LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 2021 >> S500 >> Repair and Diagnosis >> Collision >> Body Panels >> Collision - Side Wall (223 Chassis) >> Side Wall Body Repair >> Rear Fender Complete Replacement - Ar63.50-P-1401SZ

Rear Fender Complete Replacement - Ar63.50-P-1401SZ

Model 223.9 

MODIFICATION NOTES

28.02.2022 Method extended Step 9  
Fig 1: Quarter Panel Component Location (Complete Replacement) (Model 223.9)
G16191774DANGERDANGERDANGERWARNINGCAUTIONREMOVINGIMPORTANTREFER TO SPECIAL TOOLSREFER TO SPECIAL TOOLSINSTALLINGDANGERREFER TO SPECIAL TOOLSREFER TO SPECIAL TOOLSHAND-HELD TESTERHAND-HELD TESTERHAND-HELD TESTERSPECIAL TOOLIMPORTANTIMPORTANTCourtesy of MERCEDES-BENZ USA
DANGER 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
DANGER 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
DANGER 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
WARNING Risk of injury  . Skin or eye injuries may result when handling hot or glowing objects. Wear protective gloves, protective clothing and safety glasses, if necessary. AS00.00-Z-0002-01A
CAUTION 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 Information on preventing damage to electronic components due to electrostatic discharge   AH54.00-P-0001-01A
Notice General information on body repair   AH60.00-P-0001-01S
Notice Pretreatment of bonding surfaces   AH60.00-P-0008-01SX
Notice General information on crack diagnosis of aluminum parts   AH60.00-P-0014-01N
Notice Notes on processing of 2-K structural foam adhesive during body repairs   AH60.00-P-0040-01A
  Note on working on aluminum components and vehicles   AH60.00-P-0034-01RG
  Notes on foam-protected insulation in body   AH60.00-P-0041-01S
  General information on MB materials   AH98.00-P-9409-03A
REMOVING Remove     
1 Remove detachable parts in area of repair point.    
2 Cover detachable parts that remain in vehicle with welding protection blankets. IMPORTANT When replacing right rear fender (1), standard fuel filler cap must be installed and filler neck covered with a welding blanket.  
3 Cut off rear fender (1).   AR63.50-P-1401-01SZ 
Notice General notes on touch-up applicators and paint spray cans   AH98.00-P-9409-06A
REFER TO SPECIAL TOOLS 000 588 04 39 00 Rivet press tool   WS60.00-P-0440B
REFER TO SPECIAL TOOLS 000 588 15 84 00 Heat gun Primer stick WS54.00-P-0125B*BR00.45-Z-1012-07A 
INSTALLING Install     
DANGER 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-0003-01S
  General notes on welding   AH60.00-P-0005-01N
4 Prepare rear fender (1).   AR63.50-P-1401-02SZ 
5 Install rear fender (1) and fit.    
6 Execute common separating cuts on rear fender (1) and body.    
7 Remove rear fender (1).    
8 Prepare weld puddle retainer.   AR60.00-P-0070-01S
9 Repair insulation at inner side wall.   AR63.50-P-1401-04SZ 
  General note on use of 2-component acoustic filler foam following repairs   AH60.00-P-0033-01RQ
    2K-component filler foam *BR00.45-Z-1090-01A 
    Seam seal, sprayable 300 ml *BR00.45-Z-1149-01A 
10 Install rear fender (1).   AR63.50-P-1401-03SZ 
    Make weld seam on vehicles with aluminum body AR60.00-P-0070-01S
REFER TO SPECIAL TOOLS 000 588 04 39 00 Rivet press tool   WS60.00-P-0440B
REFER TO SPECIAL TOOLS 000 588 12 84 00 Welder   WS00.00-P-0318K
    HAND-HELD TESTER Rear door to side section, bottom *BE60.00-P-1009-01PA 
    HAND-HELD TESTER Trunk lid to rear fender *BE60.00-P-1011-01PA 
    HAND-HELD TESTER Rear fender to taillamp *BE60.00-P-1014-01PA 
    White sealing compound, 310 ml, DBL 6069.20 *BR00.45-Z-1003-01A 
    Basic body filler *BR00.45-Z-1057-07A 
    Parts kit for 2-component adhesive for body *BR00.45-Z-1162-02A 
    2-component adhesive for reinforcements *BR00.45-Z-1152-02A 
    Rivet nut M5x19 *BR00.45-Z-1097-13A 
    Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) *BR00.45-Z-1012-13A 
    Blind rivet Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) *BR00.45-Z-1016-13A 
    Flow-form rivet structure W1 up to 3.5 mm clamping range (S1) *BR00.45-Z-1026-13A 
    Flow-form rivet structure W4 4 mm up to 5.15 mm clamping range (S3) *BR00.45-Z-1028-13A 
    Blind rivet Y1 6.4x12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) *BR00.45-Z-1035-13A 
    Countersunk-head blind rivet Z1 6.4x14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) *BR00.45-Z-1043-13A 
    Countersunk-head blind rivet Z2 6.4x15.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) *BR00.45-Z-1044-13A 
    Countersunk-head blind rivet Z3 6.4x17.0 (clamping area 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) *BR00.45-Z-1055-13A 
    SPECIAL TOOL Feeler gauge Fig 2
11 Clean weld joints and sheet metal flange.    
12 Remove welding protection blankets.    
13 Clean repair area.    
14 Treat repair areas with primer filler.    
Notice Notes on paintwork repairs   AH98.00-P-9408-02A
  General information on operation items and work procedures for painting IMPORTANT Use only primer fillers approved by manufacturer.
See guidelines for paint technology in the workshop portal.		 AH98.00-P-0003-01A
15 Seal seam after repair.   AR97.10-P-4000S
  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 IMPORTANT Only use paints approved by the manufacturer.
See guidelines for paint technology in the workshop portal.		 AH98.00-P-0003-01A
17 Supplement cavity preservation.   AR97.20-P-1500S
18 Reinstall all detachable parts in area of repair point.    
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 2: Feeler Gauge (129 589 03 21 00)
G07469060Courtesy 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-1012-07A Primer stick A 000 986 27 50
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-1016-13A Blind rivet Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) A 004 990 17 97
BR00.45-Z-1026-13A Flow-form rivet structure W1 up to 3.5 mm clamping range (S1) A 000 991 11 33
BR00.45-Z-1028-13A Flow-form rivet structure W4 4 mm up to 5.15 mm clamping range (S3) A 000 991 12 33
BR00.45-Z-1035-13A Blind rivet Y1 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 Countersunk-head blind rivet Z1 6.4x14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) A 000 991 82 32
BR00.45-Z-1044-13A Countersunk-head blind rivet Z2 6.4x15.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) A 000 991 83 32
BR00.45-Z-1055-13A Countersunk-head blind rivet Z3 6.4x17.0 (clamping area 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) A 000 991 86 32
BR00.45-Z-1057-07A Basic body filler A 012 989 29 71
BR00.45-Z-1090-01A 2K-component filler foam A 000 989 35 73
BR00.45-Z-1097-13A Rivet nut M5x19 N 000000 003768
BR00.45-Z-1149-01A Seam seal, sprayable 300 ml A 000 989 46 06
BR00.45-Z-1152-02A 2-component adhesive for reinforcements A 011 989 99 71
BR00.45-Z-1162-02A Parts kit for 2-component adhesive for body A 012 989 17 71
scientia non olet · About LEMON Manuals