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

CHECK VALUES FOR GAPS

Number	Designation				Model 221
BE60.00-P-1002-01R	Gap dimension	Front door to A-pillar	Dimension "D"	mm	4.5 (±0.5)
		Front door to fender	Dimension "E"	mm	4 (±0.5)
		Front door to rear door	Dimension "F"	mm	4.5 (±0.5)
		Trim strip at front door to roof frame	Dimension "G"	mm	4.5 (±0.5)
		Trim strip at rear door to roof frame	Dimension "H"	mm	4.5 (±0.5)
		Rear door to side section, bottom	Dimension "I"	mm	4.5 (±0.5)
		Front door cover to rear door cover	Dimension "S"	mm	4.5 (±0.5)
		Front door cover to rear door cover	See picture		AR60.00-P-0700-01S X
BE60.00-P-1003-01R	Gap dimension	Trunk lid to rear fender, top	Dimension "J"	mm	4 (±0.5)
		Trunk lid to rear lamp unit	Dimension "K"	mm	4 (±0.5)
		Trunk lid to bumper	Dimension "L"	mm	5.5 (±1.5)
		Rear fender to rear lamp unit	Dimension "M"	mm	2.5 (±0.5)
		Trunk lid license plate panel to rear lamp unit	Dimension "N"	mm	4 (±0.5)
		Trunk lid license plate panel to rear lamp unit	See picture		AR60.00-P-0700-01S X
BE60.00-P-1004-01R	Gap dimension	Fuel filler flap	Dimension "O"	mm	3.5 (±0.5)
BE60.00-P-1004-01R	Gap dimension	Fuel filler flap	See picture		AR60.00-P-0700-01S X

Fig 1: Identifying Bending Iron (129 589 00 27 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Feeler Gauge (129 589 03 21 00)

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Fig 3: Identifying Welding Bead Catcher (129 589 01 98 00)

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REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	Sealant, white, 310 ml, DB supply specification 6069.20	A 001 989 63 20
BR00.45-Z-1092-02A	Adhesive kit, body, 2-component adhesive	A 009 989 36 71
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42
BR00.45-Z-1002-13A	Polygrip countersunk head rivet, 6.4 x14	A 003 990 86 97 05
BR00.45-Z-1001-13A	Blind rivet 6.4x14	A 003 990 35 97

Install rear fender (1), trunk lid, taillamps and rubber seal and fit.
Check and adjust gaps: rear door to bottom side section (I), trunk lid to taillamp (K), trunk lid cover to taillamp (N), rear fender to taillamp (M), fuel filler flap (O).
Use feeler gauge.
Fasten rear fender (1) with clamping pliers.
Remove trunk lid, taillamps and rubber seal.

Fig 4: Identifying Gaps
Courtesy of MERCEDES-BENZ USA
Cover windowbag (2) with welding bead catcher (3).
Cover windowbag (2) to prevent damage.

Fig 5: Identifying Welding Bead Catcher And Window Bag
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Drill dia. 6.5 mm rivet holes (areas E, F, G, H, I, J, K and L).
Drill rivet holes with dia. 6.7 mm Usibor drill bit (area D).
To drill out rivet holes on rear fender (1), transfer every second spot weld from old rear fender to new part.
Remove rear fender (1)
Deburr rivet holes on rear fender (1) on both sides.

Fig 6: Identifying Rear Fender Rivet Hole Areas
Courtesy of MERCEDES-BENZ USA
Remove drill shavings using wet/dry vacuum cleaner
Coat insides of riveted joints with zinc dust paint (area D).
Apply 2-component adhesive to mating surfaces in cross-hatched areas (areas X, Y, Z and AA).
Observe pretreatment of bonding surfaces.

Refer to manufacturer specifications for adhesive curing and application times.

Fig 7: Identifying Mating Surfaces
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Apply MB body sealant to foam parts (areas N and N₁ ).
Damaged foam parts must be removed and replaced.

Fig 8: Identifying Foam Parts
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Apply adhesive to shaded areas (areas M, M₁ , O, P, Q, R, S, T, U, V, W and AJ).
Observe pretreatment of bonding surfaces.

Refer to manufacturer specifications for adhesive curing and application times.

Fig 9: Identifying Bonding Surfaces
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Fig 10: Identifying Rear Fender Riveting Areas
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Install rear fender (1) and fasten using clamping pliers and manual temporary fasteners.
Rivet rear fender (1) using Polygrip flat round head rivet, dia. 6.4x14 (areas D, I, J, K and L).
Rivet rear fender (1) with Polygrip countersunk head rivet, dia. 6.4 x14 (areas AD, AE and AF).
Rivet rear fender (1) using Polygrip flat round head rivet, dia. 6.4x14 (areas E, F, G and H).
Weld in rear fender (1) with (areas AC, AG and AH).

Fig 11: Identifying Rear Fender Welding & Riveting Areas
Courtesy of MERCEDES-BENZ USA

Fig 12: Identifying Rear Fender Welding Areas
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Weld in rear fender (1) with (areas B, Z, AA and AB)
Weld in rear fender (1) with (areas A and C).
Weld in intervals, allow to cool down in between to minimize heat distortion (areas A and C).

Fig 13: Identifying Rear Fender Welding Areas
Courtesy of MERCEDES-BENZ USA

Fig 14: Adjusting Spot Weld Flange
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Readjust spot weld flange on wheel well with crimping iron.
Spot weld flange position analog to undamaged vehicle side.
Clean welds on rear fender (1) with round wire brush.
Grind rear fender (1) down flat in cross-hatched areas (areas A and C).
Finish surface on rear fender (1), fill and smooth.
Remove grinding and drill shavings using wet/dry vacuum cleaner.

Fig 15: Identifying Rear Fender Grinding Areas
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