Replace complete rear fender

AR63.50-P-1400AK

Replace complete rear fender

22.12.10



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 columns of vehicle lift and position four support plates at vehicle lift support points specified by 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



General information on body repair

AH60.00-N-0001-01A



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

AH60.00-P-0001-02A



General information on riveting

AH60.00-P-0003-01N

1

Remove all detachable parts in repair area.

2

Cover all detachable parts remaining in vehicle

Welding protective blanket

gotis://K_60-65_23.0

3

Separate rear fender (1)

AR63.50-P-1400-02AK

 Set of cutting templates

*169589042300

Round wire brush

gotis://K_58.3_06.0

Weld-spot milling machine

gotis://K_58.1_02.0

Hot-air gun

gotis://K_60-65_11.0

Body jig saw

gotis://K_58.1_01.0

Beading pliers

gotis://K_58.3_04.1

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

4

Prepare new rear fender (1)

AR63.50-P-1400-03AK

Round wire brush

gotis://K_58.3_06.0

Body jig saw

gotis://K_58.1_01.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

5

Install protective cover for water drain hose

 with Code 417 Lamella roof.

Position C-pillar on water drain hose protective tube in welding area

Protective tube

*BR00.45-Z-1003-15A

6

Install rear fender (1)

AR63.50-P-1400-04AK

 Bending iron

*129589002700

 Feeler gauge

*129589032100

Round wire brush

gotis://K_58.3_06.0

Hand riveting tool (for blind pop rivets)

gotis://K_68-80_06.0

Multifunction device (spot welding)

gotis://K_60-65_15.0

Inert gas welder

gotis://K_60-65_17.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

Rear door to rear fender

*BE60.00-P-1003-01N

Rear fender taillamp

*BE60.00-P-1003-01N

Rear fender to rear-end door

*BE60.00-P-1003-01N

Front fuel filler flap

*BE60.00-P-1004-01N

Rear fuel filler flap

*BE60.00-P-1004-01N

Rear-end door to taillamp

*BE60.00-P-1005-01N

Rear-end door to roof

*BE60.00-P-1005-01N

Sealant

*BR00.45-Z-1003-01A

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

7

Adjust gaps on hoods, doors and lids

AR60.00-P-0700-01AK

Feeler gauge

*129589032100

Rear door to rear fender

*BE60.00-P-1003-01N

Rear fender taillamp

*BE60.00-P-1003-01N

Rear fender to rear-end door

*BE60.00-P-1003-01N

Front fuel filler flap

*BE60.00-P-1004-01N

Rear fuel filler flap

*BE60.00-P-1004-01N

Rear-end door to taillamp

*BE60.00-P-1005-01N

Rear-end door to roof

*BE60.00-P-1005-01N

8

Clean weld joints and sheet metal flanges with rotary wire brush

Round wire brush

gotis://K_58.3_06.0

9

Remove welding protection blankets

10

Clean repair area

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

11

Prime repair area with primer filler

 Only use approved primer filler from

Daimler AG. Refer to:



http://portal.aftersales.i.daimler.com

12

Carry out seam sealing after repairs

 Supplement standard seam seal.

AR97.10-P-4000AK

13

Paint repair area adjacent surfaces

 Use only paints approved by Daimler AG. Refer to:



http://portal.aftersales.i.daimler.com

14

Apply additional cavity preservation

AR97.20-P-1500AK

15

Install all removed detachable parts

Number

Designation

Type
169.0

BE60.00-P-1003-01N

Gap dimension

Rear door to side roof paneling

Dimension "L"

mm

6.5 (1)

Rear door to rear fender

Dimension "M"

mm

4.0 (1)

Rear door to rear side window

Dimension "N"

mm

6.5 (-0.5/+1)

Rear fender to taillamp

Dimension "O"

mm

2.5 (0.5)

Rear fender to rear-end door

Dimension "P"

mm

4.0 (1)

See picture

AR60.00-P-0700-01AK

BE60.00-P-1004-01N

Gap dimension

Front fuel filler flap

Dimension "Q"

mm

4.5 (0.5)

Rear fuel filler flap

Dimension "R"

mm

4.0 (0.5)

See picture

AR60.00-P-0700-01AK

BE60.00-P-1005-01N

Gap dimension

Bumper to taillamp

Dimension "S"

mm

2.5 (1)

Rear-end door to taillamp

Dimension "T"

mm

4.0(1.5)

Rear-end door to bumper

Dimension "U"

mm

5.0 (2)

Rear-end door to roof

Dimension "V"

mm

4.5 (1)

See picture

AR60.00-P-0700-01AK

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-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

BR00.45-Z-1003-15A

Protective tube

A 169 611 01 46