Replace complete rear fender - AR63.50-P-1400SX
MODEL 221 except CODE (Z07) Top protection
| 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 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. | AS00.00-Z-0010-01A | |
| Risk of explosion from pressurized spray cans | Protect cans from direct sunlight and temperatures above 50 °C | AS00.00-Z-0015-01A | |
| Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes | Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only. | AS00.00-Z-0016-01A | |
| 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 | |
| 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. |
AS47.00-Z-0001-01A | |
| Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust | Wear protective respiratory mask, protective gloves and safety glasses. Use suitable, grounded vacuum cleaner |
AS60.00-Z-0007-01N | |
| General information on repair of vehicles with ultra-strength steels. | Failure to observe instructions when straightening/repairing, separating, preparing adhesive points, joining/connecting, resistance spot welding, MIG welding, MIG brazing can lead to considerable damage to ultra-strength steels and their joints. | AH60.00-P-0024-01N | |
| 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 | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| Notes on various body materials | AH60.00-P-0011-01SX | ||
| General information on dent removal and straightening aluminum parts | AH60.00-P-0012-01N | ||
| General information on body connection techniques | AH60.00-P-0015-01SX | ||
| 1 | Remove rear door sill molding | AR68.30-P-4100SX | |
| 2 | Remove headliner | AR68.30-P-4300SX | |
| 3 | Remove rear wall window | AR67.20-P-2000SX | |
| 4 | Remove taillamps | AR82.10-P-4905SX | |
| 5 | Remove rear bumper | AR88.20-P-2200SX | |
| 6 | Remove trim in trunk | AR68.30-P-4600SX | |
| 7 | Cover all detachable parts remaining in vehicle | Tarp (fire-resistant) | |
| 8 | Separate rear fender (1) | AR63.50-P-1400-02SX | |
| Sheet metal crimping pliers for areas not easily accessible | WF58.50-P-6350-01Y | ||
| Recycle aluminum parts | OS60.00-P-0001-01N | ||
| Figure | |||
| Figure | |||
Ball cutter, dia. 12 mm Vario Drill WS 91 spot weld removing tool Beading pliers Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Hot air gun - 3000 W Aluminum workshop vehicle Drill Angle grinder Body jig saw Wet/dry vacuum cleaner |
Figure | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 9 | Prepare new rear fender (1) | AR63.50-P-1400-03SX | |
Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Aluminum workshop vehicle Drill Angle grinder Body jig saw |
Figure | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 10 | Install rear fender (1) and weld in | AR63.50-P-1400-04SX | |
| General information on riveting | AH60.00-P-0003-01N | ||
| Rear door to side piece, bottom | *BE60.00-P-1002-01R | ||
| Trunk lid to rear lamp unit | *BE60.00-P-1003-01R | ||
| Rear fender to lamp unit | *BE60.00-P-1003-01R | ||
| Trunk lid license plate panel to rear lamp unit | *BE60.00-P-1003-01R | ||
| Fuel filler flap | *BE60.00-P-1004-01R | ||
| Fig 7 | |||
| Figure | |||
Electrode miller BTR Usibor drill bit, dia. 6.7 mm Clamping pliers Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver Round wire brush, braided, dia. 70 mm |
Figure | ||
| Taurus 3 blind rivet tool with 100 mm extension unit | Blind rivet/punch riveting method Aluminum workshop vehicle MIG MAG gas welder (steel, brazing, aluminum) Inverter spot welder Drill Wet/dry vacuum cleaner |
||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Polygrip flat round head rivet, 6.4X14 | *BR00.45-Z-1001-13A | ||
| Polygrip countersunk-head rivet, 6.4X14 | *BR00.45-Z-1002-13A | ||
| Adhesive | *BR00.45-Z-1092-02A | ||
| 11 | Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01SX | |
| Figure | |||
| Rear door to side piece, bottom | *BE60.00-P-1002-01R | ||
| Trunk lid to rear lamp unit | *BE60.00-P-1003-01R | ||
| Rear fender to lamp unit | *BE60.00-P-1003-01R | ||
| Trunk lid license plate panel to rear lamp unit | *BE60.00-P-1003-01R | ||
| Fuel filler flap | *BE60.00-P-1004-01R | ||
| 12 | Clean weld joints and sheet metal flange with round wire brush | Round wire brush, braided, dia. 70 mm Drill |
|
| 13 | Clean repair areas | ||
| 14 | Prime repair area using primer filler | ||
| 15 | Carry out seam sealing after repairs | AR97.10-P-4000SX | |
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 16 | Paint repair areas and adjacent surfaces | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 17 | Apply additional cavity preservation | AR97.20-P-1500SX | |
| Notes on cavity preservation | Combination pressure spray gun (corrosion protection) |
AH97.20-P-0001-01B | |
| MB cavity wax preservation, 1 l | *BR00.45-Z-1003-05A | ||
| 18 | Remove tarp | ||
| 19 | Install rear wall window | AR67.20-P-2000SX | |
| 20 | Install headliner | AR68.30-P-4300SX | |
| 21 | Install taillamps | AR82.10-P-4905SX | |
| 22 | Install rear bumper | AR88.20-P-2200SX | |
| 23 | Install paneling in trunk | AR68.30-P-4600SX | |
| 24 | Install rear door sill molding | AR68.30-P-4100SX |
CHECK VALUES FOR GAPS
| Number | Designation | Model 221 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01R | Gap dimension | Front door to A-pillar | Dimension "D" | mm | 4.5 (±0.5) |
| Front door to fender | Dimension "E" | mm | 4 (±0.5) | ||
| Front door to rear door | Dimension "F" | mm | 4.5 (±0.5) | ||
| Trim strip at front door to roof frame | Dimension "G" | mm | 4.5 (±0.5) | ||
| Trim strip at rear door to roof frame | Dimension "H" | mm | 4.5 (±0.5) | ||
| Rear door to side piece, bottom | Dimension "I" | mm | 4.5 (±0.5) | ||
| Front door cover to rear door cover | Dimension "S" | mm | 4.5 (±0.5) | ||
| See picture | |||||
| AR60.00-P-0700-01SX | |||||
| BE60.00-P-1003-01R | Gap dimension | Trunk lid to rear fender, top | Dimension "J" | mm | 4 (±0.5) |
| Trunk lid to rear lamp unit | Dimension "K" | mm | 4 (±0.5) | ||
| Trunk lid to bumper | Dimension "L" | mm | 5.5 (±1.5) | ||
| Rear fender to lamp unit | Dimension "M" | mm | 2.5 (±0.5) | ||
| Trunk lid license plate panel to rear lamp unit | Dimension "N" | mm | 4 (±0.5) | ||
| See picture | |||||
| AR60.00-P-0700-01SX | |||||
| BE60.00-P-1004-01R | Gap dimension | Fuel filler flap | Dimension "O" | mm | 3.5 (±0.5) |
| See picture | |||||
| AR60.00-P-0700-01SX | |||||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 20 |
| BR00.45-Z-1003-01A | White sealing compound, 310 ml, DBL 6069.20 | A 001 989 63 20 |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |
| BR00.45-Z-1003-05A | Cavity sealant, 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-1002-13A | Polygrip countersunk-head rivet, 6.4X14 | A 003 990 86 97 05 |
| BR00.45-Z-1001-13A | Blind rivet 6.4X14 | A 003 990 35 97 |