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

TEST AND ADJUSTMENT VALUES, GAP DIMENSIONS AT HOODS, DOORS AND COVERS

Number	Designation				Model 171
BE60.00-P-1002-01A	Gap dimension	Front door to rear fender	Dimension "P"	mm	3.0+0.8
BE60.00-P-1002-01A	Gap dimension	Front door to rear fender	See picture		AR60.00-P-0700-01V
BE60.00-P-1003-01A	Gap dimension	Trunk lid to rear fender	Dimension "F"	mm	3.5+1.5
		Trunk lid to taillamp	Dimension "M"	mm	4.0 (+1.6/-0.5)
		Rear fender to taillamp	Dimension "U"	mm	2.5 ± 0.5
		Rear fender to taillamp	See picture		AR60.00-P-0700-01V
BE60.00-P-1004-01A	Gap dimension	Fuel filler flap	Dimension "K"	mm	3.0 ± 0.5
BE60.00-P-1004-01A	Gap dimension	Fuel filler flap	See picture		AR60.00-P-0700-01V

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

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Protective Cover (129 589 00 98 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Bending Pliers (202 589 00 37 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Spacer (000 589 87 63 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-1003-29A	Hand riveter
WH58.30-Z-1001-40A	Tarp (fire-resistant)

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-1002-03A	Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A	Angle grinder (electric/pneumatic)
WE58.40-Z-1005-03A	Wet/dry vacuum cleaner
WE58.40-Z-1001-05A	Two-post lifting platform
WE58.40-Z-1003-14A	Blind rivet tool

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1092-02A	Adhesive	A 009 989 36 71
BR00.45-Z-1001-13A	Rivet	A 003 990 35 97

Install and fit rear fender (1), tubular frame, trunk lid, taillamps, rubber seal, locking eye.
Check and adjust gaps: Trunk lid to taillamp (M) Front door to rear fender (P) Trunk lid to rear fender (F) Rear fender to taillamp (U) Fuel filler flap (K)
Use feeler gage.
Fasten rear fender (1) with clamping pliers.
Remove tubular frame with trunk lid, taillamps, rubber seal and locking eye.

Fig 5: Identifying Adjustment Gaps
Courtesy of MERCEDES-BENZ USA

Fig 6: Identifying Areas For Drilling Rivet Hole On Rear Fender
Courtesy of MERCEDES-BENZ USA
Drill dia. 6.5 mm rivet hole on rear fender (1) (areas A₁ , E and H).
If MIG welder is available, it is not necessary to drill the rivet holes in (area A₁ ).
Remove rear fender (1)
Deburr rivet holes on both sides
Coat insides of riveted joints with zinc dust paint.
Apply 2-component adhesive DP 490 in cross-hatched area.
Observe preliminary treatment of surfaces to be bonded.

Refer to the manufacturer's information for the curing and working times of the adhesive.

Fig 7: Identifying Adhesive Applying Area (Cross-Hatched Area)
Courtesy of MERCEDES-BENZ USA
Install rear fender (1) and fasten with manual temporary fasteners and clamping pliers.
Readjust wheelhouse on rear fender (1) with hammer and anvil iron (area N).
Connect wheelhouse (1) at rear fender with bending pliers (area N).

Fig 8: Identifying Rear Fender And Wheelhouse Areas
Courtesy of MERCEDES-BENZ USA
Rivet rear fender (1) with 6.4x14 mm Polygrip flat head rivets (areas A 1 and H).
If MIG welder is available, the (area A₁ ) rear fender (1) to side longitudinal member can also be MIG brazed
Weld in rear fender (1) with (areas A, B, G and I).

Fig 9: Identifying Welding Areas On Rear Fender
Courtesy of MERCEDES-BENZ USA

Fig 10: Identifying Welding Areas On Rear Fender
Courtesy of MERCEDES-BENZ USA
Rivet rear fender (1) with Polygrip flat head rivet, dia. 6.4x14 (area E).
Weld in rear fender (1) with (areas A, F, F₁ , K and L).
Weld in rear fender (1) with (area M).