Remove/install outer rear wheel well - AR63.10-P-0665PB
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 | |
| 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 repair area | ||
| 2 | Cover all detachable parts remaining in vehicle (repair area) | Tarp (fire-resistant) | |
| 3 | Remove rear fender | AR63.50-P-1400PB | |
| 4 | Remove outer rear wheel well | AR63.10-P-0660-01PB | |
Ball cutter, Ø 12 mm Round wire brush, braided, Ø 70 mm Vario Drill WS 91 spot weld removing tool Hole punching pliers, Ø 7 mm Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 rpm) Drill (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Straight grinder (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 |
Figure | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 5 | Prepare outer rear wheel well for installation | AR63.10-P-0670-05PB | |
| Round wire brush, braided, Ø 70 mm Hole punching pliers, Ø 7 mm Drill (electric/pneumatic), refer to GOTIS http://gotis.aftersales.daimlerchrysler.com |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 6 | Install outer rear wheel well | AR63.10-P-0670-06PB | |
Electrode miller Round wire brush, braided, Ø 70 mm Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 rpm) Clamping pliers 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 |
Figure | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 7 | 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 | |||
| 8 | Install rear fender | AR63.50-P-1400PB | |
| 9 | Clean weld joints and metal flanges using wire brush | ||
| 10 | Clean repair areas and prime using primer filler | ||
| 11 | Seam seal following repair | AR97.10-P-4000P | |
| MB body sealant for seam sealant (paintable/310 ml cartridge) | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 12 | Paint repair areas and adjacent surfaces | ||
| 13 |
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 | |
| 14 | Install all removed assembly parts |
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-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 20 |
| BR00.45-Z-1003-01A | Sealant | A 001 989 63 20 |
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |