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

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 section, bottom	Dimension "I"	mm	4.5 (±0.5)
		Front door cover to rear door cover	Dimension "S"	mm	4.5 (±0.5)
		Front door cover to rear door cover	See picture		AR60.00-P-0700-01S X
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 rear lamp unit	Dimension "M"	mm	2.5 (±0.5)
		Trunk lid license plate panel to rear lamp unit	Dimension "N"	mm	4 (±0.5)
		Trunk lid license plate panel to rear lamp unit	See picture		AR60.00-P-0700-01S X
BE60.00-P-1004-01R	Gap dimension	Fuel filler flap	Dimension "O"	mm	3.5 (±0.5)
BE60.00-P-1004-01R	Gap dimension	Fuel filler flap	See picture		AR60.00-P-0700-01S X

Fig 1: Identifying Bending Iron (129 589 00 27 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Feeler Gauge (129 589 03 21 00)

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Fig 3: Identifying Welding Bead Catcher (129 589 01 98 00)

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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-1092-02A	Adhesive kit, body, 2-component adhesive	A 009 989 36 71
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, 6.4 x14	A 003 990 86 97 05
BR00.45-Z-1001-13A	Blind rivet 6.4x14	A 003 990 35 97

Install rear fender (1), trunk lid, taillamps and rubber seal and fit.
Check and adjust gaps: rear door to bottom side section (I), trunk lid to taillamp (K), trunk lid cover to taillamp (N), rear fender to taillamp (M), fuel filler flap (O).
Use feeler gauge.

Shown on model 221 without code Z07 Top protection

Fig 4: Identifying Gaps
Courtesy of MERCEDES-BENZ USA
Fasten rear fender (1) with clamping pliers.
Remove trunk lid, taillamps and rubber seal.
Drill dia. 6.5 mm rivet holes (areas E, F, G, H, I, J, K and L).
Drill rivet holes with dia. 6.7 mm BRT Usibor drill bit (area D).
To drill out rivet holes on rear fender (1), transfer every second spot weld from old rear fender to new part.

Shown on model 221 without code Z07 Top protection

Fig 5: Identifying Rear Fender Drilling Areas
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Remove rear fender (1)
Deburr rivet holes on rear fender (1) on both sides.
Remove drill shavings using wet/dry vacuum cleaner
Coat insides of riveted joints with zinc dust paint (area D).
Shown on model 221 without code Z07 Top protection

Fig 6: Identifying Mating Surfaces
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Apply 2-component adhesive to mating surfaces in cross-hatched areas (areas X, Y, Z and AA).
Observe pretreatment of bonding surfaces.

Refer to manufacturer specifications for adhesive curing and application times.
Apply MB body sealant to foam part (area N1).
Damaged foam parts must be removed and replaced.

Shown on model 221 without code Z07 Top protection

Fig 7: Identifying Foam Parts
Courtesy of MERCEDES-BENZ USA
Apply adhesive to cross-hatched areas (areas M₁ , O, P, Q, R, S, T, U, V, W and AJ).
Observe pretreatment of bonding surfaces.

Refer to manufacturer specifications for adhesive curing and application times.

Shown on model 221 without code Z07 Top protection

Fig 8: Identifying Bonding Surfaces
Courtesy of MERCEDES-BENZ USA

Shown on model 221 without code Z07 Top protection

Fig 9: Identifying Rear Fender Riveting Areas
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Install rear fender (1) and fasten using clamping pliers and manual temporary fasteners.
Rivet rear fender (1) using Polygrip flat round head rivet, dia. 6.4x14 (areas D, I, J, K and L).
For blind rivet tool, see GOTIS.

Fig 10: Identifying Rear Fender Riveting Areas
Courtesy of MERCEDES-BENZ USA
Rivet rear fender (1) with Polygrip countersunk head rivet, dia. 6.4x14 (areas AD, AE and AF).
For blind rivet tool, see GOTIS.
Rivet rear fender (1) using Polygrip flat round head rivet, dia. 6.4x14 (areas E, F, G and H).
For blind rivet tool, see GOTIS.
Rear fender (1) (areas AG and AH).
Rear fender (1) (area AC).
Rear fender (1) to guard plate (2) (area AJ).
Grind MIG plug welds down flat (area AC).
Grind inert gas welds down flat (area AJ).
Shown on model 221 without code Z07 Top protection

Fig 11: Identifying Rear Fender Weld Areas
Courtesy of MERCEDES-BENZ USA
Rear fender (1) (areas Z, AA and AB).
Rear fender (1) (area B).
Grind MIG plug welds down flat (area B).
Rear fender (1) on guard plate (2) (area B₁ ).
Grind inert gas welds down flat (area B ₁ ).

Fig 12: Identifying Inert Gas Welds
Courtesy of MERCEDES-BENZ USA
Weld in rear fender (1) with (areas A and C).
Weld in intervals, allow to cool down in between to minimize heat distortion (areas A and C).

Shown on model 221 without code Z07 Top protection

Fig 13: Identifying Rear Fender Welding Areas
Courtesy of MERCEDES-BENZ USA

Shown on model 221 without code Z07 Top protection

Fig 14: Adjusting Spot Weld Flange
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Readjust spot weld flange on wheel well with crimping iron.
Spot weld flange position analog to undamaged vehicle side.
Clean welds on rear fender (1) with round wire brush.
Grind rear fender (1) down flat in cross-hatched areas (areas A and C).
Finish surface on rear fender (1), fill and smooth.
Remove grinding and drill shavings using wet/dry vacuum cleaner.
Shown on model 221 without code Z07 Top protection

Fig 15: Identifying Rear Fender Grinding Areas
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