Prepare inner section of rear wheel well for installation - AR63.10-P-0610-02CW

WARNING: This page is about a different car, the 2011 Mercedes-Benz C300, 2010 Mercedes-Benz C300, 2009 Mercedes-Benz C300, and 2008 Mercedes-Benz C300. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Rear Wheel Inner Section Dimensions

Courtesy of MERCEDES-BENZ USA

Dimensions:

The following steps are shown on components for model 204.0.

Scribe separation points on complete wheel well (2) (areas A, B and C).
Cut complete wheel well (2) at separation points (areas A, B and C).
Drill Ø 6.7 mm spot welds on complete wheel well (2) (area D).
Drill spot weld at bottom in area of front crossmember.
Grind mating surfaces on complete wheel well (2) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.
Coat insides of spot weld flanges with zinc dust paint.
Only perform on model 218.3.

Observe pretreatment of bonding surfaces.

Do not coat bonding surfaces with zinc dust paint (areas XX₁ and XX₂ ). Adhesion problems can occur.

Fig 2: Identifying Wheel Well Grinding Areas & 7 mm Hole
Courtesy of MERCEDES-BENZ USA
Drill Ø 7 mm hole in complete wheel well (2) (area D₁ ).
Grind mating surfaces on complete wheel well (2) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.
Coat insides of spot weld flanges with zinc dust paint.
Perform operation steps 9, 10 and 11 only on model 204.
Scribe holes in rear axle crossmember (6) (areas F₁ and F₂ ).
Drill dia. 6.7 mm rivet holes in rear axle crossmember (6) (areas F₁ and F₂ ).
Deburr holes on both sides.
Dimensions:

Fig 3: Identifying Rear Axle Crossmember Rivet Hole Dimensions
Courtesy of MERCEDES-BENZ USA
Punch Ø 6 mm holes in rear axle crossmember (6) areas F and G).
Grind mating surfaces on rear axle crossmember (6) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces (area E).
Grind crosshatched areas on rear axle crossmember (6) down to bare metal around holes (areas F and G).

Fig 4: Identifying Rear Axle Crossmember Grinding Areas
Courtesy of MERCEDES-BENZ USA
Coat insides of spot weld flange on rear axle crossmember (6) with zinc dust paint.
Do not apply zinc dust paint to bonding surfaces (area E). Adhesion problems can occur.

Fig 5: Identifying Grinding Areas On Spare Wheel Well Locking Lug And Rear Axle Crossmember
Courtesy of MERCEDES-BENZ USA
Grind mating surfaces on spare wheel well locking lug (4) and upper rear axle crossmember (5) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.

Observe pretreatment of bonding surfaces (area H).
Coat insides of spot weld flanges with zinc dust paint.
Do not coat bonding surfaces with zinc dust paint (area H). Adhesion problems can occur.
18.1 Cut Ø 6.7 mm spot welds in loading floor crossmember (3) (areas I and J).
On model 204.
18.2 Cut out spot welds on loading floor crossmember (3) (areas I and J).
With model 212.0, 218.3.

The loading floor crossmember (3) is located below the loading floor crossmember remaining section (3.1)
Remove loading floor crossmember remaining section (3.1).
Deburr holes on both sides.

Fig 6: Identifying Spot Welds Drilling Areas On Floor Crossmember
Courtesy of MERCEDES-BENZ USA
Grind loading floor crossmember (3) down to bare metal in crosshatched areas.
Loading floor crossmember (3) (area M).
Perform operation steps 23 only on model 218.3.
Grind mating surfaces on loading floor crossmember (3) down to bare metal in crosshatched areas.
Observe pretreatment of bonding surfaces (areas XY₁ XY₂ , XY₃ and XY₄ .

Fig 7: Identifying Bonding Surfaces Of Floor Crossmember (Areas Xy1, Xy2, Xy3 And Xy4)
Courtesy of MERCEDES-BENZ USA

Fig 8: Identifying Grinding Areas On Loading Floor Crossmember
Courtesy of MERCEDES-BENZ USA
Grind mating surfaces on loading floor crossmember (3) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.
Coat insides of spot weld flanges with zinc dust paint.
Perform operation steps 26, 27, 28, 29, 30 and 31 only on model 204.
Scribe separation points on inner longitudinal member (8) (area K).
Transfer separation point from vehicle.
Cut inner longitudinal member (8) at separation point (area K).
Drill Ø 7 mm holes in inner longitudinal member (8) (area L).
Grind mating surfaces on inner longitudinal member (8) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.

Fig 9: Identifying Inner Longitudinal Member Hole Drilling Areas, Separation Points & Mating Surfaces
Courtesy of MERCEDES-BENZ USA
Grind crosshatched areas on inner longitudinal member (8) down to bare metal around holes (area L).
Coat insides of spot weld flanges with zinc dust paint.

Fig 10: Identifying Inner Longitudinal Member And Offset Reinforcement Grinding Areas & Separation Points
Courtesy of MERCEDES-BENZ USA

Perform operation steps 32, 33, 34 and 35 only on model 212.0, 218.3.
Scribe separation points on inner longitudinal member (8) and offset reinforcement (9) (areas M and N).
Take separation points from vehicle
Cut inner longitudinal member (8) and offset reinforcement (9) at separation points (areas M and N).
Grind mating surfaces on inner longitudinal member (8) and offset reinforcement (9) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.
Coat insides of spot weld flanges with zinc dust paint.

Fig 11: Identifying Outer Longitudinal Member Grinding Areas & Separation Points
Courtesy of MERCEDES-BENZ USA
Scribe separation points on outer longitudinal member (1) (area O).
Transfer separation point from vehicle.
Cut outer longitudinal member (1) at separation point (area O).
Grind mating surfaces on outer longitudinal member (1) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.
Coat insides of spot weld flanges with zinc dust paint.