Install rear fender - AR63.50-P-1400-04Q

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)
		Front door to rear fender	Fig., see		AR60.00-P-0700-01Q
BE60.00-P-1003-01G	Gap dimension	Trunk lid to top of rear fender	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	-
		Trunk lid cover to taillamp	Fig., see		AR60.00-P-0700-01Q
BE60.00-P-1004-01G	Gap dimension	Fuel filler flap	Dimension "L"	mm	3.5 (± 0.5)
BE60.00-P-1004-01G	Gap dimension	Fuel filler flap	Fig., see		AR60.00-P-0700-01Q

Fig 1: Identifying Feeler Gage (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Bending Jig (129 589 00 27 00)

Courtesy of MERCEDES-BENZ USA

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1003-01A	Electrode miller
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-1003-29A	Hand riveter

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-1003-03A	Angle grinder (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

Install rear fender and fit.
Insert taillamp and trunk lid cover, install rubber seal and striker eye.
Check and adjust gaps:
Rear fender to taillamp Trunk lid to top of rear fender Trunk lid cover to taillamp Trunk lid to taillamp Front door to rear fender

Use feeler gauge!
Drill dia. 6.5 mm rivet holes (area C).
Remove rear fender and deburr rivet holes on both sides.

Fig 3: Identifying Adjust Gaps Rear Fender To Taillamp Trunk
Courtesy of MERCEDES-BENZ USA
Apply MB body sealant to foam parts on C-pillar.
Replace damaged foam parts (group 68).
Apply MB body sealant to adhesive surfaces on B and C-pillars.

Fig 4: Applying MB Body Sealant To Adhesive Surfaces On B And C-Pillars
Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Polygrip Flat Head Rivets
Courtesy of MERCEDES-BENZ USA
Install rear fender and fit.
Weld in rear fender with (areas B, C1, F, G and H).
Rivet rear fender and outer longitudinal member with Polygrip flat head rivets, dia. 6.4 x 14 mm (area C).

Fig 6: Identifying Welding Area
Courtesy of MERCEDES-BENZ USA
Weld in rear fender with (areas I, J, K, L and M).
Weld in rear fender with (area K1).
Weld in rear fender with (areas A).
Weld area A at intervals, allowing seam to cool each time, thus causing minimum heat distortion.

Fig 7: Identifying Welding Area
Courtesy of MERCEDES-BENZ USA
Weld in rear fender and C-pillar with (area O).
Weld in rear fender with (areas D and E).
Place bending jig around spot weld flange on wheel arch panel.
Bend over spot welding flange analog to undamaged side of vehicle.
Grind welds down flat and clean with wire brush.
Flush rear fender with flushing tin in checked area and smoothen.

Fig 8: Identifying Grinding Area
Courtesy of MERCEDES-BENZ USA