Completely replace rear fender - AR63.50-P-1400P
MODEL 203.0
| Removing | |||
| General information on repairs to body | All models | AH60.00-N-0001-01A | |
| 1 | Remove detachable parts on outer side of rear fender | ||
| 2 | Remove rear wall window | AR67.20-P-2000P | |
| 3 | Remove trunk lid | AR88.50-P-5000P | |
| 4 | Remove detachable parts from trunk, rear fender area and rear center section | ||
| 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 | |
| 5 | Install filler neck covering | When replacing right rear fender | AR63.50-P-1400-01P |
| Figure | |||
| Guidelines for removing fuel tank when performing welding on bodies | AH60.00-P-3000-01Z | ||
| 6 | Remove detachable parts in vehicle interior (repair area) | ||
| 7 | Cover all detachable parts remaining in vehicle (repair area) | Tarp (fire-resistant) | |
| 8 | Separate rear fender | AR63.50-P-1400-02P | |
| Figure | |||
| Figure | |||
| 9 | Prepare new rear fender part | AR63.50-P-1400-03P | |
| Install | |||
| 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 | |
| 10 | Install rear fender and weld in | AR63.50-P-1400-04P | |
| Measures for preventing damage to vehicles or components when performing electric welding work | All models | AH00.00-N-0005-01A | |
| Figure | |||
| Figure | |||
| 11 | Adjust gaps at doors, rear door and covers. | Gaps on rear door | *BE60.00-P-1002-01E |
| Trunk lid gaps | *BE60.00-P-1003-01E | ||
| Gap dimensions. Tank cap. | *BE60.00-P-1005-01E | ||
| 12 | Clean repair areas and prime using primer filler | ||
| 13 | Seam seal following repair | AR97.10-P-4000P | |
| Sealant | *BR00.45-Z-1003-01A | ||
| Notes on paintwork repairs | |||
| 14 | Paint rear fender and adjoining surfaces | ||
| Notes on paintwork repairs | |||
| 15 | Install detachable parts in area of rear fender and rear center section. | ||
| 16 | Install trunk lid | AR88.50-P-5000P | |
| 17 | Install rear wall window | AR67.20-P-2000P | |
| 18 | Install detachable parts on outside of rear fender | ||
| 19 | Apply additional cavity preservation | AP97.20-P-0640-01A | |
| Notes on cavity preservation | Model 124, 126, 129, 140, 170, 201, 202, 203, 208, 210, 215, 220, 463, 671 | AH97.20-P-0001-01B |
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS
| Number | Designation | Model 203.004/006/ 007/008/016/ 018/020/035/ 040/042/043/ 045/046/052/ 056/061/064/ 065/081/084/ 087 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01E | Gap dimension | Front door to A-pillar | Dimension "B" | mm | 6.5 (+1) |
| Front door to fender | Dimension "H" | mm | 3.5 (-0.5/+1) | ||
| Front door to rear door | Dimension "I" | mm | 4 (-0.5/+1) | ||
| Front door to roof | Dimension "C" | mm | 6.5 (+1) | ||
| Rear door to C-pillar | Dimension "T" | mm | - | ||
| Rear door to side piece, bottom | Dimension "J" | mm | 3.5 (+1) | ||
| Front door to rear fender | Dimension "P" | mm | - | ||
| See picture | AR60.00-P-0700-01P | ||||
| BE60.00-P-1003-01E | Gap dimension | Trunk lid to rear fender, top | Dimension "F" | mm | 3.5 (± 1) |
| Trunk lid to taillamp | Dimension "M" | mm | 4 (± 1) | ||
| Rear fender to taillamp | Dimension "U" | mm | - | ||
| See picture | AR60.00-P-0700-01P | ||||
| BE60.00-P-1005-01E | Gap dimension | Fuel filler flap | Dimension "K" | mm | 3.5 (± 0.5) |
| See picture | AR60.00-P-0700-01P | ||||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | Sealant | A 001 989 63 20 |
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |