Replace Complete Rear Fender - AR63.50-P-1400GQ
MODEL 166
| Remove/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 | |
| 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 | |
| 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. | AH54.10-P-0002-01A | |
| General information on body repair | AH60.00-P-0001-01A | ||
| Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | ||
| Notes on avoiding damage to windows installed in special high-security vehicles | Model 166.0 with code Z04 (Light armoring) Model 166.0 with code Z05 (B5 armoring on special protection version) |
AH67.00-P-0003-01FB | |
| 1 | Remove all detachable parts in repair area | ||
| 2 | Cover all detachable parts remaining in vehicle with welding protection blankets | ||
| 3.1 | Cut off rear wheel well section | Only if rear fender (1) is repaired and not replaced. | AR63.10-P-0662-01CW |
Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint |
*BR00.45-Z-1001-07A | ||
| 3.2 | Separate rear fender (1) | Only if rear fender (1) is repaired and not replaced. Model 166.0 except code Z04 (Light armoring) except code Z05 (B5 armoring on special protection version) |
AR63.50-P-1400-02GQ |
| Model 166.0 with code Z04 (Light armoring) | AR63.50-P-1400-02GQS | ||
| Sheet metal crimping pliers for areas not easily accessible | Glass removal Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint |
*BR00.45-Z-1001-07A | |
| 4.1 | Prepare rear wheel well section for installation | Only if rear fender (1) is repaired and not replaced. | AR63.10-P-0662-02CW |
| 4.2 | Prepare rear fender (1) for installation | Only if rear fender (1) is repaired and not replaced. | |
| Model 166.0 except code Z04 (Light armoring) except code Z05 (B5 armoring on special protection version) | AR63.50-P-1400-03GQ | ||
| Model 166.0 with code Z04 (Light armoring) | AR63.50-P-1400-03GQS | ||
| Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint | *BR00.45-Z-1001-07A | ||
| Install | |||
| 5.1 | Install rear wheel well section | Only if rear fender (1) is repaired and not replaced. | AH60.00-P-0003-01N |
| General information on riveting | AR63.10-P-0662-03CW | ||
| Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint | *BR00.45-Z-1001-07A | ||
| Blind rivet for power window to left door 4.8 8 (clamping range 1.5 mm to 4 mm, draw-off strength min. 8 kN) | *BR00.45-Z-1008-13A | ||
| 5.2 | Install rear fender (1), fit and weld in General information on riveting | Only if rear fender (1) is repaired and not replaced. | AH60.00-P-0003-01N |
| Model 166.0 except code Z04 (Light armoring) except code Z05 (B5 armoring on special protection version) | AR63.50-P-1400-04GQ | ||
| Model 166.0 with code Z04 (Light armoring) | AR63.50-P-1400-04GQS | ||
| 000 588 02 84 00 Welder | WS60.00-P-0022K | ||
| *BR00.45-Z-1003-01A | |||
| Gap dimension | *BE60.00-P-1003-01Z | ||
| Gap dimension | *BE60.00-P-1004-01Z | ||
| Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint | *BR00.45-Z-1001-07A | ||
| Blind rivet with polygrip countersunk head 6.4 14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN) | *BR00.45-Z-1002-13A | ||
| Figure | |||
| 6 | Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01GQ | |
| Gap dimension | *BE60.00-P-1003-01Z | ||
| Gap dimension | *BE60.00-P-1004-01Z | ||
| Figure | |||
| 7 | Remove welding protection blankets | ||
| 8 | Clean repair areas | ||
| Risk of explosion caused by paint vapors igniting. Risk of poisoning 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 | Use only primer filler approved by Daimler AG. | |
| 10 | Seal seam following repairs | AR97.10-P-4000GQ | |
| Risk of explosion caused by paint vapors igniting. Risk of poisoning 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 | Use only paints approved by Daimler AG. | |
| 12 | Add cavity preserving agent | AR97.20-P-1500GQ | |
| 13 | Install all detachable parts in area to be repaired |
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 166 | |||
|---|---|---|---|---|---|
| BE60.00-P-1003-01Z | Gap dimension | Liftgate to bumper at bottom | Dimension "L" | mm | 5, 5 (±1, 5) |
| Liftgate to rear fender | Dimension "J" | mm | 4, 8 (±1) | ||
| Liftgate to bumper at side | Dimension "K" | mm | 4, 9 (±1, 3) | ||
| Liftgate to roof | Dimension "W" | mm | 5, 5 (±1, 5) | ||
| Liftgate to rear window | Dimension "O" | mm | 4, 0 (±1, 0) | ||
| Rear fender to backup | Dimension "M" | mm | 1, 4 (±0, 7) | ||
| D-pillar to rear window | Dimension "V" | mm | - | ||
| For picture, see | AR60.00-P-0700-01GQ | ||||
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 166 | |||
|---|---|---|---|---|---|
| BE60.00-P-1004-01Z | Gap dimension | Fuel filler flap | Dimension "N" | mm | 2, 7 (±0, 3) |
| For picture, see | AR60.00-P-0700-01GQ | ||||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint | A 000 986 34 42 |
| BR00.45-Z-1002-13A | Blind rivet with polygrip countersunk head 6.4 14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN) | 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-1008-13A | Blind rivet for power window to left door 4.8 8 (clamping range 1.5 mm to 4 mm, draw-off strength min. 8 kN) | A 003 990 24 97 |