Replace complete rear fender - AR63.50-P-1400QA: Notes
MODEL 209.4
| Remove | |||
|---|---|---|---|
| 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. | AS00.00-Z-0017-01A | |
| Deburr repair panels. | |||
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between the columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of death caused by high voltage used for arc welding. Risk of explosion caused by welding in the area of highly inflammable materials. Injury hazard from welding spatter and UV-light while welding. Risk of poisoning caused by inhaling welding vapors. | Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor. |
AS00.00-Z-0007-01A | |
| 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 | |
| General information on body repair | All models | AH60.00-N-0001-01A | |
| Measures for preventing damage to vehicles or components when performing arc welding work | All models | AH00.00-N-0005-01A | |
| Notes on paintwork repairs | All models | AH98.00-P-9408-02A | |
| Guidelines for removing fuel tank when performing welding work on bodies | AH60.00-P-3000-01Z | ||
| General information on MB materials | All models | AH98.00-P-9409-03A | |
| 1 | Prepare all required workshop equipment and commercially available tools for repair | ||
| 2 | Remove detachable body components in area to be repaired. | ||
| 3 | Cover all detachable parts remaining on vehicle with fireproof tarp | ||
| 4 | Install cover for filler fitting | When replacing right rear fender with deeper damage. | AR63.50-P-1400-01QA |
| Fig 5 | |||
| Fig 6 | |||
| 5 | Separate rear fender | AR63.50-P-1400-02QA | |
| Fig 2 | |||
| *WH58.30-Z-1002-01A | |||
| *WH58.30-Z-1001-03A | |||
| *WH58.30-Z-1006-01A | |||
| *WH58.30-Z-1024-04A | |||
| *WH58.30-Z-1004-20A | |||
| Drill (electric/pneumatic) | *WE58.40-Z-1001-03A | ||
| Straight grinder (electric/pneumatic) | *WE58.40-Z-1002-03A | ||
| Angular 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 | ||
| 6 | Prepare new rear fender part | AR63.50-P-1400-03QA | |
| *WH58.30-Z-1001-03A | |||
| Drill (electric/pneumatic) | *WE58.40-Z-1001-03A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 7 | Install standard tank cap and tank flap, mask gap | ||
| 8 | Install rear fender and weld in | AR63.50-P-1400-04QA | |
| General information on riveting | AH60.00-P-0003-01N | ||
| Fig 4 | |||
| Fig 3 | |||
| *WH58.30-Z-1001-03A | |||
| *WH58.30-Z-1003-01A | |||
| *WH58.30-Z-1003-02A | |||
| *WE58.40-Z-1003-14A | |||
| *WH58.30-Z-1003-29A | |||
6.4 mm - Clamping range 0-15 mm, identification color silver |
*WH58.30-Z-1038-02A | ||
| Polygrip flat/round head rivet, 6.4 x 14 mm | *BR00.45-Z-1001-13A | ||
| *WH58.30-Z-1024-04A | |||
| Inert gas welder | *WE58.40-Z-1001-02A | ||
| Spot welder | *WE58.40-Z-1002-02A | ||
| Angular grinder (electric/pneumatic) | *WE58.40-Z-1003-03A | ||
| Wet/dry vacuum cleaner | *WE58.40-Z-1005-03A | ||
| Sealant | *BR00.45-Z-1003-01A | ||
| 9 | Adjust gap dimensions on hoods, doors and lids | ||
| Rear fender and taillamp | *BE60.00-P-1003-01G | ||
| Trunk lid to rear fender, top | *BE60.00-P-1003-01G | ||
| Trunk lid to taillamp | *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 | ||
| Fig 3 | |||
| 10 | Shape body flange for taillamp with embossing tool | AR63.50-P-1400-09CW | |
| Fig 7 | |||
| 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 | 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 | AR63.50-P-1400-01QA | |
| 18 | Remove tarp | ||
| 19 | Install all detachable body components in repaired area. | ||
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS
| 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 in | 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 taillamp | Dimension "H" | mm | 3.5 (± 0.5/+1) | ||
| Trunk lid to bumper | Dimension "I" | mm | 6.5 (+1) | ||
| Rear fender to taillamp | Dimension "J" | mm | 3 (± 1) | ||
| Trunk lid cover to taillamp | Dimension "K" | mm | 2.5 (± 0.5) | ||
| See picture in | AR60.00-P-0700-01QA | ||||
| BE60.00-P-1004-01G | Gap dimension | Fuel filler flap | Dimension"L" | mm | 3.2 (+0.5) |
| See picture in | 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 in | 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 in | AR60.00-P-0700-01QA | ||||
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-1024-04A | Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM) |
| WH58.30-Z-1004-20A | Hot-air gun |
| 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-1001-05A | Two-post lifting platform |
| WE58.40-Z-1006-08A | Cavity preservation gun |
| 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 | 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 |