Replace complete rear fender

AR63.50-P-1400BK

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-1400-02BK

 Cutting template

*245589012300

 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-1400-03BK

 Cutting template

*245589012300

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

AR63.50-P-1400-08AK

Protective tube

*BR00.45-Z-1003-15A

6

Install rear fender (1)

AR63.50-P-1400-04BK

 Feeler gauge

*129589032100

 Bending iron

*129589002700

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 side roof paneling

*BE60.00-P-1003-01Q

Rear door to rear fender

*BE60.00-P-1003-01Q

Rear fender taillamp

*BE60.00-P-1003-01Q

Rear fender to rear-end door

*BE60.00-P-1003-01Q

Fuel filler flap

*BE60.00-P-1004-01Q

Rear-end door to taillamp

*BE60.00-P-1005-01Q

Rear-end door to roof

*BE60.00-P-1005-01Q

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-0700-01BK

Feeler gauge

*129589032100

Rear door to rear fender

*BE60.00-P-1003-01Q

Rear fender taillamp

*BE60.00-P-1003-01Q

Rear fender to rear-end door

*BE60.00-P-1003-01Q

Fuel filler flap

*BE60.00-P-1004-01Q

Rear-end door to taillamp

*BE60.00-P-1005-01Q

Rear-end door to roof

*BE60.00-P-1005-01Q

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-4000BK

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-1500BK

15

Install all removed detachable parts

Number

Designation

Type
245.2

BE60.00-P-1003-01Q

Gap dimension

Rear door to side roof paneling

Dimension "L"

mm

6.5 (-0.5/+1)

Rear door to rear fender

Dimension "M"

mm

4.0 (1)

Rear door to rear side window

Dimension "N"

mm

6.5 (1)

Rear fender taillamp

Dimension "O"

mm

2.5 (1)

Rear fender to rear-end door

Dimension "P"

mm

4.0 (1)

See picture

AR60.00-P-0700-01BK

BE60.00-P-1004-01Q

Gap dimension

Fuel filler flap

Dimension "Q"

mm

4.0 (0.5)

See picture

AR60.00-P-0700-01BK

BE60.00-P-1005-01Q

Gap dimension

Bumper to taillamp

Dimension "R"

mm

2.5 (1)

Rear-end door to taillamp

Dimension "S"

mm

3.5 (+1)

Rear-end door to bumper

Dimension "T"

mm

5.0 (2)

Rear-end door to roof

Dimension "U"

mm

4.5 (1)

Taillamp in rear-end door to taillamp

Dimension "V"

mm

4.0(1.5)

See picture

AR60.00-P-0700-01BK

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