Replace complete rear wheel well - AR63.10-P-0661QA: Notes

MODEL 209.4 

Fig 1: Identifying Rear Wheel Well

Courtesy of MERCEDES-BENZ USA

	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. 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 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
	Risk of poisoning  caused by inhaling vapors or swallowing adhesive. Risk of injury  from adhesive coming into contact with skin and eyes	Wear respiratory protection, protective gloves and safety glasses. Only pour glue into suitable and appropriately marked containers.	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 arc 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)	Tarpaulin (fire-resistant)	*WH58.30-Z-1001-40A
3	Equip Celette or Car-Bench straightening bench with module members or crossmembers and straightening bracket set	Observe setup plans enclosed! Celette straightening bench M8S	*WE58.40-Z-1001-01E
		Celette straightening bench Sevenne	*WE58.40-Z-1001-01E
		Set of Celette module members 955.940	*WE58.40-Z-1007-01E
		Celette additional member 955.908	*WE58.40-Z-1008-01E
		Celette straightening bracket set 7203.300	*WE58.40-Z-1029-01A
		Celette straightening bracket set 7209.309 (for model A 209) as supplement to 7203.300 (model 203) as well as 7203.310 (model C 209)	*WE58.40-Z-1042-01A
		Multi-Z straightening set system MZ 450.000	*WE58.40-Z-1006-01E
		Car-Bench straightening bench BT 17	*WE58.40-Z-1003-01E
		Car-Bench straightening bench BT 43/1	*WE58.40-Z-1010-01E
		Car-Bench universal crossmember set A296	*WE58.40-Z-1003-01E
		Car-Bench straightening bracket set 82434	*WE58.40-Z-1030-01A
4	Set vehicle onto straightening bench using two-post lift and fasten	Two-post lift	*WE58.40-Z-1001-05A
5	Install rear portal frame with welding device	Observe setup plans enclosed!
		Portal frame	Figure
		Multi-Z element MZ 260	Figure
		When installing rear portal frame use additional set of MZ multi-Z elements.
		Welding devices	Figure
6	Remove rear fender		AR63.50-P-1400QA
7	Cut out complete rear wheel well		AR63.10-P-0661-01QA
		Welding spot miller cutter	Figure
		Spherical milling 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. 1 15 mm, 80 m/s (max. 13.250 RPM)	*WH58.30-Z-1024-04A
		Cutting disk, dia. 65 mm, 80 m/s (max. 23.500 RPM) 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
8	Prepare complete rear wheel well for installation		AR63.10-P-0661-02QA
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Abrasive disk, dia. 115 mm, 80 m/s (max. 13.250 RPM)	*WH58.30-Z-1024-04A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Angular 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
9	Fit rear fender
10	Adjust gap dimensions on hoods, doors and covers		AR60.00-P-0700-01QA
		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
		Feeler gauge	Figure
11	Install complete rear wheel well and weld in		AR63.10-P-0661-03QA
	General information on riveting		AH60.00-P-0003-01N
		Portal frame	Figure
		Welding devices	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
		Inert gas welder	*WE58.40-Z-1001-02A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		PowerBird blind rivet tool	*WE58.40-Z-1003-14A
		Manual temporary fastener, dia. 6.4 mm - Clamping range 0-15 mm,	*WH58.30-Z-1038-02A
		identification color silver Hand riveter	*WH58.30-Z-1003-29A
		Polygrip flat/round head rivet, 6.4_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
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-post lift, remove straightening bench	Two-post lift	*WE58.40-Z-1001-05A
15	Clean areas to be repaired and prime with priming filler
16	Seam sealing following repair	Supplement standard seals 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

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

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

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Portal Frame (129 589 03 23 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Multi-Z Elements MZ 260 (140 589 26 23 00)

Courtesy of MERCEDES-BENZ USA

Fig 6: Identifying Welding Devices (209 589 05 23 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-1029-01A	Celette straightening bracket set 7203.300 (model 203)
WE58.40-Z-1030-01A	Car bench straightening bracket set 82434, (model 203)
WE58.40-Z-1042-01A	Celette straightening bracket set 7209.309 (model A 209), as supplement to 7203.300 (model 203), as well as 7203.310 (model C209)
WE58.40-Z-1001-01E	Celette straightening bench
WE58.40-Z-1003-01E	Car-Bench straightening bench
WE58.40-Z-1006-01E	Celette Multi-Z straightening set system
WE58.40-Z-1007-01E	Celette module crossmember set 955.940
WE58.40-Z-1008-01E	Celette additional member 955.908
WE58.40-Z-1010-01E	Car-Bench universal cross member set A 296
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-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-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