Completely replace rear fender - AR63.50-P-1400PB
MODEL 203.7
| 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 | |
| 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 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 | |
| Guidelines for removing fuel tank when performing welding on bodies | AH60.00-P-3000-01Z | ||
| General information on MB materials | All models | AH98.00-P-9409-03A | |
| 1 | Install filler neck covering | When replacing right rear fender. | AR63.50-P-1400-01P |
| Figure | |||
| 2 | Remove detachable parts on outer side of rear fender | ||
| 3 | Remove rear-end door | AR72.20-P-3500PB | |
| 4 | Remove detachable parts in trunk, in area of rear fender | ||
| 5 | Remove detachable parts in vehicle interior (repair area) | ||
| 6 | Cover all detachable parts remaining in vehicle (repair area) | Tarp (fire-resistant) | |
| 7 | Separate rear fender | AR63.50-P-1400-02PB | |
| Figure | |||
| Figure | |||
| Vario Drill WS 91 spot weld removing tool | |||
| Round wire brush, braided, Ø 70 mm | |||
| Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 rpm) | |||
| Sheet metal crimping pliers | |||
| Hot air gun - 3000 W | |||
| Drill (electric/pneumatic), refer to GOTIS | |||
| http://gotis.aftersales.daimlerchrysler.com | |||
| Angle grinder (electric/pneumatic), refer to GOTIS | |||
| http://gotis.aftersales.daimlerchrysler.com | |||
| Body saw (electric/pneumatic), refer to GOTIS | |||
| http://gotis.aftersales.daimlerchrysler.com | |||
| Wet/dry vacuum cleaner, refer to GOTIS | |||
| http://gotis.aftersales.daimlerchrysler.com | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 8 | Prepare new rear fender part | AR63.50-P-1400-03PB | |
| Figure | |||
| Round wire brush, braided, Ø 70 mm | |||
| Hole punching pliers, Ø 6 mm | |||
| Hole punching pliers, Ø 7 mm | |||
| Drill (electric/pneumatic), refer to GOTIS | |||
| http://gotis.aftersales.daimlerchrysler.com | |||
| Body saw (electric/pneumatic), refer to GOTIS | |||
| http://gotis.aftersales.daimlerchrysler.com | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 9 | Install rear fender and weld in | AR63.50-P-1400-04PB | |
| General information on riveting | AH60.00-P-0003-01N | ||
| Figure | |||
| Figure | |||
| Electrode miller | |||
| Round wire brush, braided, Ø 70 mm | |||
| Abrasive disk, 115 mm, 80 m/s (max. 13,250 Ø rpm) | |||
| Clamping pliers | |||
| Polygrip flat round head rivet, 6.4 x 14 mm | *BR00.45-Z-1001-13A | ||
| Hand riveter | |||
| Insert gas welder, refer to GOTIS | |||
| http://gotis.aftersales.daimlerchrysler.com | |||
| Spot welder, refer to GOTIS | |||
| http://gotis.aftersales.daimlerchrysler.com | |||
| Drill (electric/pneumatic), refer to GOTIS | |||
| http://gotis.aftersales.daimlerchrysler.com | |||
| Angle grinder (electric/pneumatic), refer to GOTIS | |||
| http://gotis.aftersales.daimlerchrysler.com | |||
| Wet/dry vacuum cleaner, refer to GOTIS | |||
| http://gotis.aftersales.daimlerchrysler.com | |||
| MB body sealant for seam sealant (paintable/310 ml cartridge) | *BR00.45-Z-1003-01A | ||
| 10 | Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01PB | |
| Front door to rear fender | *BE60.00-P-1002-01E | ||
| Rear fender to taillamp | *BE60.00-P-1003-01E | ||
| Rear-end door to rear fender |
*BE60.00-P-1004-01E | ||
| Fuel filler flap |
*BE60.00-P-1005-01E | ||
| Figure | |||
| 11 | Clean repair areas and prime using primer filler | ||
| 12 | Seam seal following repair | AR97.10-P-4000P | |
| MB body sealant for seam sealant (paintable/310 ml cartridge) | *BR00.45-Z-1003-01A | ||
| 13 | Paint repair areas and adjacent surfaces | ||
| 14 |
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 | |
| 15 | Remove covers for filler neck | When replacing right rear fender. | AR63.50-P-1400-01P |
| 16 | Install detachable parts on outside of rear fender | ||
| 17 | Install rear-end door | AR72.20-P-3500PB | |
| 18 | Install detachable parts in luggage compartment, in area of rear fender | ||
| 19 | Install detachable parts in passenger compartment (repair area) |
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS
| Number | Designation | Model 203.706/707/ 708/718/730/ 735/740/742/ 743/745/746/ 747/752/756/ 764 | |||
|---|---|---|---|---|---|
| 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 | - | ||
| Front door to roof | Dimension "C" | mm | - | ||
| Rear door to C-pillar | Dimension "T" | mm | - | ||
| Rear door to side piece, bottom | Dimension "J" | mm | - | ||
| Front door to rear fender | Dimension "P" | mm | 3.5 (+1.0/-0.5) | ||
| See picture | AR60.00-P-0700-01PB | ||||
| BE60.00-P-1003-01E | Gap dimension | Trunk lid to rear fender, top | Dimension "F" | mm | - |
| Trunk lid to taillamp | Dimension "M" | mm | - | ||
| Rear fender to taillamp | Dimension "U" | mm | 2.5 (± 0.5) | ||
| See picture | AR60.00-P-0700-01PB | ||||
| BE60.00-P-1004-01E | Gap dimension | Rear-end door to roof | Dimension "E" | mm | 8.5 (+1) |
| Rear-end door to rear fender | Dimension "M" | mm | 3.5 (± 1) | ||
| Rear-end door to taillamp | Dimension "L" | mm | 4 (± 1) | ||
| Rear-end door to bumper | Dimension "S" | mm | 6.5 (-1.5) | ||
| Rear-end door to D-pillar | Dimension "Q" | mm | - | ||
| See picture | AR60.00-P-0700-01PB | ||||
| BE60.00-P-1005-01E | Gap dimension | Fuel filler flap | Dimension "K" | mm | 3.5 (± 1) |
| See picture | AR60.00-P-0700-01PB | ||||
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 |