Replace complete rear fender - AR63.50-P-1400RK

MODEL 231 

Fig 1: Rear Fender And Taillamp Reinforcement

Courtesy of MERCEDES-BENZ USA

	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
	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 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 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.	AS00.00-Z-0017-01A
	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
	Notes on cavity preservation		AH97.20-P-0001-01B
	Notes on paintwork repairs		AH98.00-P-9408-02A
	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A
	General information on body repair		AH60.00-P-0001-01A
	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	General information on crack diagnosis of aluminum parts		AH60.00-P-0014-01N
	General information on riveting		AH60.00-P-0003-01N
	General notes on welding		AH60.00-P-0005-01N
	General information on MB materials		AH98.00-P-9409-03A
	Remove
1	Prepare all workshop equipment and commercially available tools required for repair
2	Detach detachable parts in area of repair point
3	Cover all detachable parts remaining in vehicle	Commercially available tools Protective cover
4	Separate taillamp reinforcement (2)	Only when replacing taillamp reinforcement (2).
			WS60.00-P-0010B
		Commercially available tools Hot air blower Rotary wire brush Vacuum unit suitable for aluminum dusts	AR63.20-P-2011-01RK
5	Separate rear fender (1)
			WS60.00-P-0010B
		Commercially available tools Hot air blower Rotary wire brush Vacuum unit suitable for aluminum dusts	AR63.50-P-1400-02RK
	Preparation
6	Prepare taillamp reinforcement new part (2)	Only when replacing taillamp reinforcement (2). Commercially available tools Hot air blower Rotary wire brush Vacuum unit suitable for aluminum dusts	AR63.20-P-2011-02RK
7	Prepare new rear fender (1)	Commercially available tools Hot air blower Rotary wire brush Vacuum unit suitable for aluminum dusts	AR63.50-P-1400-03RK
	Install
8	Install rear fender (1)
			WS60.00-P-0022K
			WS60.00-P-0010B
			AR60.00-P-0700-01RK
		Commercially available tools Rotary wire brush Blind rivet gun	AR63.50-P-1400-04RK
		Flow-form rivet structure 6.0 mm up to 7.2 mm clamping range (S58)	*BR00.45-Z-1053-13A
		Gap dimension	*BE60.00-P-1011-01AB
		Gap dimension	*BE60.00-P-1013-01AB
		Gap dimension	*BE60.00-P-1018-01AB
		Gap dimension	*BE60.00-P-1021-01AB
		Blind rivet, 6.4 x 14	*BR00.45-Z-1001-13A
		White sealing compound, 310 ml, DBL 6069.20	*BR00.45-Z-1003-01A
		Adhesive kit, body, 2-component adhesive	*BR00.45-Z-1092-02A
		Flow-form rivet up to 3.5 mm clamping range (A1)	*BR00.45-Z-1023-13A
		Flow-form rivet 3.35 mm up to 4.1 mm clamping range (A2)	*BR00.45-Z-1024-13A
		Feeler gauge	Fig 2
		Bending pliers	Fig 3
9	Install taillamp reinforcement (2)	Only when replacing taillamp reinforcement (2).
			WS60.00-P-0022K
			WS60.00-P-0010B
			AR63.20-P-2011-03RK
		Commercially available tools Rotary wire brush Adhesive kit, body, 2-component adhesive	*BR00.45-Z-1092-02A
		Flow-form rivet up to 3.5 mm clamping range (A1)	*BR00.45-Z-1023-13A
10	Clean welds and sheet metal flange	Commercially available tools Rotary wire brush Vacuum unit suitable for aluminum dusts
11	Remove protective covers
12	Clean repair area	Commercially available tools Vacuum unit suitable for aluminum dusts
13	Prime repair area using primer filler	Use only paints approved by Daimler AG.
14	Carry out seam sealing after repairs	Supplement standard sealants with MB body sealant.	AR97.10-P-4000RK
15	Paint repair areas and adjacent surfaces	Use only paints approved by Daimler AG.
16	Apply additional cavity preservation		AR97.20-P-1500RK
17	Install all detachable body components in area to be repaired

TEST AND ADJUSTMENT VALUES

Number	Designation				Model 231
BE60.00-P-1011-01AB	Gap dimension	Front door to longitudinal member panel	Dimension "K"	mm	5, 0 (±1)
			For picture, see		AR60.00-P-0700-01RK

TEST AND ADJUSTMENT VALUES

Number	Designation				Model 231
BE60.00-P-1013-01AB	Gap dimension	Front door to Rear fender	Dimension "M"	mm	4, 0 (0, 5)
			For picture, see		AR60.00-P-0700-01RK

TEST AND ADJUSTMENT VALUES

Number	Designation				Model 231
BE60.00-P-1018-01AB	Gap dimension	Trunk lid to fender	Dimension "R"	mm	4, 5 (±1)
			For picture, see		AR60.00-P-0700-01RK

TEST AND ADJUSTMENT VALUES

Number	Designation				Model 231
BE60.00-P-1021-01AB	Gap dimension	Taillamp to fender	Dimension "U"	mm	1, 5 (± 0, 5)
			For picture, see		AR60.00-P-0700-01RK

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

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Bending Pliers (202 589 00 37 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1001-13A	Blind rivet, 6.4 x 14	A 003 990 35 97
BR00.45-Z-1003-01A	White sealing compound, 310 ml, DBL 6069.20	A 001 989 63 20
BR00.45-Z-1023-13A	Flow-form rivet up to 3.5 mm clamping range (A1)	A 000 991 07 33
BR00.45-Z-1024-13A	Flow-form rivet 3.35 mm up to 4.1 mm clamping range (A2)	A 000 991 08 33
BR00.45-Z-1053-13A	Flow-form rivet structure 6.0 mm up to 7.2 mm clamping range (S58)	A 000 991 28 33
BR00.45-Z-1092-02A	Adhesive kit, body, 2-component adhesive	A 009 989 36 71