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Separate deformed rear area - AR64.20-P-1200-11T

Fig 1: Identifying Cutting Templates (211 589 05 23 00)
G07265087Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G07265088Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Tool - When Replacing Right Rear Fender (211 589 00 91 00)
G07265089Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1002-01A Ball cutter, dia. 12 mm
WH58.30-Z-1006-01A Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1001-03A Round wire brush, braided, dia. 70 mm
WH58.30-Z-1024-04A Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 RPM)
WH58.30-Z-1004-20A Hot-air gun
WH58.30-Z-1001-40A Tarp (fire-resistant)
WORKSHOP EQUIPMENT CHART

WE58.40-Z-1001-03A Drill (electric/pneumatic)
WE58.40-Z-1002-03A Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A Body saw (electric/pneumatic)
WE58.40-Z-1005-03A Wet/dry vacuum cleaner
WE58.40-Z-1001-05A Two-post lifting platform
REPAIR MATERIALS CHART

Number Designation Order number
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
Fig 4: Marking Separation Points With Cutting Templates (Areas A And B)
G07256301Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  1. Mark separation points with cutting templates (areas A and B).
  2. Cut separation points with body saw (areas A and B).

    IMPORTANT Do not damage C-pillar located below and outer side longitudinal member.

    Fig 5: Marking Separation Point (Area C)
    G07265091Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  3. Mark separation point (area C).
  4. Cut separation point with body saw (area C).
  5. Mark separation point (area I).
  6. Cut separation point with body saw (area I).
  7. Remove section.
    Fig 6: Marking Separation Point (Area I)
    G07265092Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  8. Mark separation point (area H).
  9. Cut separation point with body saw (area H).
  10. Remove section.

    IMPORTANT Area H approx. 30 mm parallel to edge.

    Fig 7: Marking Separation Point (Area H)
    G07265093Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 8: Identifying Spot Welds (Areas J, K, L, M, R And S)
    G07265094Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  11. Expose spot welds (areas J, K, L, M, R and S).
  12. Cut out spot welds with SPECIAL TOOL spot weld milling cutter (areas J, K, L, M, R and S).
  13. Expose spot welds (areas G and T).
  14. Cut out spot welds with SPECIAL TOOL spot weld milling cutter (areas G and T).
    Fig 9: Identifying Spot Welds (Areas G And T)
    G07265095Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 10: Identifying Spot Welds (Areas C, D, E And F)
    G07256302Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  15. Expose spot welds (areas C, D, E and F).
  16. Cut out spot welds with SPECIAL TOOL spot weld milling cutter (areas C, D, E and F).
  17. Expose spot welds (area D).
  18. Perforate spot welds with Ø 7 mm bit (area D).
    Fig 11: Identifying Spot Welds (Areas N, O, P And Q)
    G07265097Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  19. Expose spot welds (areas N, O, P and Q).
  20. Cut out spot welds with SPECIAL TOOL spot weld milling cutter (areas N, O, P and Q).
  21. Heat rear fender with hot air blower in shaded areas.

    IMPORTANT Shaded areas are foam filled.

  22. Remove rear fender.
  23. Heat reinforcement in shaded area with hot air blower and remove.

    IMPORTANT Shaded area is glued

  24. Remove reinforcement.
    Fig 12: Locating Rear Fender Heating Areas
    G07265098Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 13: Identifying Spot Welds (Areas u, v, w, x, Y, Z, AA, AB, AC And AD)
    G07265099Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  25. Expose spot welds (areas u, v, w, x, Y, Z, AA, AB, AC and AD).
  26. Cut out spot welds with SPECIAL TOOL spot weld milling cutter (areas u, v, w, x, Y, Z, AA, AB, AC and AD).
  27. Remove sections.
    Fig 14: Locating Connection Surfaces Shaded Areas
    G07256306Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  28. Sand connection surfaces down to bare metal in the shaded areas.

    IMPORTANT Sand spot weld flanges down to bare metal on both sides.

  29. Remove grinding and drilling chips using wet/dry vacuum cleaner.
  30. Coat insides of spot welding flanges and rivet connections with zinc dust paint.
    Fig 15: Coating Insides Of Spot Welding Flanges And Rivet Connections With Zinc Dust Paint
    G07265101Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  31. Crimp rear fender in area of C-pillar at top with sheet metal crimping pliers toward inside (arrow).
    Fig 16: Crimping Rear Fender In Area Of C-Pillar At Top
    G07265102Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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