Replace complete rear fender - AR63.50-P-1400CW
WARNING: This page is about a different car, the 2011 Mercedes-Benz C300, 2010 Mercedes-Benz C300, 2009 Mercedes-Benz C300, and 2008 Mercedes-Benz C300. However, it is still accessible from the selected car via links, so may be relevant.
MODEL 204.0
| Removing | ||||
| 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 splatter 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 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 | ||
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-N-0005-01A | |||
| General information on body repair | AH60.00-N-0001-01A | |||
| General information on MB materials | AH98.00-P-9409-03A | |||
| 1 | Prepare all workshop equipment and commercially available tools required for repair | |||
| 2 | Remove all detachable parts in repair area. | |||
| 3 | Cover all detachable parts remaining in vehicle with welding protection blanket | |||
| 4.1 | Cut off rear wheel well section | AR63.10-P-0662-01CW | ||
| 4.2 | Separate rear fender (1) | AR63.50-P-1400-02CW | ||
| Sheet metal crimping pliers for areas not easily accessible | WF58.50-P-6350-01SC | |||
| Figure | ||||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | |||
| 5.1 | Prepare rear wheel well section for installation | AR63.10-P-0662-02CW | ||
| 5.2 | Prepare rear fender (1) for installation | AR63.50-P-1400-03CW | ||
| Figure | ||||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | |||
| Install | ||||
| 6.1 | Install rear wheel well section | AR63.10-P-0662-03CW | ||
| Sealant | *BR00.45-Z-1003-01A | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | |||
| Blind rivet, power window at left door 4.8X8 | *BR00.45-Z-1008-13A | |||
| 6.2 | Install rear fender (1), fit and weld in | AR63.50-P-1400-04CW | ||
| General information on riveting | AH60.00-P-0003-01N | |||
| Fig 2 *BE60.00-P-1002-01U *BE60.00-P-1003-01U *BE60.00-P-1004-01U |
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| Sealant | *BR00.45-Z-1003-01A | |||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | |||
| Blind rivet 6.4X14 | *BR00.45-Z-1001-13A | |||
| Polygrip countersunk-head rivet, 6.4X14 | *BR00.45-Z-1002-13A | |||
| 7 | Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01CW | ||
| Fig 2 *BE60.00-P-1002-01U *BE60.00-P-1003-01U *BE60.00-P-1004-01U |
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| 8 | Clean weld joints and sheet metal flanges with rotary wire brush | |||
| 9 | Clean repair areas | |||
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | ||
| 10 | Prime area to be repaired using primer filler | |||
| Notes on paintwork repairs | AH98.00-P-9408-02A | |||
| 11 | Carry out seam sealing after repairs | AR97.10-P-4000CW | ||
| Sealant | *BR00.45-Z-1003-01A | |||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | |||
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | ||
| 12 | Paint repair areas and adjacent surfaces | |||
| Notes on paintwork repairs | AH98.00-P-9408-02A | |||
| 13 | Apply additional cavity preservation | AR97.20-P-1500CW | ||
| Notes on cavity preservation | AH97.20-P-0001-01B | |||
| Preservation agent | *BR00.45-Z-1003-05A | |||
| 14 | Remove welding protection blankets | |||
| 15 | Install all detachable body components in area to be repaired. | |||
CHECK VALUES FOR GAPS
| Number | Designation | Model 204.0 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01U | Gap dimension | Front door to fender | Dimension "G" | mm | 4 (+1/-0.5) |
| Front door to rear door | Dimension "H" | mm | 4 (+1/-0.5) | ||
| Front door to roof frame | Dimension "I" | mm | 15 (+0.5/-1) | ||
| Rear door to roof frame | Dimension "J" | mm | 15.5 (+1/-0.5) | ||
| Rear door to side section, bottom | Dimension "K" | mm | 4 (+1/-0.5) | ||
| Driver door cover to rear door cover | Dimension "W" | mm | 4 (+1.5) | ||
| See illustration | AR60.00-P-0700-01CW | ||||
| BE60.00-P-1003-01U | Gap dimension | Trunk lid to rear fender, top | Dimension "L" | mm | 4 (± 1) |
| Trunk lid to rear lamp unit | Dimension "M" | mm | 4 (± 1) | ||
| Trunk lid to bumper | Dimension "N" | mm | 5, 5 (± 1) | ||
| Rear fender to rear lamp unit | Dimension "O" | mm | 1 (± 1) | ||
| Taillamp to bumper | Dimension "P" | mm | 2 (± 1) | ||
| Taillamp, trunk lid to taillamp | Dimension "M1" | mm | - | ||
| See illustration | AR60.00-P-0700-01CW | ||||
| BE60.00-P-1004-01U | Gap dimension | Fuel filler flap (around) | Dimension "Q" | mm | 3.0 (± 0.5) |
| See illustration | AR60.00-P-0700-01CW | ||||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | White sealing compound, 310 ml, DBL 6069.20 | A 001 989 63 20 |
| BR00.45-Z-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 20 |
| BR00.45-Z-1003-05A | Cavity preservation, solvent-free (1 l container) | 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 | Blind rivet 6.4X14 | A 003 990 35 97 |
| BR00.45-Z-1002-13A | Polygrip countersunk-head rivet, 6.4X14 | A 003 990 86 97 05 |
| BR00.45-Z-1008-13A | Blind rivet, power window at left door 4.8X8 | A 003 990 24 97 |