoiler to roof

Dimension "R2"

mm

5 (1,5)

Liftgate to rear fender

Dimension "S"

mm

4 (+1,5/-1)

Liftgate to taillamp

Dimension "T"

mm

–

Liftgate to bumper

Dimension "U"

mm

6 (1,5)

Liftgate to D-pillar

Dimension "V"

mm

–

Rear window and D-pillar

Dimension "X"

mm

–

Top sliding roof to roof

Dimension "Y"

mm

5 (1,5)

Rear window to liftgate, bottom

Dimension "Z"

mm

3 (1,5)

Picture

-

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-1002-13A

Blind rivet with polygrip countersunk head 6.414 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)

A 003 990 86 97 05

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1003-05A

Cavity preservation (free of solvents), 1 liter

A 000 986 72 70 10

BR00.45-Z-1012-07A

Primer stick

A 000 986 27 50

BR00.45-Z-1092-02A

Adhesive kit, body, 2-component adhesive

A 012 989 17 71