Replace complete rear fender - AR63.50-P-1400TA
MODEL 211.2
| 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. | AS00.00-Z-0007-01A | |
| 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 | |
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-N-0005-01A | ||
| General information on repairs to body | AH60.00-N-0001-01A | ||
| Guidelines for removing fuel tank when performing welding work on bodies | AH60.00-P-3000-01Z | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1 | Prepare required workshop equipment and commercially available tools for repair | ||
| 2 | Remove all detachable body components in area to be repaired. | ||
| 3 | Cover all detachable parts remaining vehicle with fireproof tarpaulin | ||
| 4 | Install filler neck covering | AR63.50-P-1400-01TA | |
| *211589009100 | |||
| *211589029100 | |||
| 5 | Separate rear fender | AR63.50-P-1400-02TA | |
| *201589005100 | |||
Round wire brush gotis://K_58.3_06.0 Weld-spot milling machine gotis://K_58.1_02.0 Hot-air gun gotis://K_60-65_11. Hand drill (with chuck up to 16 mm dia.) gotis://G_58.0_00.1 Keyhole saw gotis://K_58.1_01.0 Wet and dry vacuum cleaner gotis://P_00.12_06.0 |
*211589052300 | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 6 | Prepare new rear fender part | AR63.50-P-1400-03TA | |
| Round wire brush gotis://K_58.3_06.0 Hand drill (with chuck up to 16 mm dia.) gotis://G_58.0_00.1 Keyhole saw gotis://K_58.1_01.0 |
|||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 7 | Install standard tank cap and tank flap, mask gap | ||
| 8 | Install rear fender, fit and weld in | AR63.50-P-1400-04TA | |
| General information on riveting | AH60.00-P-0003-01N | ||
| *000589876300 | |||
| *129589002700 | |||
| *129589019800 | |||
| *129589032100 | |||
| *211589009100 | |||
Round wire brush gotis://K_58.3_06.0 Vice grip pliers (standard) gotis://K_58.3_04.2 Vice grip pliers (special, small) gotis://K_58.3_04.3 Manual temporary fastener gotis://K_58.3_10.0 Hand riveting tool (for blind pop rivets) gotis://K_68-80_06.0 Inert gas welder gotis://K_60-65_17.0 Multifunction device (spot welding) gotis://K_60-65_15. Hand drill (with chuck up to 16 mm dia.) gotis://G_58.0_00.1 Angle grinder up to 125 mm gotis://G_58.0_06.0 Wet and dry vacuum cleaner gotis://P_00.12_06.0 Cavity preservation gun gotis://K_91-97_01. Abrasive disk, Ø 115 mm, 80 m/s (max. 13,250 RPM) |
*211589029100 | ||
| Rear door to side section, bottom | *BE60.00-P-1002-01F | ||
| Rear fender and taillamp | *BE60.00-P-1003-01F | ||
| Fuel filler flap | *BE60.00-P-1004-01F | ||
| Rear-end door to rear fender | *BE60.00-P-1005-01F | ||
| Taillamp in rear-end door to taillamp | *BE60.00-P-1005-01F | ||
| Rear window and D-pillar | *BE60.00-P-1005-01F | ||
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| Preservation agent | *BR00.45-Z-1003-05A | ||
| Rivet | *BR00.45-Z-1001-13A | ||
| 9 | Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01TA | |
| *129589032100 | |||
| Rear door to side section, bottom | *BE60.00-P-1002-01F | ||
| Rear fender and taillamp | *BE60.00-P-1003-01F | ||
| Fuel filler flap | *BE60.00-P-1004-01F | ||
| Rear-end door to rear fender | *BE60.00-P-1005-01F | ||
| Taillamp in rear-end door to taillamp | *BE60.00-P-1005-01F | ||
| Rear window and D-pillar | *BE60.00-P-1005-01F | ||
| 10 | Shape body flange for taillamp with embossing tool | AR63.50-P-1400-09CW | |
| *164589003900 | |||
| 11 | Clean weld joints and sheet metal flange with round wire brush | ||
| 12 | Clean repair areas | ||
| 13 | Prime area to be repaired using primer filler | ||
| 14 | Carry out seam sealing after repairs | AR97.10-P-4000T | |
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 15 | Paint repair areas and adjacent surfaces | ||
| 16 | Apply additional cavity preservation | AR97.20-P-1500T | |
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Preservation agent | *BR00.45-Z-1003-05A | ||
| 17 | Remove covers for filler neck | AR63.50-P-1400-01TA | |
| 18 | Remove tarp | ||
| 19 | Install all detachable body components in area to be repaired. |
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS
| Number | Designation | Model 211.2 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01F | Gap dimension | Front door to A-pillar | Dimension "D" | mm | 4.5 (-0.5/+1) |
| Front door to fender | Dimension "E" | mm | 4 (-0.5/+1) | ||
| Front door to rear door | Dimension "F" | mm | 4 (-0.5/+1) | ||
| Front door to roof | Dimension "G" | mm | 4.5 (-0.5/+1) | ||
| Rear door to top of side section | Dimension "H" | mm | - | ||
| Rear door to side section, bottom | Dimension "I" | mm | 3.5 (-0.5/+1) | ||
| See picture | AR60.00-P-0700-01T A | ||||
| BE60.00-P-1003-01F | Gap dimension | Trunk lid to rear fender, top | Dimension "J" | mm | - |
| Trunk lid to rear lamp unit | Dimension "K" | mm | - | ||
| Trunk lid to bumper | Dimension "L" | mm | - | ||
| Rear fender to rear lamp unit | Dimension "M" | mm | 2.5 (±1) | ||
| Trunk lid license plate panel to rear lamp unit | Dimension "N" | mm | - | ||
| See picture | AR60.00-P-0700-01T A | ||||
| BE60.00-P-1004-01F | Gap dimension | Fuel filler flap | Dimension "O" | mm | 3.5 (±0.5) |
| See picture | AR60.00-P-0700-01TA | ||||
| BE60.00-P-1005-01F | Gap dimension | Liftgate spoiler/roof | Dimension "P" | mm | 7 (-0.5/+1) |
| Rear-end door to rear fender | Dimension "Q" | mm | 4.5 (±1) | ||
| Taillamp in rear-end door to taillamp | Dimension "R" | mm | 5 (±1) | ||
| Rear-end door to bumper | Dimension "S" | mm | 6 (±1.5) | ||
| Rear window and D-pillar | Dimension "T" | mm | 4.5 (1) | ||
| Front door to roof | Dimension "U" | mm | 4.5 (-0.5/+1) | ||
| See picture | AR60.00-P-0700-01T A | ||||
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-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 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 |