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

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				Model 209.4
BE60.00-P-1002-01G	Gap dimension	Front door to A-pillar	Dimension "D"	mm	1
		Front door to fender	Dimension "E"	mm	3.5 (-0.5/+1)
		Front door to rear fender	Dimension "F"	mm	3.5 (-0.5/+1)
		Front door to rear fender	Fig., see		AR60.00-P-0700-01QA
BE60.00-P-1003-01G	Gap dimension	Trunk lid to top of rear fender	Dimension "G"	mm	3.5 (± 1)
		Trunk lid to taillamp	Dimension "H"	mm	3.5 (± 0.5/+1)
		Trunk lid to bumper	Dimension "I"	mm	6.5 (+1)
		Rear fender to taillamp	Dimension "J"	mm	3 (± 1)
		Trunk lid cover to taillamp	Dimension "K"	mm	2.5 (± 0.5)
		Trunk lid cover to taillamp	Fig., see		AR60.00-P-0700-01QA
BE60.00-P-1004-01G	Gap dimension	Fuel filler flap	Dimension "L"	mm	3.2 (+0.5)
BE60.00-P-1004-01G	Gap dimension	Fuel filler flap	Fig., see		AR60.00-P-0700-01QA
BE60.00-P-1006-01G	Gap dimension	Soft top to windshield frame	Dimension "M"	mm	10 (± 2)
		Soft top to soft top compartment cover	Dimension "N"	mm	3 (± 0.5)
		Soft top to soft top compartment cover	Fig., see		AR60.00-P-0700-01QA
BE60.00-P-1007-01G	Gap dimension	Soft top compartment cover/rear fender	Dimension "O"	mm	3 (± 0.5)
		Soft top compartment cover to trunk lid	Dimension "P"	mm	4.5 (± 1)
		Soft top compartment cover to trunk lid	Fig., see		AR60.00-P-0700-01QA

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

Courtesy of MERCEDES-BENZ USA

Fig 2: 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-1010-02A	Sheet metal crimping shears
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-1001-03A	Round wire brush, braided, dia. 70 mm
WH58.30-Z-1024-04A	Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM)
WH58.30-Z-1003-29A	Hand riveter 201 of 212
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-1003-03A	Angle grinder (electric/pneumatic)
WE58.40-Z-1005-03A	Wet/dry vacuum cleaner
WE58.40-Z-1006-08A	Cavity preservation gun
WE58.40-Z-1003-14A	Blind rivet tool

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	Sealant	A 001 989 63 20
BR00.45-Z-1003-05A	Preservation agent	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	Rivet	A 003 990 35 97

Fig 3: Identifying Adjust Gaps Front Door And Rear Fender

Courtesy of MERCEDES-BENZ USA

Install rear fender and fit.
Install taillamp and trunk lid cover, spacers and striker eye
Use feeler gauge!
Check and adjust gaps:
Front door/rear fender

Rear fender/taillamp

Trunk lid/taillamp

Trunk lid/upper rear fender

Trunk lid/soft top cover
Drill rivet holes with dia. 6.5 mm (area B).
Remove rear fender and deburr rivet holes on both sides.
Apply MB body sealant t foam parts on wheel well (area M)
Remove and replace damaged foam parts.

Fig 4: Identifying Rivet Holes Area
Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Welding Area
Courtesy of MERCEDES-BENZ USA
Install rear fender and fasten with manual temporary fasteners and clamping pliers.
Rivet rear fender with Polygrip flat head rivets, dia. 6.4 x 14 mm (area B).
Weld in rear fender with (areas D, G, H, I, J, K and L).
Weld in rear fender with (area J 1).
Grind welds.

Fig 6: Identifying Welding On Rear Fender Area
Courtesy of MERCEDES-BENZ USA
Weld in rear fender with (areas A, C, E and F).
Clean all welds with wire brush.