Repair bodyshell complaint on rear fender - SM63.50-P-1000B

MODEL 220

	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 spatter 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.
	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.
	Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof	Keep body parts and limbs well clear of moving parts.
	Measures for preventing damage to vehicles or components when performing electric welding work
	General information on repairs to body
	Notes on paintwork repairs
	General information on MB materials
1	Prepare tools	All required workshop equipment and commercially available tools for repair.
2	Prepare vehicle		SM63.50-P-1001A
3	Determine repair scope	If necessary, adapt repair panel.
		Repair panel (left)	*BR00.45-Z-1015-16A
		Repair panel (right)	*BR00.45-Z-1016-16A
4	Cover up detachable parts	Cover all detachable parts remaining vehicle with fireproof tarpaulin
5	Separate affected areas	On rear fender.	SM63.50-P-1000-01B
		Spot weld milling cutter Weld-spot milling machine Hot-air gun Angle grinder up to 125 mm Keyhole saw Wet and dry vacuum cleaner	Figure
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
6	Prepare repair area for installation		SM63.50-P-1000-02B
		Round wire brush Keyhole saw	SM63.50-P-1000-02B
		Repair panel (left)	*BR00.45-Z-1015-16A
		Repair panel (right)	*BR00.45-Z-1016-16A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
7	Install repair panel		SM63.50-P-1000-03B
		Bending iron	Figure
		Feeler gauge Vice grip pliers (standard) Inert gas welder Multifunction device (spot welding) Angle grinder up to 125 mm Wet and dry vacuum cleaner	Figure
		Sealant	*BR00.45-Z-1003-01A
8	Adjust gap dimensions on doors	Model 220	AR60.00-P-0700-01M
		Model 220.875/878	AR60.00-P-0700-01MP
		Gap dimensions	*BE60.00-P-1002-01A
		Feeler gauge	Figure
9	Clean weld joints.	Clean welds and sheet metal flange using round wire brush Round wire brush
10	Clean repair areas
11	Prime area to be repaired using primer filler
12	Carry out seam sealing after repairs	Supplement standard sealant with sealant.	AR97.10-P-4000CW
12	Carry out seam sealing after repairs	Sealant	*BR00.45-Z-1003-01A
13	Supplement standard underfloor protection with MB permanent underbody sealant		AR97.20-P-0500-03A
14	Paint repair areas and adjacent surfaces
15	Apply additional cavity preservation		AR97.20-P-1500CW
	Notes on cavity preservation		AH97.20-P-0001-01B
	Notes on cavity preservation	Preservation agent	*BR00.45-Z-1003-05A
16	Remove tarp	On all covered parts remaining in vehicle.
17	Install all detachable body components in area to be repaired.		SM63.50-P-1002A

TABLE

Weld-spot milling machine
Hot-air gun
Angle grinder up to 125 mm
Keyhole saw
Wet and dry vacuum cleaner
Round wire brush
Vice grip pliers (standard)
Inert gas welder
Multifunction device (spot welding)

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

Number	Designation				Model 220.0/1	Model 220.875/878
BE60.00-P-1002-01A	Gap dimension	Front door to A-pillar	Dim. "B"	mm	8, 0 (±0, 5)	6, 5 (±0, 5)
		Front door to fender	Dim. "H"	mm	5, 0 (±0, 5)	5, 0 (±0, 5)
		Front door to rear door	Dim. "I"	mm	5, 0 (±0, 5)	-
		Front door to roof	Dim. "C"	mm	8, 0 (±0, 5)	6, 5 (±0, 5)
		Rear door to top of side section	Dim. "D"	mm	5, 0 (±0, 5)	5, 0 (±0, 5)
		Rear door to side section, bottom	Dim. "J"	mm	5, 0 (±0, 5)	5, 0 (±0, 5)
		Fender to A-pillar	Dim. "Q"	mm	-	-
		Front door to rear fender	Dim. "P"	mm	-	-
			See picture		AR60.00-P-0700-01M
			See picture		AR60.00-P-0700-01M	AR60.00-P-0700-01MP

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Bending Iron (129 589 00 27 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

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-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-1015-16A	Left rear fender panel only for sectional repair	A 220 637 23 09
BR00.45-Z-1016-16A	Right rear fender panel only for sectional repair	A 220 637 24 09