Replace complete rear fender front section

AR63.50-P-1460E

Replace complete rear fender front section

10.9.97



Remove

Danger!

Risk of explosion if ignition takes place, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to 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



General information on body repair

All models

AH60.00-N-0001-01A



Notes on rear fender repair

Model 202

AH63.50-P-1400-01E

1.1

Remove fuel tank

When cut is located in area of side longitudinal member

2

Remove rear seat and rear backrest

AR91.12-P-1700E

3

Remove detachable body components in area to be repaired

4

Cover all attached parts remaining in vehicle

 In area to be repaired

5

Separate rear fender front section

AR63.50-P-1460-01E

Spot weld cutter

*201589005100

6

Prepare new rear fender front section

AR63.50-P-1460-02E



Install

 Danger!

Risk of death caused by high voltage used for arc welding. Risk of explosion caused by welding in the area of high combustible materials. Risk of injury caused by welding spatter and UV-light while welding. Risk of poisoning caused by inhaling welding vapors.

Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor.

AS00.00-Z-0007-01A



Measures for preventing damage to vehicles or components when performing arc welding work

All models

AH00.00-N-0005-01A

7

Install and weld in rear fender front section

 Before welding sheet metal part check gaps and adjust. Refer to

AR63.50-P-1460-03E

Gap dimensions at hoods, doors and covers

Model 202.01/02/033/12/13

AR60.00-P-0700-01E

Gap dimensions at hoods, doors and covers

Model 202.07/08/093/18/19

AR60.00-P-0700-01EA

Gap dimensions

*BE60.00-P-1002-01A

 Feeler gage

*129589032100

8

Clean areas to be repaired and prime with MB 2-component primer/filler

9

Supplement standard sealing with MB body sealant

 Seam sealing after repair work

AR97.10-P-4000E

10

Supplement standard underfloor protection with MB permanent underfloor protection agent

 Permanent underbody protection

AR97.20-P-0500A

11

Paint rear fender and adjoining surfaces

12

Apply additional cavity preservation

13

Install detachable body components removed

Number

Designation

Model 202.01/02/033/
12/13

BE60.00-P-1002-01A

Gap dimension

Front door to A-pillar

Dimension "B"

mm

6.0 (+1)

Front door to fender

Dimension "H"

mm

5.0 (+1)

Front door to rear door

Dimension "I"

mm

6.0 (+1)

Front door to roof

Dimension "C"

mm

6.0 (+1)

Rear door to upper side section

Dimension "D"

mm

6.0 (+1)

Rear door to lower side section

Dimension "J"

mm

5.0 (0.5)

Fender to A-pillar

Dimension "Q"

mm

-

Front door to rear fender

Dimension "P"

mm

-

Fig., see

AR60.00-P-0700-01E

Number

Designation

WH58.30-Z-1002-01A

Ball cutter, dia. 12 mm

WH58.30-Z-1003-01A

Electrode miller

WH58.30-Z-1006-01A

Vario Drill WS 91 spot weld removing tool

WH58.30-Z-1001-03A

Round wire brush, braided, dia. 70 mm

WH58.30-Z-1021-04A

Cutting disk, dia. 65 mm, 80 m/s (max. 23,500 rpm)

WH58.30-Z-1024-04A

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

WE58.40-Z-1001-02A

Inert gas welder

WE58.40-Z-1002-02A

Spot welder

WE58.40-Z-1001-03A

Drill (electric/pneumatic)

WE58.40-Z-1002-03A

Straight grinder (electric/pneumatic)

WE58.40-Z-1003-03A

Angle grinder (electric/pneumatic)

WE58.40-Z-1004-03A

Body saw (electric/pneumatic)