Replace Rear Fender Complete - Ar63.50-P-1401LWO

Model 238.3 

Fig 1: Rear Fender Complete Component Location (Model 238.3)

Courtesy of MERCEDES-BENZ USA

	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 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 contactwith 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
	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
Notice	General information on body repair		AH60.00-P-0001-01KOA
Notice	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
Notice	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	Notes on acoustic foam and structural foam in the vehicle		AH60.00-P-0039-01LWO
	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	When replacing the right rear fender (1), the standard tank lock must be installed and the filler neck covered with a welding protection blanket.
3	Remove rear fender (1)		AR63.50-P-1401-01LWO
	000 588 00 84 00 Heat gun	Commercially available devices/tools  Round wire brush Body power jigsaw Spot weld milling machine Wet/dry vacuum cleaner	WS54.00-P-0049B
		1K-zinc dust paint	*BR00.45-Z-1056-07A
4	Prepare rear fender (1)	Commercially available devices/tools  Round wire brush Body power jigsaw	AR63.50-P-1401-02LWO
		1K-zinc dust paint	*BR00.45-Z-1056-07A
	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
Notice	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-1401-03LWO
	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 Commercially available devices/tools  Round wire brush Manual temporary fastener 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Hand riveter Wet/dry vacuum cleaner	AR60.00-P-0700-01LWO
		Model 238.3Front door to sidewall	*BE60.00-P-1007-01HA
		Model 238.3Trunk lid to fender at rear, top	*BE60.00-P-1009-01HA
		Model 238.3Taillamp to bumper	*BE60.00-P-1010-01HA
		Model 238.3Rear fender to taillamp	*BE60.00-P-1012-01HA
		Model 238.3Outside of taillamp to inside of taillamp	*BE60.00-P-1014-01HA
		1K-zinc dust paint	*BR00.45-Z-1056-07A
		White sealing compound, 310 ml, DBL 6069.20	*BR00.45-Z-1003-01A
		Parts kit for 2-component adhesive for body	*BR00.45-Z-1162-02A
		2-component adhesive repair kit, Betaforce 2850L	*BR00.45-Z-1154-02A
		Blind rivet Y2 6.5 x 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	*BR00.45-Z-1012-13A
		Countersunk-head blind rivet Z1 6.4 x 14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN)	*BR00.45-Z-1043-13A
		Blind rivet for power window to left door 4.8 x 8 (clamping range 1.5 mm to 4 mm, draw-off strength min. 8 kN)	*BR00.45-Z-1008-13A
		Feeler gauge As an alternative to restoring surfaces with body solder. ↓ Apply basic body filler.	Fig 2
			AR60.00-P-0031-01LWG
		Parts kit for 2-component adhesive for body	*BR00.45-Z-1162-02A
		Basic body filler	*BR00.45-Z-1057-07A
6	Clean welds and sheet metal flanges	Commercially available devices/tools  Round wire brush
7	Remove spark protection blankets
8	Clean repair area	Commercially available devices/tools  Wet/dry vacuum cleaner
9	Prime repair area using primer filler
Notice	Notes on paintwork repairs		AH98.00-P-9408-02A
	General information on operation items and work procedures for painting	Use only primer fillers approved by manufacturer. See guidelines for paint technology in the workshop portal.	AH98.00-P-0003-01A
10	Seal seam following repairs		AR97.10-P-4000LWO
11	Paint repair areas and adjacent surfaces
Notice	Notes on paintwork repairs		AH98.00-P-9408-02A
	General information on operation items and work procedures for painting	Only use paints approved by the manufacturer. See guidelines for paint technology in the workshop portal.	AH98.00-P-0003-01A
12	Add cavity preserving agent		AR97.20-P-1500LWO
13	Install all detachable body components in area to be repaired

CHECK VALUES FOR GAP DIMENSIONS

Number	Designation			Model 238.3
BE60.00-P-1007-01HA	Front door to sidewall	Dimension "H1"	mm	3, 5 (± 0, 5)
		For picture, see		AR60.00-P-0700-01LWO

CHECK VALUES FOR GAP DIMENSIONS

Number	Designation			Model 238.3
BE60.00-P-1009-01HA	Trunk lid to fender at rear, top	Dimension "K"	mm	3, 5 (± 0, 5)
		Dimension "K1"	mm	4 (± 0, 5)
		For picture, see		AR60.00-P-0700-01LWO

CHECK VALUES FOR GAP DIMENSIONS

Number	Designation			Model 238.3
BE60.00-P-1010-01HA	Taillamp to bumper	Dimension "L"	mm	1, 5 (± 0, 5)
		For picture, see		AR60.00-P-0700-01LWO

CHECK VALUES FOR GAP DIMENSIONS

Number	Designation			Model 238.3
BE60.00-P-1012-01HA	Rear fender to taillamp	Dimension "N"	mm	1 (± 0, 5)
		For picture, see		AR60.00-P-0700-01LWO

CHECK VALUES FOR GAP DIMENSIONS

Number	Designation			Model 238.3
BE60.00-P-1014-01HA	Outside of taillamp to inside of taillamp	Dimension "T"	mm	4 (± 1)
		For picture, see		AR60.00-P-0700-01LWO

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

Courtesy of MERCEDES-BENZ USA

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-1008-13A	Blind rivet for power window to left door 4.8 x 8 (clamping range 1.5 mm to 4 mm, draw-off strength min. 8 kN)	A 003 990 24 97
BR00.45-Z-1012-13A	Blind rivet Y2 6.5 x 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	A 004 990 16 97
BR00.45-Z-1043-13A	Countersunk-head blind rivet Z1 6.4 x 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-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-1154-02A	2-component adhesive repair kit, Betaforce 2850L	A 012 989 12 71
BR00.45-Z-1162-02A	Parts kit for 2-component adhesive for body	A 012 989 17 71