Replace Complete Rear Fender - Ar63.50-P-1400CLW
Model 205.3
| 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 . | |
| Topical note | General information on body repair | AH60.00-N-0001-01A . | |
| Topical note | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A . | |
| Topical note | Pretreatment of bonding surfaces | AH60.00-P-0008-01SX . | |
| Notes on acoustic foam and structural foam in the vehicle | AH60.00-P-0039-01LW . | ||
| 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 on vehicle with spark protection blankets | ||
| 3 | Separate rear fender (1) | AR63.50-P-1400-02CLW . | |
| 2 |
000 588 00 84 00 Heat gun | WS54.00-P-0049B . | |
Round wire brush Body power jigsaw Spot weld milling machine Wet/dry vacuum cleaner Primer stick |
*BR00.45-Z-1012-07A . | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A . | ||
| 4 | Prepare rear fender (1) | Round wire brush Body power jigsaw |
AR63.50-P-1400-03CLW . |
| 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 inflammable materials from the hazard area. Use air extraction system. | AS00.00-Z-0007-01A . | |
| Topical note | 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 . | ||
| 5 | Install rear fender (1) | AR63.50-P-1400-04CLW . | |
| 000 588 01 84 00 Welder | WS60.00-P-0021K . | ||
| 000 588 02 84 00 Welder | WS60.00-P-0022K . | ||
| Gap dimensions on hoods, doors and lids Round wire brush Manual temporary fastener 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Wet/dry vacuum cleaner |
AR60.00-P-0700-01LW . | ||
| Front door to sidewall | *BE60.00-P-1007-01BB . | ||
| Trunk lid to fender at rear, top | *BE60.00-P-1012-01BB . | ||
| Rear fender to taillamp | *BE60.00-P-1015-01BB . | ||
| Outside of taillamp to inside of taillamp | *BE60.00-P-1022-01BB . | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A . | ||
| White sealing compound, 310 ml, DBL 6069.20 | *BR00.45-Z-1003-01A . | ||
| Adhesive kit, body, 2-component adhesive | *BR00.45-Z-1092-02A . | ||
| Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1035-13A . | ||
| Blind rivet with countersunk head 6.4X 14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1043-13A . | ||
| 6 | Clean welds and sheet metal flanges | Round wire brush |
|
| 7 | Remove spark protection blankets | ||
| 8 | Clean repair area | Wet/dry vacuum cleaner |
|
| 9 | Prime repair area using primer filler | ||
| Topical note | Notes on paintwork repairs | AH98.00-P-9408-02A . | |
| 10 | Seal seam following repairs | AR97.10-P-4000LW . | |
| 11 | Paint repair areas and adjacent surfaces | ||
| Topical note | Notes on paintwork repairs | AH98.00-P-9408-02A . | |
| 12 | Add cavity preserving agent | AR97.20-P-1500LW | |
| 13 | Install all detachable body components in area to be repaired |
CHECK VALUES FOR GAP DIMENSIONS (Model 205.3) (Front Door To Sidewall)
| Number | Designation | Model 205.3 | ||
|---|---|---|---|---|
| BE60.00-P-1007-01BB | Front door to sidewall | Dimension "H1" | mm | 3, 5 (±0, 5) |
| For picture, see | AR60.00-P-0700-01LW . | |||
CHECK VALUES FOR GAP DIMENSIONS (Model 205.3) (Trunk Lid To Fender)
| Number | Designation | Model 205.3 | ||
|---|---|---|---|---|
| BE60.00-P-1012-01BB | Trunk lid to fender at rear, top | Dimension "K" | mm | 3, 5 (±1) |
| Dimension "K1" | mm | 4 (+1, 5/-1) | ||
| For picture, see | AR60.00-P-0700-01LW . | |||
CHECK VALUES FOR GAP DIMENSIONS (Model 205.3) (Rear Fender To Taillamp)
| Number | Designation | Model 205.3 | ||
|---|---|---|---|---|
| BE60.00-P-1015-01BB | Rear fender to taillamp | Dimension "N" | mm | 1 (±1) |
| For picture, see | AR60.00-P-0700-01LW . | |||
CHECK VALUES FOR GAP DIMENSIONS (Model 205.3) (Taillamp)
| Number | Designation | Model 205.3 | ||
|---|---|---|---|---|
| BE60.00-P-1022-01BB | Outside of taillamp to inside of taillamp | Dimension "T" | mm | 3, 5 (±1) |
| For picture, see | AR60.00-P-0700-01LW . | |||
REAR FENDER REPAIR MATERIALS (Model 205.3)
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
| 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-1035-13A | Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | A 000 991 76 32 |
| BR00.45-Z-1043-13A | Blind rivet with countersunk head 6.4X 14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) | A 000 991 82 32 |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 012 989 17 71 |