Replace complete rear fender - AR63.50-P-1400LW
Model 205.0/1
MODIFICATION NOTES
| 29.8.14 | Rear Fender to Tail lamp | TYPE 205.0/1 | BE60.00-P-1015-01BB |
| 29.8.14 | Trunk lid to rear fender, top | TYPE 205.0/1 | BE60.00-P-1012-01BB |
| 29.8.14 | Rear door to side panel below | TYPE 205.0/1 | BE60.00-P-1010-01BB |
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| 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 as well as risk of injury to eyes and skin caused by contact with fuel. | No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. Wear protective clothing when handling fuel. |
AS47.00-Z-0001-01A | |
| Risk of death when touching components on vehicles with high-voltage on-board electrical system | Do not touch components and open lines of the high-voltage on-board electrical system. Persons who wear electronic implants (e.g. cardiac pacemakers), must not carry out any work on high-voltage on-board electrical systems. | AS54.00-Z-0001-01A | |
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| Note on high-voltage on-board electrical system | AH54.00-P-0010-01A | ||
| Note on high-voltage battery | AH54.10-P-0006-01MEV | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| Evaluation of high-voltage components | AH54.00-P-6500-01SXH | ||
| General information on body repair | AH60.00-P-0001-01A | ||
| Notes on foam-protected insulation in body | AH60.00-P-0041-01A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| Remove | |||
| 1 | Remove detachable parts in area to be repaired | ||
| 2 | Cover all detachable parts remaining on vehicle with spark protection blanket | ||
| 3 | Separate rear fender (1) | AR63.50-P-1400-02LW | |
Round wire brush Body jig saw Spot weld milling machine Heat gun Glass removal Wet/dry vacuum cleaner |
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| Primer stick | *BR00.45-Z-1012-07A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 4 | Prepare new rear fender (1) | AR63.50-P-1400-03LW | |
Round wire brush Body jig saw Spot weld milling machine |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases | Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly flammable materials from the hazard area. Use air extraction system. | AS00.00-Z-0007-01A | |
| 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 | |
| Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| 5 | Install rear fender (1) | AR63.50-P-1400-04LW | |
| 000 588 02 39 00 Rivet press tool | WS60.00-P-0010B | ||
| 000 588 02 84 00 Welder | WS60.00-P-0022K | ||
Round wire brush Manual temporary fastener, 6.35 mm Spot welder Wet/dry vacuum cleaner |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| White sealing compound, 310 ml, DBL 6069.20 | *BR00.45-Z-1003-01A | ||
| Adhesive kit, body, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| Blind rivet 6.4 X 12 (clamping range 1 mm to 3.5 mm) | *BR00.45-Z-1035-13A | ||
| Polygrip countersunk-head rivet, 6.4 X 14 | *BR00.45-Z-1002-13A | ||
For measuring points of gap dimensions on body see: ↓ Gap dimensions on hoods, doors and lids |
Figure | ||
| AR60.00-P-0700-01LW | |||
| Rear door to side section, bottom | *BE60.00-P-1010-01BB | ||
| Trunk lid to fender at rear, top | *BE60.00-P-1012-01BB | ||
| Rear fender to tail lamp | *BE60.00-P-1015-01BB | ||
| 6 | Clean welds and sheet metal flange | Round wire brush |
|
| 7 | Remove spark protection blankets | ||
| 8 | Clean repair area | Wet/dry vacuum cleaner |
|
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 9 | Prime repair area using primer filler | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 10 | Carry out seam sealing after repairs | AR97.10-P-4000LW | |
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 11 | Paint repair areas and adjacent surfaces | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 12 | Apply additional cavity preservation | AR97.20-P-1500LW | |
| 13 | Install all detachable body components in area to be repaired |
CHECK VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 205.0/1 | ||
|---|---|---|---|---|
| BE60.00-P-1010-01BB | Rear door to side section, bottom | Dimension "I" | mm | 3, 5 (± 0, 5) |
| For picture, see | AR60.00-P-0700-01LW | |||
CHECK VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 205.0/1 | ||
|---|---|---|---|---|
| BE60.00-P-1012-01BB | Trunk lid to fender at rear, top | Dimension "K" | mm | 3, 5 (+0, 5/-1) |
| Dimension "K1" | mm | - | ||
| For picture, see | AR60.00-P-0700-01LW | |||
CHECK VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 205.0/1 | ||
|---|---|---|---|---|
| BE60.00-P-1015-01BB | Rear fender to tail lamp | Dimension "N" | mm | 1 (± 1) |
| For picture, see | AR60.00-P-0700-01LW | |||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| 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 X 14 | A 003 990 86 97 05 |
| BR00.45-Z-1003-01A | White sealing compound, 310 ml, DBL 6069.20 | A 001 989 63 20 |
| BR00.45-Z-1012-07A | Primer stick | A 000 986 27 50 |
| BR00.45-Z-1035-13A | Blind rivet 6.4 X 12 (clamping range 1 mm to 3.5 mm) | A 000 991 76 32 |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |