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

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
Fig 1: Identifying Feeler Gauge (129 589 03 21 00)
G04738969
Fig 2: Identifying Bending Iron (129 589 00 27 00)
G04738970
REPAIR MATERIALS

Number Designation Order number
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
  1. Apply MB body sealant (arrows) on foam parts of B and C-pillar

    IMPORTANT Remove and replace damaged foam parts.

    Fig 3: Locating MB Body Sealant On Foam Parts Of B And C-Pillar
    G04738971
    Fig 4: Installing Rear Fender
    G04738972
  2. Install and fit rear fender.
  3. Insert rear lamp, install rubber seal and locking eye.
  4. Check gaps and adjust rear fender/taillamps rear fender/front door rear fender/rear-end door.

    IMPORTANT Use feeler gauge!

    Fig 5: Identifying Rear Fender Spot Welds Area (1 Of 4)
    G04738973
  5. Rear fender POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas A - C and G).
    Fig 6: Identifying Rear Fender Spot Welds Area (2 Of 4)
    G04738974
  6. Readjust spot weld flange on wheel well with crimping iron.

    IMPORTANT Bend over spot weld flange analog to undamaged side of vehicle.

  7. Rear fender on wheel well SHIELDED GAS SEAM WELD INTERRUPTED (areas F and G).
  8. Rear fender POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas H-J).
    Fig 7: Identifying Rear Fender Spot Welds Area (3 Of 4)
    G04738975
  9. Rear fender SHIELDED GAS STITCH WELD (areas M, N and O).

    IMPORTANT Take breaks while welding in area M to allow the metal to cool down for minimum heat distortion.

  10. Rear fender SHIELDED GAS PLUG WELD (area D).
  11. Rear fender on wheel well POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area F).
  12. Drill Ø 6 mm holes on outer longitudinal member, rear fender and outer longitudinal member using steel/steel flat head rivets, Ø 6 x 14 mm (area E).
    Fig 8: Identifying Rear Fender Spot Welds Area (4 Of 4)
    G04738976
  13. Clean weld joints using wire brush.
  14. Fill rear fender with body solder in cross-hatched area and smooth.
    Fig 9: Identifying Rear Fender Filling Area
    G04738977
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