Remove/install outer rear wheel well - AR63.10-P-0665Q

MODEL 209.3 

Fig 1: Identifying Outer Rear Wheel Well

Courtesy of MERCEDES-BENZ USA

	Removing
	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
	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
	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
	General information on repairs to body	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)	*WH58.30-Z-1001-40A
3	Remove rear fender		AR63.50-P-1400-02Q
4	Remove outer rear wheel well		AR63.10-P-0660-01Q
		Welding spot miller cutter	Figure
		Ball cutter, dia. 12 mm	*WH58.30-Z-1002-01A
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Vario Drill WS 91 spot weld removing tool	*WH58.30-Z-1006-01A
		Abrasive disk, dia. 115 mm, 80m/s (max. 13, 250 RPM)	*WH58.30-Z-1024-04A
		Cutting disk, 65 mm dia., 80 m/s (max. 23, 500 RPM)	*WH58.30-Z-1021-04A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Straight grinder (electric/pneumatic)	*WE58.40-Z-1002-03A
		Angle grinder (electric/pneumatic)	*WE58.40-Z-1003-03A
		Body saw (electric/pneumatic)	*WE58.40-Z-1004-03A
		Wet/dry vacuum cleaner	*WE58.40-Z-1005-03A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
5	Prepare outer rear wheel well for installation		AR63.10-P-0670-05Q
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Abrasive disk, dia. 115 mm, 80m/s (max.13, 250 RPM)	*WH58.30-Z-1024-04A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Angle grinder (electric/pneumatic)	*WE58.40-Z-1003-03A
		Body saw (electric/pneumatic)	*WE58.40-Z-1004-03A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
6	Install outer rear wheel well		AR63.10-P-0670-06Q
		Feeler gauge	Figure
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Electrode miller	*WH58.30-Z-1003-01A
		Clamping pliers	*WH58.30-Z-1003-02A
	General information on riveting		AH60.00-P-0003-01N
		Hand riveter	*WH58.30-Z-1003-29A
		PowerBird blind rivet tool	*WE58.40-Z-1003-14A
		Inert gas welder	*WE58.40-Z-1001-02A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Manual temporary fastener, dia. 6.4 mm-clamping range 0 - 15 mm, identification color silver	*WH58.30-Z-1038-02A
		Flat/round head rivet, 6.4 x 14	*BR00.45-Z-1001-13A
		Spot welder	*WE58.40-Z-1002-02A
		Wet/dry vacuum cleaner	*WE58.40-Z-1005-03A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
7	Adjust gap dimensions on hoods, doors and covers
		Rear fender to taillamp	*BE60.00-P-1003-01G
		Trunk lid to rear fender, top	*BE60.00-P-1003-01G
		Trunk lid cover to taillamp	*BE60.00-P-1003-01G
		Front door to rear fender	*BE60.00-P-1002-01G
		Fuel filler flap	*BE60.00-P-1004-01G
8	Install rear fender		AR63.50-P-1400-04Q
9	Clean weld joints and metal flanges with wire brush
10	Clean areas to be repaired and prime with primer filler
11	Seam sealing following repair	Supplement standard seals with MB preservative.	AR97.10-P-4000Q
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
12	Paint areas to be repaired and adjacent surfaces
13	Cavity preservation following repair work
	Notes on cavity preservation	Models 124, 126, 129, 140, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 463, 671	AH97.20-P-0001-01B
14	Install all removed assembly parts

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				Model 209.3
BE60.00-P-1002-01G	Gap dimension	Front door to A-pillar	Dimension "D"	mm	-
		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-0700-01Q
BE60.00-P-1003-01G	Gap dimension	Trunk lid to rear fender, top	Dimension "G"	mm	3, 5 (± 0, 5)
		Trunk lid to taillamp	Dimension "H"	mm	3, 5 (± 0, 5)
		Trunk lid to bumper	Dimension "I"	mm	5 (-1)
		Rear fender to taillamp	Dimension "J"	mm	2 (±0.5)
		Trunk lid cover to taillamp	Dimension "K"	mm	-
			See picture		AR60.00-P-0700-01Q
BE60.00-P-1004-01G	Gap dimension	Fuel filler flap	Dimension "L"	mm	3, 5 (± 0, 5)
			See picture		AR60.00-P-0700-01Q

Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1002-01A	Ball cutter, dia. 12 mm
WH58.30-Z-1003-01A	Electrode miller
WH58.30-Z-1006-01A	Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1003-02A	Clamping pliers
WH58.30-Z-1038-02A	Manual temporary fastener, dia.6.4 mm - clamping range 0 -15 mm, identification color silver Firma Hausmann GmbH D-34346 Hann. Munden, Germany
WH58.30-Z-1001-03A	Round wire brush, braided, dia. 70 mm
WH58.30-Z-1021-04A	Cutting disk, dia. 65 mm, 80 m/s (max. 23, 500 RPM)
WH58.30-Z-1024-04A	Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM)
WH58.30-Z-1003-29A	Hand riveter
WH58.30-Z-1001-40A	Tarp (fire-resistant)

WORKSHOP EQUIPMENT

WE58.40-Z-1001-02A	Inert gas welder
WE58.40-Z-1002-02A	Spot welder
WE58.40-Z-1001-03A	Drill (electric/pneumatic)
WE58.40-Z-1002-03A	Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A	Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A	Body saw (electric/pneumatic)
WE58.40-Z-1005-03A	Wet/dry vacuum cleaner
WE58.40-Z-1003-14A	Blind rivet tool

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	Sealant	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	Preservation agent	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	Rivet	A 003 990 35 97