Replace complete rear fender - AR63.50-P-1400M
MODEL 220
Shown on model 220.0/1
| Removing | |||
| Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel | No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel. |
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| 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. | ||
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. | ||
| 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. |
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| Guidelines for removing fuel tank when performing welding work on bodies | All models | ||
| Measures for preventing damage to vehicles or components when performing electric welding work | All models | ||
| General information on body repair | All models | ||
| Notes on paintwork repairs | Model 124, 126, 129, 140, 163, 168, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463, 639 | ||
| General information on MB materials | Model 124, 126, 129, 140, 163, 168, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463, 639 | ||
| 1 | Remove rear bumper | ||
| Model 220 with trailer hitch, code 550, except AMG optical package - front spoiler, side skirts and rear apron, code 772, Trailer hitch with removable ball neck Model 220 with trailer hitch, code 550, except AMG optical package - front spoiler, side skirts and rear apron, code 772, Mechanical swing-away trailer hitch |
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| 2 | Remove rear bumper | ||
| 3 | Remove trunk lid | ||
| 4 | Remove fuel tank | Model 220.025/125/126/163/178 with ski bag (through-loading feature), code 282a, with refrigerator compartment in rear center backrest, code 308 Model 220.025/125/126/163/176/178 except ski bag (through-loading feature), code 282a, except refrigerator compartment in rear center backrest, code 308 |
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| Model 220.026/028/063/065/067/070/075/083/084/087/128/165/167/170/175/176/179/183/184/187/875/878 with ski bag (through-loading feature), code 282a, with refrigerator compartment in rear center backrest, code 308 |
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| Model 220.026/028/063/065/067/070/073/074/075/083/084/087/128/165/167/170/173/174/175/179/183/184/187/875/878 except ski bag (through-loading feature), code 282a, with refrigerator compartment in rear center backrest, code 308 | |||
| 5 | Remove rear seat backrest | Model 220 875/878 with electrically adjustable rear bench seat, code 223b Model 220 875/878 except electrically adjustable rear bench seats, code (223b), except electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c Model 220 875/878 electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c |
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| Model 220 0/1 with electrically adjustable rear bench seat, code 223b |
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| Model 220. 0/1 except electrically adjustable rear bench seat, code 223b, except electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c |
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| Model 220 0/1 with electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c |
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| Model 220.875/878 with Vis-a-vis seats |
AR91.12-P-1620MP | ||
| 6 | Remove floor mats | ||
| 7 | Remove detachable parts in area to be repaired | ||
| 8 | Cover all detachable parts remaining in vehicle | Tarp (fire-resistant) | |
| 9 | Separate rear fender | AR63.50-P-1400-02M | |
| Figure | |||
| Fig 4 | |||
Vario Drill WS 91 spot weld removing tool Ball cutter, dia. 12 mm Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Cutting disk, Ø 65 mm, 80 m/s (max. 23, 500 rpm) Sheet metal crimping pliers Drill Straight grinder Angle grinder Body jig saw Two-post lifting platform 3.0-3.5 t, electromechanical Tarp (fire-resistant) |
Fig 5 | ||
| 10 | Prepare new rear fender part | AR63.50-P-1400-03M | |
| Fig 4 | |||
Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Drill Angle grinder |
Fig 5 | ||
| Install | |||
| 11 | Install rear fender and weld in | AR63.50-P-1400-04M | |
| Figure | |||
| Fig 3 | |||
Electrode miller Round wire brush, braided, dia. 70 mm Clamping pliers Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) MIG MAG gas welder (steel, brazing, aluminum) Inverter spot welder Drill Angle grinder Wet/dry vacuum cleaner Two-post lifting platform 3.0-3.5 t, electromechanical Tarp (fire-resistant) |
Fig 7 | ||
| 12 | Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01M | |
| Figure | |||
| Rear door to top of side section | *BE60.00-P-1002-01A | ||
| Rear door to side piece, bottom | *BE60.00-P-1002-01A | ||
| Trunk lid to rear fender, top | *BE60.00-P-1003-01A | ||
| Trunk lid to bottom of rear fender | *BE60.00-P-1003-01A | ||
| Trunk lid to rear lamp unit | *BE60.00-P-1003-01A | ||
| Rear fender to lamp unit | *BE60.00-P-1003-01A | ||
| Fuel filler flap | *BE60.00-P-1005-01A | ||
| 13 | Clean weld joints and sheet metal flange with round wire brush | Round wire brush, braided, dia. 70 mm | |
| 14 | Clean repair areas | ||
| 15 | Prime repair area using primer filler | ||
| 16 | Carry out seam sealing after repairs | ||
| Sealant | *BR00.45-Z-1003-01A | ||
| 17 | Paint repair areas and adjacent surfaces | ||
| 18 | Apply additional cavity preservation | ||
| Notes on cavity preservation | Model 124, 126, 129, 140, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 463, 639, 671, 690.6, 901, 902, 903, 904, 905 Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7 Combination pressure spray gun (corrosion protection) |
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| MB cavity wax preservation, 1 l | *BR00.45-Z-1003-05A | ||
| 19 | Remove tarp from all covered parts that remained in the vehicle. | Tarp (fire-resistant) | |
| 20 | Install rear seat backrest | Model 220 875/878 with electrically adjustable rear bench seat, code 223b Model 220.875/878 except electrically adjustable rear bench seat, code 223b, except electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c Model 220 875/878 with electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c |
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| Model 220 0/1 with electrically adjustable rear bench seat, code 223b |
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| Model 220 0/1 except electrically adjustable rear bench seat, code 223b, except electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c |
|||
| Model 220 0/1 with electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c |
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| Model 220.875/878 with Vis-a-vis seats |
AR91.12-P-1620MP | ||
| 21 | Install fuel tank | Model 220.025/125/126/163/178 with ski bag (through-loading feature), code 282a, with refrigerator compartment in rear center backrest, code 308 Model 220.025/125/126/163/176/178 except ski bag (through-loading feature), code 282a, except refrigerator compartment in rear center backrest, code 308 |
|
| Model 220.026/028/063/065/067/070/075/083/084/087/128/165/167/170/175/176/179/183/184/187/875/878 with ski bag (through-loading feature), code 282a, with refrigerator compartment in rear center backrest, code 308 | |||
| Model 220.026/028/063/065/067/070/073/074/075/083/084/087/128/165/167/170/173/174/175/179/183/184/187/875/878 except ski bag (through-loading feature), code 282a, with refrigerator compartment in rear center backrest, code 308 | |||
| 22 | Install rear bumper | ||
| Model 220 with trailer hitch, code 550, except AMG optical package - front spoiler, side skirts and rear apron, code 772, Trailer hitch with removable ball neck Model 220 with trailer hitch, code 550, except AMG optical package - front spoiler, side skirts and rear apron, code 772, Mechanical swing-away trailer hitch |
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| 23 | Install taillamp | ||
| 24 | Install trunk lid | ||
| 25 | Insert floor mat | ||
| 26 | Install all removed detachable parts |
TEST AND ADJUSTMENT VALUES, GAP DIMENSIONS AT HOODS, DOORS AND COVERS
| Number | Designation | Model 220.0/1 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01A | Gap dimension | Front door to A-pillar | Dimension "B" | mm | 8.0 (±0.5) |
| Front door to fender | Dimension "H" | mm | 5.0 (±0.5) | ||
| Front door to rear door | Dimension "I" | mm | 5.0 (±0.5) | ||
| Front door to roof | Dimension "C" | mm | 8.0 (±0.5) | ||
| Rear door to top of side section | Dimension "D" | mm | 5.0 (±0.5) | ||
| Rear door to side piece, bottom | Dimension "J" | mm | 5.0 (±0.5) | ||
| Fender to A-pillar | Dimension "Q" | mm | - | ||
| Front door to rear fender | Dimension "P" | mm | - | ||
| See picture | |||||
| AR60.00-P-0700-01M | |||||
| BE60.00-P-1003-01A | Gap dimension | Trunk lid to rear fender, top | Dimension "F" | mm | 4.0 (±0.5) |
| Trunk lid to bottom of rear fender | Dimension "M" | mm | - | ||
| Trunk lid to rear fender | Dimension "F" | mm | 4.0 (±0.5) | ||
| Trunk lid to rear lamp unit | Dimension "M" | mm | 4.4 (±0.5) | ||
| Trunk lid to bumper | Dimension "V" | mm | - | ||
| Rear fender to lamp unit | Dimension "U" | mm | - | ||
| See picture | |||||
| AR60.00-P-0700-01M | |||||
| BE60.00-P-1005-01A | Gap dimension | Fuel filler flap | Dimension "K" | mm | - |
| Dimension "L" | mm | 4.0 (±0.5) | |||
| See picture | |||||
| AR60.00-P-0700-01M | |||||
TEST AND ADJUSTMENT VALUES, GAP DIMENSIONS AT HOODS, DOORS AND COVERS
| Number | Designation | Model 220.875/878 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01A | Gap dimension | Front door to A-pillar | Dimension "B" | mm | 6.5 (±0.5) |
| Front door to fender | Dimension "H" | mm | 5.0 (±0.5) | ||
| Front door to rear door | Dimension "I" | mm | - | ||
| Front door to roof | Dimension "C" | mm | 6.5 (±0.5) | ||
| Rear door to top of side section | Dimension "D" | mm | 5.0 (±0.5) | ||
| Rear door to side piece, bottom | Dimension "J" | mm | 5.0 (±0.5) | ||
| Fender to A-pillar | Dimension "Q" | mm | - | ||
| Front door to rear fender | Dimension "P" | mm | - | ||
| See picture | AR60.00-P-0700-01MP | ||||
| BE60.00-P-1003-01A | Gap dimension | Trunk lid to rear fender, top | Dimension "F" | mm | 4.0 (±0.5) |
| Trunk lid to bottom of rear fender | Dimension "M" | mm | - | ||
| Trunk lid to rear fender | Dimension "F" | mm | 4.0 (±0.5) | ||
| Trunk lid to rear lamp unit | Dimension "M" | mm | 4.4 (±0.5) | ||
| Trunk lid to bumper | Dimension "V" | mm | - | ||
| Rear fender to lamp unit | Dimension "U" | mm | - | ||
| See picture | AR60.00-P-0700-01MP | ||||
| BE60.00-P-1005-01A | Gap dimension | Fuel filler flap | Dimension "K" | mm | - |
| Dimension "L" | mm | 4.0 (±0.5) | |||
| - | |||||
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-1003-05A | Cavity sealant, solvent-free (1 l container) | A 000 986 72 70 05 |