Replace rear fender complete - AR63.50-P-1401LWR

MODEL 205.4 

Fig 1: Rear Fender Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	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
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	Notes on acoustic foam and structural foam in the vehicle		AH60.00-P-0039-01LW
	General information on body repair		AH60.00-P-0001-01A
	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 blankets	When replacing the right rear fender (1), the standard tank lock must be installed and the filler neck covered with a welding protection blanket.
3	Separate rear fender (1)		AR63.50-P-1401-01LWR
	000 588 00 84 00 Heat gun		WS54.00-P-0049B
		Commercially available devices/tools  Round wire brush Spot weld milling machine Wet/dry vacuum cleaner Primer stick	*BR00.45-Z-1012-07A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
4	Prepare rear fender (1)		AR63.50-P-1401-02LWR
		Commercially available devices/tools  Round wire brush 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 inflammable materials from the hazard area. Use air extraction system.	AS00.00-Z-0007-01A
	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-1401-03LWR
	000 588 01 84 00 Welder		WS60.00-P-0021K
	000 588 02 84 00 Welder		WS60.00-P-0022K
		Gap dimensions on hoods, doors and lids	AR60.00-P-0700-01LW
		Commercially available devices/tools  Round wire brush Manual temporary fastener 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Wet/dry vacuum cleaner
		Soft top compartment lid to rear fender	*BE60.00-P-1034-01BB
		Trunk lid to fender at rear, top	*BE60.00-P-1012-01BB
		Rear fender to taillamp	*BE60.00-P-1015-01BB
		Front door to sidewall	*BE60.00-P-1007-01BB
		Soft top compartment lid to trunk lid	*BE60.00-P-1035-01BB
		White sealing compound, 310 ml, DBL 6069.20	*BR00.45-Z-1003-01A
		Parts kit for 2-component adhesive for body	*BR00.45-Z-1162-02A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	*BR00.45-Z-1012-13A
		Blind rivet 6.5 14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)	*BR00.45-Z-1016-13A
		Feeler gauge	Figure
6	Clean welds and sheet metal flanges	Commercially available devices/tools  Round wire brush
7	Remove spark protection blankets
8	Clean repair area	Commercially available devices/tools  Wet/dry vacuum cleaner
9	Prime repair area using primer filler
	Notes on paintwork repairs	Use only primer filler approved by Daimler AG.	AH98.00-P-9408-02A
10	Seal seam following repairs		AR97.10-P-4000LW
11	Paint repair areas and adjacent surfaces
	Notes on paintwork repairs	Use only paints approved by Daimler AG.	AH98.00-P-9408-02A
12	Add cavity preserving agent		AR97.20-P-1500LW
13	Install all detachable body components in area to be repaired

CHECK VALUES FOR GAP DIMENSIONS

Number	Designation			Model 205.4
BE60.00-P-1007-01BB	Front door to sidewall	Dimension "H1"	mm	3, 5 (±0, 5)
		For picture, see		AR60.00-P-0700-01LW

CHECK VALUES FOR GAP DIMENSIONS

Number	Designation			Model 205.4
BE60.00-P-1012-01BB	Trunk lid to fender at rear, top	Dimension "K"	mm	3, 5 (±0, 5)
		Dimension "K1"	mm	-
		For picture, see		AR60.00-P-0700-01LW

CHECK VALUES FOR GAP DIMENSIONS

Number	Designation			Model 205.4
BE60.00-P-1015-01BB	Rear fender to taillamp	Dimension "N"	mm	1 (±1)
		For picture, see		AR60.00-P-0700-01LW

CHECK VALUES FOR GAP DIMENSIONS

Number	Designation			Model 205.4
BE60.00-P-1034-01BB	Soft top compartment lid to rear fender	Dimension "Z3"	mm	3 (+1/-0, 5)
		For picture, see		AR60.00-P-0700-01LW

CHECK VALUES FOR GAP DIMENSIONS

Number	Designation			Model 205.4
BE60.00-P-1035-01BB	Soft top compartment lid to trunk lid	Dimension "Z4"	mm	5 (±0, 5)
		For picture, see		AR60.00-P-0700-01LW

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

Courtesy of MERCEDES-BENZ USA

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-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-1012-13A	Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	A 004 990 16 97
BR00.45-Z-1016-13A	Blind rivet 6.5 14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)	A 004 990 17 97
BR00.45-Z-1162-02A	Parts kit for 2-component adhesive for body	A 012 989 17 71