Replace complete rear fender - AR63.50-P-1400V
MODEL 171, 172
Shown on model 171
MODIFICATION NOTES
| 2.5.11 | Value changed: Gap dimension, dimension "T" | *BE60.00-P-1005-01Y |
| 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 splatter 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 death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by 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 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 | |
| General information on body repair | AH60.00-N-0001-01A | ||
| Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01N | ||
| 1 | Remove all detachable parts in area to be repaired | ||
| 2 | Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket | ||
Welding protective blanket |
Figure | ||
| 3 | Separate rear fender (1) | AR63.50-P-1400-02V | |
| Weld-spot milling machine Metal needle template Window glazing device, FSC 1.6 Round wire brush Wet and dry vacuum cleaner |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 4 | Prepare new rear fender (1) | AR63.50-P-1400-03V | |
| Round wire brush |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 5 | Install rear fender (1) | AR63.50-P-1400-04V | |
| Figure | |||
| Figure | |||
| Fig 3 | |||
| Gap dimension model 171 | *BE60.00-P-1002-01L *BE60.00-P-1003-01L *BE60.00-P-1004-01L *BE60.00-P-1005-01L |
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| Gap dimension model 172 Multifunction device (spot welding) Pneumatic/hydraulic blind rivet tool Vice grip pliers (standard) Round wire brush Manual temporary fastener, 4.1 mm Vice grip pliers (standard) |
*BE60.00-P-1002-01Y *BE60.00-P-1003-01Y *BE60.00-P-1004-01Y *BE60.00-P-1005-01Y |
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| 2-component adhesive | *BR00.45-Z-1092-02A | ||
| Blind rivet | *BR00.45-Z-1012-13A | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| 6 | Adjust gaps on hoods, doors and lids | AR60.00-P-0700-01V | |
| Figure | |||
| Gap dimension model 171 | *BE60.00-P-1002-01L *BE60.00-P-1003-01L *BE60.00-P-1004-01L *BE60.00-P-1005-01L |
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| Gap dimension model 172 | *BE60.00-P-1002-01Y *BE60.00-P-1003-01Y *BE60.00-P-1004-01Y *BE60.00-P-1005-01Y |
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| 7 | Clean weld joints and metal flanges with wire brush | Round wire brush |
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| 8 | Remove welding protection blankets and protective sleeve | ||
| 9 | Clean repair area | Wet and dry vacuum cleaner |
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| 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 skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 10 | Prime repair area using primer filler | ||
| 11 | Carry out seam sealing after repairs | Model 171 | AR97.10-P-4000V |
| Model 172 | AR97.10-P-4000W | ||
| 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 skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 12 | Paint repair areas and adjacent surfaces | Use only paints approved by Daimler AG. |
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| 13 | Apply additional cavity preservation | Model 171 | AR97.20-P-1500V |
| Model 172 | AR97.20-P-1500W | ||
| 14 | Install all detachable body components in area to be repaired |
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 171 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01L | Gap dimension | Front door to fender | Dimension "H" | mm | 3.0 (+0.8) |
| Fender to A-pillar | Dimension "Q" | mm | 2.0 (+1.5/-0.5) | ||
| Front door to rear fender | Dimension "P" | mm | 3.0 (+0.8) | ||
| See picture | AR60.00-P-0700-01V | ||||
| BE60.00-P-1003-01L | Gap dimension | Trunk lid to rear fender | Dimension "F" | mm | 3.5 (+1.5) |
| Trunk lid to rear lamp unit | Dimension "M" | mm | 4.0 (+1.6/-0.5) | ||
| Trunk lid to bumper | Dimension "V" | mm | 5.0 (+1.5/-1.0) | ||
| Rear fender to lamp unit | Dimension "U" | mm | 2.5 (± 0.5) | ||
| Trunk lid tip to rear fender | Dimension "E" | mm | 5, 0 (+1, 5) | ||
| See picture | AR60.00-P-0700-01V | ||||
| BE60.00-P-1004-01L | Gap dimension | Fuel filler flap | Dimension "K" | mm | 3.0 (± 0.5) |
| See picture | AR60.00-P-0700-01V | ||||
| BE60.00-P-1005-01L | Gap dimension | Roof to windshield frame | Dimension "S" | mm | 5.0 (+1.0) |
| Roof to rear window frame | Dimension "T" | mm | 5.0 (± 0.5) | ||
| See picture | AR60.00-P-0700-01V | ||||
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 172 | |||
|---|---|---|---|---|---|
| BE60.00-P-1002-01Y | Gap dimension | Front door to fender | Dimension "H" | mm | 4.5 (+1/-0.5) |
| Fender to A-pillar | Dimension "Q" | mm | 3.5 (± 1.5) | ||
| Front door to rear fender | Dimension "P" | mm | 4.0 (± 1) | ||
| See picture | AR60.00-P-0700-01V | ||||
| BE60.00-P-1003-01Y | Gap dimension | Trunk lid to rear fender | Dimension "F" | mm | 4.5 (± 1) |
| Trunk lid to rear lamp unit | Dimension "M" | mm | 4.5 (+1.5/-0.5) | ||
| Trunk lid to bumper | Dimension "V" | mm | 6.0 (± 1.5) | ||
| Rear fender to lamp unit | Dimension "U" | mm | 1.5 (± 1) | ||
| Trunk lid tip to rear fender | Dimension "E" | mm | 6, 5 (+1/-0.5) | ||
| See picture | AR60.00-P-0700-01V | ||||
| BE60.00-P-1004-01Y | Gap dimension | Fuel filler flap | Dimension "K" | mm | 3.0 (+1, 5/-0.5) |
| See picture | AR60.00-P-0700-01V | ||||
| BE60.00-P-1005-01Y | Gap dimension | Roof to windshield frame | Dimension "S" | mm | 7.0 (+1.0) |
| Roof to rear window frame | Dimension "T" | mm | 5.0 (± 1.0) | ||
| See picture | AR60.00-P-0700-01V | ||||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
| BR00.45-Z-1012-13A | Blind rivet 6.5 X 12.5 | A 004 990 16 97 |