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Rear Fender Complete Installation - Ar63.50-P-1401-03SZ

Model 223.9 

MODIFICATION NOTES

20.04.2023 Method modified. Operation steps 31, 32, 33, 34, 35  
GAP DIMENSIONS

Number Designation Model 223
BE60.00-P-1009-01PA Rear door to side section, bottom Dimension "I" mm 3 (+0, 5)
For picture, see   AR60.00-P-0900-01S
GAP DIMENSIONS

Number Designation Model 223
BE60.00-P-1011-01PA Trunk lid to rear fender Dimension "K" mm 3 (-0, 5/+1)
For picture, see   AR60.00-P-0900-01S
GAP DIMENSIONS

Number Designation Model 223
BE60.00-P-1014-01PA Rear fender to taillamp Dimension "N" mm 1 (-0, 5/+1)
For picture, see   AR60.00-P-0900-01S
Fig 1: Feeler Gauge (129 589 03 21 00)
G07469060Courtesy of MERCEDES-BENZ USA

IMPORTANT The following operation steps are shown on model 223.9 on the left side of the vehicle and must be similarly performed on the right side of the vehicle in the event of damage.

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

The graphics show the vehicle from the mechanic's perspective. At the same time, this perspective also specifies the direction in which the rivets must be placed.

G16228192Courtesy of MERCEDES-BENZ USA

Countersunk-head rivet (Z) 

  1. Z1 = countersunk-head rivet 6.4x14.0
  2. Z2 = countersunk-head rivet 6.4x15.5
  3. Z3 = countersunk-head rivet 6.4x17.0
  4. Z4 = countersunk-head rivet 6.4x19.0
  5. Z5 = countersunk-head rivet 6.4x21.0

Blind rivet (Y) 

  1. Y1 = rivet 6.4x12
  2. Y2 = rivet 6.5x12.5
  3. Y3 = rivet 6.5x14.5
  4. Y4 = Rivet 6.4M6
  5. Y5 = Rivet 6.4
  6. Y6 = rivet 6.5x13.5
  7. Y7 = rivet 6.4x14
  8. Y8 = rivet 6.4x17
  9. Y9 = rivet 6.4x20

Flow-form rivet with countersunk head (X) 

  1. X1 = Flow-form rivet with countersunk head 1.3 mm to 2.5 mm clamping range
  2. X2 = Flow-form rivet with countersunk head 2.3 mm to 3.5 mm clamping range
  3. X3 = Flow-form rivet with countersunk head 3.35 mm to 4.1 mm clamping range
  4. X4 = Flow-form rivet with countersunk head 4 mm to 5.15 mm clamping range
  5. X5 = Flow-form rivet with countersunk head 5.0 mm to 6.1 mm clamping range
  6. X6 = Flow-form rivet with countersunk head 6.0 mm to 7.2 mm clamping range
  7. X7 = Flow-form rivet with countersunk head 7.1 mm to 8.3 mm clamping range

Flow-form rivet (W) 

  1. W1 = Flow-form rivet structure with 3.5 mm clamping range
  2. W3 = Flow-form rivet structure 3.35 mm up to 4.1 mm clamping range
  3. W4 = Flow-form rivet structure 4 mm up to 5.15 mm clamping range
  4. W5 = Flow-form rivet structure 5.0 mm up to 6.1 mm clamping range
  5. W6 = Flow-form rivet structure 6.0 mm up to 7.2 mm clamping range
  6. W7 = Flow-form rivet structure 7.1 mm up to 8.3 mm clamping range

Blind rivet (V) 

  1. V1 = rivet 3.2x4.5
  2. V2 = rivet 3.2x6.5

Blind rivet (U) 

  1. U1 = rivet 3.2x9.5

Blind rivet with countersunk head (T) 

  1. T1 = blind rivet with countersunk head 3.0 mm to 5.0 mm clamping range
  2. T2 = blind rivet with countersunk head 1.5 mm to 3.0 mm clamping range
G16228681Courtesy of MERCEDES-BENZ USA
  1. Install rear fender (1) and fit.
  2. Install trunk lid.
  3. Install rear bumper.
  4. Install tail lamp.
  5. Install door seal.
  6. Install lock striker.
  7. Check gaps using SPECIAL TOOL feeler gauge and adjust. HAND-HELD TESTERHAND-HELD TESTERHAND-HELD TESTER
  8. Fasten rear fender (1).
  9. Remove striker eye.
  10. Remove door seal.
  11. Remove tail lamp.
  12. Remove rear bumper.
  13. Remove trunk lid.
  14. Punch rivet holes in rear fender (1) with ø 6.0 mm bit using a rivet press tool (areas C).
  15. Drill rivet holes in rear fender (1) with ø 6.7 mm (areas D).
    G16228675Courtesy of MERCEDES-BENZ USA
  16. Drill rivet holes in rear fender (1) with ø 6.7 mm bit (areas F1 ,
  17. Countersink rivet holes in rear fender (1) (areas F1 , F3 ).
  18. Punch rivet holes in rear fender (1) with ø 6.0 mm bit using a rivet press tool (areas G).
  19. Remove rear fender (1).
  20. Deburr rivet holes on rear fender (1) and body on both sides.
  21. Remove drilling chips.
    G16228683Courtesy of MERCEDES-BENZ USA
  22. Install suitable spacers on outer rear wheel well such that they are evenly spaced (areas H1 and H2 ).
  23. Apply sealant to outer rear wheel well and foam parts (areas H1 , H2 , and L).
  24. Apply 2-component adhesive for reinforcements in cross-hatched area on structured foam part (area J).

    IMPORTANT Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive.

  25. Apply 2-component adhesive in cross-hatched area on body (areas K).

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G16228677Courtesy of MERCEDES-BENZ USA
  26. Install and fasten rear fender (1).
  27. Rivet rear fender (1) with countersunk-head rivets ø 6.4x14.0 (areas Z1 ).
  28. Rivet rear fender (1) with ø 6.4x15.5 countersunk-head rivets (areas Z2 ).
  29. Rivet rear fender (1) with countersunk-head rivets ø 6.4x17.0 (areas Z3 ).
  30. Rivet rear fender (1) with structured flow form rivets with 3.5 mm clamping range (areas W1 ).
    G16228685Courtesy of MERCEDES-BENZ USA
  31. Rivet rear fender (1) with flow-form rivet structure 4 mm to 5.15 mm clamping range (areas W4 ).
  32. Rivet rear fender (1) with structured flow form rivets with 3.5 mm clamping range (areas W1 ).
  33. Rivet rear fender (1) with ø 6.5x12.5 rivets (areas Y2 ).
  34. Rivet rear fender (1) with ø 6.4x12 rivets (areas Y1 ).
  35. Rivet rear fender (1) with ø 6.5x14.5 rivets (areas Y3 ).
  36. Rear fender (1) SHIELDED GAS SEAM WELD (areas P, Q, and R).
  37. Install rivet nut (2) on rear fender (1).
  38. Face-grind shielding gas weld joints (areas P, Q, and R).
  39. Spackle surfaces on rear fender (1) with basic body filler (areas P, Q, and R).
  40. Remove grinding dust.
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