Install Rear Fender - Ar63.50-P-1400-04MFV

Model 177.1/9

MODIFICATION NOTES

24.06.2020

Repair method modified.

Operation steps 24 and 25

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation			Model 177.1/9
BE60.00-P-1011-01JA	Rear door to side wall	Dimension "K"	mm	3 (+0, 5)
BE60.00-P-1011-01JA	Rear door to side wall	For picture, see		AR60.00-P-0700-01MFA

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation			Model 177.1/9
BE60.00-P-1012-01JA	Fuel filler flap/fuel filler flap hybrid to side wall (circumferential)	Dimension "L"	mm	2 (±0, 5)
BE60.00-P-1012-01JA		For picture, see		AR60.00-P-0700-01MFA

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation			Model 177.1/9
BE60.00-P-1015-01JA	Liftgate/trunk lid to side wall	Dimension "O"	mm	3 (+1/-0, 5)
BE60.00-P-1015-01JA	Liftgate/trunk lid to side wall	For picture, see		AR60.00-P-0700-01MFA

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation			Model 177.1/9
BE60.00-P-1016-01JA	Liftgate/trunk lid to bumper at rear	Dimension "P"	mm	5, 5 (± 1)
BE60.00-P-1016-01JA	Liftgate/trunk lid to bumper at rear	For picture, see		AR60.00-P-0700-01MFA

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation			Model 177.1/9
BE60.00-P-1017-01JA	Outer tail lamp to side wall	Dimension "Q"	mm	1 (+1)
BE60.00-P-1017-01JA	Outer tail lamp to side wall	For picture, see		AR60.00-P-0700-01MFA

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation			Model 177.1/9
BE60.00-P-1018-01JA	Outer tail lamp to bumper at rear	Dimension "R"	mm	1, 5 (+1)
BE60.00-P-1018-01JA	Outer tail lamp to bumper at rear	For picture, see		AR60.00-P-0700-01MFA

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation			Model 177.1/9
BE60.00-P-1020-01JA	Outside of taillamp to inside of taillamp	Dimension "T"	mm	3, 5 (+1/-0, 5)
BE60.00-P-1020-01JA	Outside of taillamp to inside of taillamp	For picture, see		AR60.00-P-0700-01MFA

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation			Model 177.1/9
BE60.00-P-1023-01JA	Bumper at rear to side wall	Dimension "W"	mm	0 (+0, 5)
BE60.00-P-1023-01JA	Bumper at rear to side wall	For picture, see		AR60.00-P-0700-01MFA

Fig 1: Feeler Gauge (129 589 03 21 00)

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REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	White sealing compound, 310 ml, DBL 6069.20	A 001 989 63 20
BR00.45-Z-1012-13A	Blind rivet Y2 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	A 004 990 16 97
BR00.45-Z-1056-07A	1K-zinc dust paint	A 000 986 28 00
BR00.45-Z-1057-07A	Basic body filler	A 012 989 29 71
BR00.45-Z-1162-02A	Parts kit for 2-component adhesive for body	A 012 989 17 71

The next steps are shown on the left side of the vehicle. In case of damage, these steps must be similarly performed on the right side of the vehicle.

The superordinate service document as well as the safety information in the service document must be observed.

Install rear fender (1) and fit.
Install trunk lid.
Install rear bumper.
Install left rear lamp.
Install door seal.
Install lock striker.
Check gap dimensions with feeler gauge and adjust.
Fix rear fender (1) in place.
Remove lock striker.
Remove door seal.
Remove left rear lamp.
Remove rear bumper.
Remove trunk lid.
Drill rivet holes on rear fender (1) with a Ø 6.7 mm bit (areas A₁ and A₂ ).
Remove rear fender (1).
Deburr rivet holes in rear fender (1) and body on both sides.
Remove drill chips.

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Coat insides of riveted joints with zinc dust paint.
Apply sealant to foam part in cross-hatched area (area B₁ ).
Observe processing specification of the sealant.
Sealant to body in cross-hatched area (area B₂ ).
Observe processing specification of the sealant.
Apply 2-component adhesive to body in cross-hatched area (area C).
Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive.

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Install rear fender (1) and fix in place.
Rivet rear fender (1) with Ø 6 5x12 5 rivets (areas D₁ and D₂ ).
Clamping range is between 2 mm and 5 mm.

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Rear fender (1) (areas E₁ , E₂ , E₃ , E₄ , E₅ , E₆ , and E₇ ).
Rear fender (1) (areas E₈ and F).
Rear fender (1) (areas H₁ and H₂ ).
Perform inert gas welding at intervals and allow to cool down in between. This reduces heat distortion.
Face-grind inert gas welds (areas H₁ and H₂ ).
Tin-plate surfaces on rear fender (1) with body solder or use basic body filler to spackle and grind off (areas H₁ and H₂ ).
Remove solder residues or grinding dust.

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