Replace complete wheel well liner assembly at rear

AR63.10-P-0661QA

Replace complete wheel well liner assembly at rear

18.11.11



Removing

 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 death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 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 explosion as fuel vapors can ignite. Risk of poisoning from inhaling fuel vapors and exposed handling of fuel. Risk of injury if fuel splashes hit the eyes.

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

 Danger!

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



General information on body repair

All models

AH60.00-N-0001-01A



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

All models

AH00.00-N-0005-01A



Notes on paintwork repairs

All models

AH98.00-P-9408-02A



General information on MB materials

All models

AH98.00-P-9409-03A

1

Remove detachable parts in area to be repaired

2

Cover all detachable body components remaining in vehicle (area to be repaired)

Tarp (fire-resistant)

3

Equip Celette or Car-Bench straightening bench with modular members or crossmembers and straightening set

Observe set-up plans enclosed!

Passenger car straightening system (Celette)

gotis://K_60-65_02.0

Accessories for straightening systems (Celette)

gotis://K_60-65_04.1

Straightening systems for passenger cars (Car Bench)

gotis://K_60-65_03.0

Straightening system accessories (Car Bench)

gotis://K_60-65_04.2

4

Set vehicle onto straightening bench using two-post lift and fasten

Two-post lifting platform 3.0-3.5 t, electromechanical
gotis://H_00.1_01.0

5

Set up rear portal frame with welding devices

Observe set-up plans enclosed!

 Portal frame

*129589032300

 Multi-Z element MZ 260

*140589262300

 When mounting rear portal frame, use additional set of Multi-Z elements MZ 260.

 Welding devices

*209589052300

6

Remove rear fender

AR63.50-P-1400QA

7

Cut away rear wheel well liner assembly

AR63.10-P-0661-01QA

 Welding spot miller cutter

*201589005100

Ball cutter, dia. 12 mm

Round wire brush, braided, dia. 70 mm

Vario Drill WS 91 spot weld removing tool

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

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

Drill
gotis://K_58.1_04.0

Straight grinder
gotis://K_58.0_03.0

Angle grinder
gotis://K_58.1_07.0

Body jig saw
gotis://K_58.1_01.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

8

Prepare complete rear wheel well liner assembly for installation

AR63.10-P-0661-02QA

Round wire brush, braided, dia. 70 mm

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

Drill
gotis://K_58.1_04.0

Angle grinder
gotis://K_58.1_07.0

Body jig saw
gotis://K_58.1_01.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

9

Fit rear fender

10

Adjust gap dimensions on hoods, doors and covers

AR60.00-P-0700-01QA

Rear fender to lamp unit

*BE60.00-P-1003-01G

Trunk lid to rear fender, top

*BE60.00-P-1003-01G

Trunk lid license plate panel to rear lamp unit

*BE60.00-P-1003-01G

Front door to rear fender

*BE60.00-P-1002-01G

Fuel filler flap

*BE60.00-P-1004-01G

 Feeler gauge

*129589032100

11

Install wheel well liner assembly at rear and weld in

AR63.10-P-0661-03QA



General information on riveting

AH60.00-P-0003-01N

 Portal frame

*129589032300

 Welding devices

*209589052300

Round wire brush, braided, dia. 70 mm

Electrode miller

Clamping pliers

MIG MAG gas welder (steel, brazing, aluminum)
gotis://K_60-65_17.1

Drill
gotis://K_58.1_04.0

Blind rivet/punch riveting method
gotis://K_68-80_06.0

Manual temporary fastener, dia. 6.4 mm - clamping range 0 - 15 mm, identification color silver

Hand riveter

Polygrip flat/round head rivet, 6.414

*BR00.45-Z-1001-13A

Inverter spot welder
gotis://K_60-65_16.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

12

Clean weld joints and metal flanges with wire brush

13

Install rear fender

AR63.50-P-1400QA

14

Release vehicle from straightening bench and lift with two-column lift, remove straightening bench

Two-post lifting platform 3.0-3.5 t, electromechanical
gotis://H_00.1_01.0

15

Clean repair areas and prime using primer filler

16

Seam sealing following repair

 Supplement standard sealants with MB body sealant.

Sealant

*BR00.45-Z-1003-01A

17

Paint repair areas and adjacent surfaces

18

Cavity preservation following repair work



Notes on cavity preservation

Model 209

AH97.20-P-0001-01B

19

Install all removed assembly parts

Number

Designation

Model
209.4

BE60.00-P-1002-01G

Gap dimension

Front door to A-pillar

Dimension "D"

mm

1

Front door to fender

Dimension "E"

mm

3.5 (-0.5/+1)

Front door to rear fender

Dimension "F"

mm

3.5 (-0.5/+1)

See picture

AR60.00-P-0700-01QA

BE60.00-P-1003-01G

Gap dimension

Trunk lid to rear fender, top

Dimension "G"

mm

3.5 (1)

Trunk lid to rear lamp unit

Dimension "H"

mm

3.5 (0.5/+1)

Trunk lid to bumper

Dimension "I"

mm

6.5 (+1)

Rear fender to lamp unit

Dimension "J"

mm

3 (1)

Trunk lid license plate panel to rear lamp unit

Dimension "K"

mm

2.5 (0.5)

See picture

AR60.00-P-0700-01QA

BE60.00-P-1004-01G

Gap dimension

Fuel filler flap

Dimension "L"

mm

3.2 (+0.5)

See picture

AR60.00-P-0700-01QA

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-1003-05A

Cavity sealant, solvent-free (1 l container)

A 000 986 72 70 05

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