Separate inner rear wheelhouse - AR63.10-P-0670-01SX

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Spot Weld Milling Cutter (215 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

The following operation steps are shown on model 221 on the left side of the vehicle and must be performed analogously on the right side in the event of damage.

1. Install support (4) and fasten.

   Support (4) should be of a stable material, e.g. wood. The length of the material corresponds to the undamaged side of the vehicle (approx. 500 mm).

   Fig 3: Identifying Support

   Courtesy of MERCEDES-BENZ USA

   Dimensions: 

2. Mark separation line on inner rear wheelhouse (1) (area A).
3. Cut inner rear wheelhouse (1) on separation point with body saw (area A).
4. Expose clinch connections on inner rear wheelhouse (1) (area B).
5. Drill clinch connections on inner rear wheelhouse (1) with 6.5 mm dia. bit (area B).
6. Expose spot welds on inner rear wheelhouse (1) (areas C and D).
   Fig 4: Identifying Separation Lines & Spot Welds On Inner Rear Wheelhouse

   Courtesy of MERCEDES-BENZ USA
7. Cut out spot welds on inner rear wheelhouse (1) with spot weld milling cutter or Vario Drill spot weld removing tool (areas C and D).
8. Heat anti-droning mat (2) in cross-hatched areas with heat gun.

   Cross-hatched areas are bonded.

9. Remove anti-droning mat (2) from rear shelf (3).

   Remove anti-droning mat (2) to expose spot welds below.

10. Expose spot welds and welds on inner rear wheelhouse (1) (areas E, F and G).
    Fig 5: Identifying Spot Welding Areas On Inner Rear Wheelhouse (E, F And G)

    Courtesy of MERCEDES-BENZ USA
11. Cut spot welds on inner rear wheelhouse (1) (area G).
12. Cut out spot welds on inner rear wheelhouse (1) with spot weld milling cutter or ball cutter (areas E and F).
    Fig 6: Identifying Spot Welding Areas On Inner Rear Wheelhouse (H, I, J, K And L)

    Courtesy of MERCEDES-BENZ USA
13. Expose spot welds on inner rear wheelhouse (1) (areas H, I, J, K and L).
14. Cut out spot welds on inner rear wheelhouse (1) with spot weld milling cutter or ball cutter (areas H, I, J, K and L).
15. Expose spot welds on inner rear wheelhouse (1) and rear shelf (3) (areas M and P).
16. Drill dia. 6.5 mm spot welds in rear shelf (3) (area P).
17. Cut out spot welds on inner rear wheelhouse (1) with spot weld milling cutter or ball cutter (area M).
18. Expose punch rivet and clinch connections on inner rear wheelhouse (1) (areas N and O).
19. Cut out punch rivet and clinch connections on inner rear wheelhouse (1) with spot weld milling cutter (areas N and O).
    Fig 7: Identifying Spot Welding Areas & Punch Rivets On Inner Rear Wheelhouse And Rear Shelf

    Courtesy of MERCEDES-BENZ USA
20. Heat inner rear wheelhouse (1) and rear shelf (3) in cross-hatched areas with heat gun.

    Cross-hatched areas are bonded.

    Fig 8: Identifying Inner Rear Wheelhouse And Rear Shelf Cross-Hatched Areas

    Courtesy of MERCEDES-BENZ USA
21. Remove damaged inner rear wheelhouse (1).
22. Grind mating surfaces in cross-hatched areas down to bare metal using round wire brush.

    Grind spot weld flanges down to bare metal on both sides.

    Fig 9: Identifying Inner Rear Wheelhouse Mating Surfaces

    Courtesy of MERCEDES-BENZ USA
23. Grind connection surfaces down to bare metal in cross-hatched areas with stainless steel round wire brush.
24. Remove grinding and drill shavings using wet/dry vacuum cleaner.
25. Using zinc dust paint, coat insides of spot weld flanges and riveted joints that were not additionally bonded.

    Observe pretreatment of bonding surfaces.

Fig 10: Identifying Connection Surfaces

Courtesy of MERCEDES-BENZ USA