Replace complete rear fender - AR63.50-P-1400LF
MODEL 222
| 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 | |
| Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust | Wear dust filter mask, safety glasses and protective gloves. Use a suitable, grounded dust extraction system. |
AS60.00-Z-0007-01N | |
| 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 | ||
| Notes on processing of 2-K structural foam adhesive during body repairs | AH60.00-P-0040-01A | ||
| Evaluation of high-voltage components | AH54.00-P-6500-01SXH | ||
| General information on body repair | AH60.00-P-0001-01A | ||
| Note on working on aluminum components and vehicles | AH60.00-P-0034-01LF | ||
| Notes on acoustic foam and structural foam in the vehicle | AH60.00-P-0039-01A | ||
| 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 in vehicle with spark protection blanket | ||
| 3 | Separate rear fender (1) | Model 222.0 Model 222.1/9 except code Z07 (Top protection) |
AR63.50-P-1401-01LF |
| Model 222.1/9 with code Z07 (Top protection) |
AR63.50-P-1401-01LFS | ||
Round wire brush Stainless steel round wire brush Body power jigsaw Spot weld milling machine Heat gun Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding |
*BR00.45-Z-1001-07A | ||
| Primer stick | *BR00.45-Z-1012-07A | ||
| 4 | Prepare new rear fender (1) | Model 222.0 Model 222.1/9 except code Z07 (Top protection) |
AR63.50-P-1401-02LF |
| Model 222.1/9 with code Z07 (Top protection) |
AR63.50-P-1401-02LFS | ||
Round wire brush Body power jigsaw 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 | ||
| General notes on welding | AH60.00-P-0005-01N | ||
| 5 | Install rear fender (1) | Model 222.0 Model 222.1/9 except code Z07 (Top protection) |
AR63.50-P-1401-03LF |
| Model 222.1/9 with code Z07 (Top protection) |
AR63.50-P-1401-03LFS | ||
| AR60.00-P-0700-01LF | |||
| WS60.00-P-0010B | |||
| 000 588 02 84 00 Welder | WS60.00-P-0022K | ||
Round wire brush Stainless steel round wire brush Manual temporary fastener, 6.35 mm Spot welder Wet/dry vacuum cleaner White sealing compound, 310 ml, DBL 6069.20 |
*BR00.45-Z-1003-01A | ||
| Adhesive kit, body, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| 2-component adhesive for reinforcements | *BR00.45-Z-1152-02A | ||
| 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 | ||
| Polygrip countersunk-head rivet, 6.4x14 | *BR00.45-Z-1002-13A | ||
| Flow-form rivet up to 3.5 mm clamping range (A1) | *BR00.45-Z-1023-13A | ||
| Blind rivet 6.4x12 (clamping range 1 mm to 3.5 mm) | *BR00.45-Z-1035-13A | ||
| Rear door to side section, bottom | *BE60.00-P-1012-01BA | ||
| Trunk lid to rear fender at top | *BE60.00-P-1014-01BA | ||
| Feeler gauge | Figure | ||
| 6 | Clean weld joints and sheet metal flange with round wire brush | Round wire brush Stainless steel round wire brush |
|
| 7 | Remove spark protection blankets | ||
| 8 | Clean repair area | ||
| 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-4000LF | |
| 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-1500LF | |
| 13 | Install all detachable body components in area to be repaired |
CHECK VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 222 | ||
|---|---|---|---|---|
| BE60.00-P-1012-01BA | Rear door to side section, bottom | Dimension "I" | mm | 4 (±0, 5) |
| For picture, see | AR60.00-P-0700-01LF | |||
CHECK VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 222 | ||
|---|---|---|---|---|
| BE60.00-P-1014-01BA | Trunk lid to rear fender at top | Dimension "K" | mm | 3, 5 (±1) |
| For picture, see | AR60.00-P-0700-01LF | |||
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, 6.4x14 | 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-1023-13A | Flow-form rivet up to 3.5 mm clamping range (A1) | A 000 991 07 33 |
| BR00.45-Z-1035-13A | Blind rivet 6.4x12 (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 |
| BR00.45-Z-1152-02A | 2-component adhesive for reinforcements | A 011 989 99 71 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |