Replace complete rear fender

AR63.50-P-1400QA

Replace complete rear fender

27.7.10



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 spatter 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 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



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

AH00.00-N-0005-01A



General information on repairs to body

AH60.00-N-0001-01A



Guidelines for removing fuel tank when performing welding work on bodies

AH60.00-P-3000-01Z



Notes on paintwork repairs

AH98.00-P-9408-02A



General information on MB materials

AH98.00-P-9409-03A

1

Prepare required workshop equipment and commercially available tools for repair

2

Remove all detachable body components in area to be repaired.

3

Cover all detachable parts remaining vehicle with fireproof tarpaulin

4

Install cover for filler fitting

 When replacing right rear fender with deeper damage.

AR63.50-P-1400-01QA

 Latches

*203589009100

 Cover panel

*209589009100

5

Separate rear fender

AR63.50-P-1400-02QA

 Spot weld milling cutter

*201589005100

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

Hand drill (with chuck up to 16 mm dia.)

gotis://G_58.0_00.1

Straight grinder

gotis://K_58.1_08.0

Angle grinder up to 125 mm

gotis://G_58.0_06.0

Keyhole saw

gotis://K_58.1_01.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

6

Prepare new rear fender part

AR63.50-P-1400-03QA

Round wire brush

gotis://K_58.3_06.0

Hand drill (with chuck up to 16 mm dia.)

gotis://G_58.0_00.1

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

7

Install standard tank cap and tank flap, mask gap

 When replacing right rear fender.

8

Install rear fender and weld in

AR63.50-P-1400-04QA



General information on riveting

AH60.00-P-0003-01N

 Spacer

*000589876300

 Feeler gauge

*129589032100

Round wire brush

gotis://K_58.3_06.0

Vice grip pliers (standard)

gotis://K_58.3_04.2

Vice grip pliers (special, small)

gotis://K_58.3_04.3

Manual temporary fastener

gotis://K_58.3_10.0

Hand riveting tool (for blind pop rivets)

gotis://K_68-80_06.0

Inert gas welder

gotis://K_60-65_17.0

Multifunction device (spot welding)

gotis://K_60-65_15.0

Hand drill (with chuck up to 16 mm dia.)

gotis://G_58.0_00.1

Angle grinder up to 125 mm

gotis://G_58.0_06.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

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

Front door to rear fender

*BE60.00-P-1002-01G

Rear fender and taillamp

*BE60.00-P-1003-01G

Trunk lid to rear fender, top

*BE60.00-P-1003-01G

Trunk lid to rear lamp unit

*BE60.00-P-1003-01G

Trunk lid license plate panel to rear lamp unit

*BE60.00-P-1003-01G

Fuel filler flap

*BE60.00-P-1004-01G

Soft top to soft top compartment cover

*BE60.00-P-1006-01G

Soft top compartment cover/
rear fender

*BE60.00-P-1007-01G

Sealant

*BR00.45-Z-1003-01A

Preservation agent

*BR00.45-Z-1003-05A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Rivet

*BR00.45-Z-1001-13A

9

Adjust gap dimensions on hoods, doors and lids

AR60.00-P-0700-01QA

 Feeler gauge

*129589032100

Front door to rear fender

*BE60.00-P-1002-01G

Rear fender and taillamp

*BE60.00-P-1003-01G

Trunk lid to rear fender, top

*BE60.00-P-1003-01G

Trunk lid to rear lamp unit

*BE60.00-P-1003-01G

Trunk lid license plate panel to rear lamp unit

*BE60.00-P-1003-01G

Fuel filler flap

*BE60.00-P-1004-01G

Soft top to soft top compartment cover

*BE60.00-P-1006-01G

Soft top compartment cover/
rear fender

*BE60.00-P-1007-01G

10

Shape body flange for taillamp with embossing tool

AR63.50-P-1400-09CW

 Embossing tool

*164589003900

11

Clean weld joints and sheet metal flange with round wire brush

12

Clean repair areas

13

Prime area to be repaired using primer filler

14

Carry out seam sealing after repairs

 Supplement standard sealant with sealant.

AR97.10-P-4000Q

Sealant

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

15

Paint repair areas and adjacent surfaces

16

Apply additional cavity preservation

AR97.20-P-1500QA



Notes on cavity preservation

AH97.20-P-0001-01B

Preservation agent

*BR00.45-Z-1003-05A

17

Install cover for filler neck

 When replacing right rear fender with deeper damage.

AR63.50-P-1400-01QA

18

Remove tarp

 On all covered parts remaining in vehicle.

19

Install all detachable body components in area to be repaired.

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 rear 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

BE60.00-P-1006-01G

Gap dimension

Soft top to windshield frame

Dimension "M"

mm

10 (2)

Soft top to soft top compartment cover

Dimension "N"

mm

3 (0.5)

See picture

AR60.00-P-0700-01QA

BE60.00-P-1007-01G

Gap dimension

Soft top compartment cover/
rear fender

Dimension "O"

mm

3 (0.5)

Soft top compartment cover to trunk lid

Dimension "P"

mm

4.5 (1)

See picture

AR60.00-P-0700-01QA

Number

Designation

Order number

BR00.45-Z-1003-01A

Sealant, white, 310 ml, DB supply specification 6069.20

A 001 989 63 20

BR00.45-Z-1041-01A

Seam sealant, sprayable 310 ml

A 002 989 84 20

BR00.45-Z-1003-05A

Cavity preservation, 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