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

TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number	Designation				Model 211.0
BE60.00-P-1001-01F	Gap dimension	Engine hood to fender	Dim. "A"	mm	3.5 (±0.5)
		Engine hood to headlamp	Dim. "B"	mm	4 (+1)
		Radiator grille/bumper	Dim. "C"	mm	5,5 (+1)
			See picture		AR60.00-P-0700-01T
BE60.00-P-1002-01F	Gap dimension	Front door to A-pillar	Dim. "D"	mm	4.5 (±0.5)
		Front door to fender	Dim. "E"	mm	4 (±0.5)
		Front door to rear door	Dim. "F"	mm	4 (+1)
		Front door to roof	Dim. "G"	mm	4.5 (±0.5)
		Rear door to top of side section	Dim. "H"	mm	4.5 (±0.5)
		Rear door to side section, bottom	Dim. "I"	mm	3.5 (±0.5)
			See picture		AR60.00-P-0700-01T
BE60.00-P-1003-01F	Gap dimension	Trunk lid to rear fender, top	Dim. "J"	mm	3,5 (+1)
		Trunk lid to rear lamp unit	Dim. "K"	mm	3.9 (+1)
		Trunk lid to bumper	Dim. "L"	mm	6.5 (-0.5/+1)
		Rear fender to rear lamp unit	Dim. "M"	mm	2.5 (±0.5)
		Trunk lid license plate panel to rear lamp unit	Dim. "N"	mm	4.3 (+1)
			See picture		AR60.00-P-0700-01T
BE60.00-P-1004-01F	Gap dimension	Fuel filler flap	Dim. "O"	mm	3.5 (±0.5)
BE60.00-P-1004-01F	Gap dimension	Fuel filler flap	See picture		AR60.00-P-0700-01T

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Set Of Covers (211 589 00 91 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Welding Bead Catcher (230 589 01 98 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS CHART

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-1001-13A	Blind rivet 6.4 14	A 003 990 35 97

Install and fit rear fender.
Insert taillamp, install rubber seal and striker eye.
Check and adjust sizes of gaps: rear fender/taillamp trunk lid/upper rear fender trunk lid covering/taillamp rear door/upper side section rear door/lower side section
Use feeler gage!
Drill 6.5 mm dia. rivet holes (area X).
Remove rear fender and deburr rivet holes on both sides.

Fig 5: Locating 6.5 mm Dia. Rivet Holes (Area X)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Locating MB Body Sealant On Foam Parts Of Wheel Well And C-Pillar
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Apply MB body sealant on foam parts of wheel well and of C-pillar.
Remove and replace damaged foam parts.

Fig 7: Locating Rear Fender Welding & Riveting Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Rear fender (areas A and P).
Rear fender (areas N and Q).
Rivet rear fender and outer longitudinal member with 6.4 x 14 mm dia. Polygrip flat head rivets (area O).
Weld in area Q in intervals, allow to cool down in between, minimum heat distortion.

Fig 8: Locating Rear Fender Welding Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Rear fender (areas I, J, L and M).
Rear fender 096 (area K).

Fig 9: Welding Rear Fender (Areas A To H)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Rear fender (areas A to H).
Readjust spot welding flange on wheel well with crimping iron.
Clean weld joints using wire brush.
Fill rear fender with body solder in cross-hatched area and smooth.
Bend over spot weld flange analog to undamaged side of vehicle.

Fig 10: Locating Rear Fender Body Solder Fill Area
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.