Remove wheelhouse - AR62.20-P-1200-21SX

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

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Front Wheelhouse Spot Welding Areas (A, B, C, And D)

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. Expose spot welds on front wheelhouse (1) (areas A, B, C, C ₁ , C ₂ and D).
2. Cut out spot welds on front wheelhouse (1) with spot weld milling cutter or ball cutter (areas A, B, C, C ₁ , C₂ and D).

   Cut out through two sheet metal thicknesses (area C ₂ ).

   Fig 3: Identifying Front Wheelhouse Spot Welding Areas (E, F, G, G And H)

   Courtesy of MERCEDES-BENZ USA
3. Expose spot welds on front wheelhouse (1) (areas E, F, G, G ₁ and H).
4. Cut out spot welds on front wheelhouse (1) with spot weld milling cutter or ball cutter (areas E, F, G, G ₁ and H).

   Cut out through two sheet metal thicknesses (area G ₁ ).

   Fig 4: Identifying Front Wheelhouse Spot Welding Areas (I, J, K, L, M, N And O)

   Courtesy of MERCEDES-BENZ USA
5. Expose spot welds on front wheelhouse (1) (areas I, J, K, L, M, N and O).
6. Cut out spot welds on front wheelhouse (1) with spot weld milling cutter or ball cutter (areas I, J, K, L, M and N).

   Cut out through two sheet metal thicknesses (areas K and L).

7. Drill dia. 6.5 mm spot welds in front wheelhouse (1) (area O).
   Fig 5: Identifying Front Wheelhouse Spot Welding Areas (P, Q, R, S, T And U)

   Courtesy of MERCEDES-BENZ USA
8. Expose spot welds on front wheelhouse (1) (areas P, Q, R, S, T and U).
9. Drill dia. 6.5 mm spot welds in front wheelhouse (1) (area P).
10. Cut out spot welds on front wheelhouse (1) with spot weld milling cutter or ball cutter (areas Q, R, S, T and U).

    Cut out through two sheet metal thicknesses (area T).

    Fig 6: Identifying Front Wheelhouse Spot Welding Areas (V, W, X, Y And AG)

    Courtesy of MERCEDES-BENZ USA
11. Expose spot welds on front wheelhouse (1) and partition wall (2) (areas V, W, X, Y and AG).
12. Drill dia. 6.5 mm spot welds in front wheelhouse (1) and partition wall (2) (areas X and AG).
13. Remove sheet metal lug (1.1) from front wheelhouse (1).

    Do not dispose of sheet metal lug (1.1); still required for installation.

14. Cut out spot welds on front wheelhouse (1) with spot weld milling cutter or ball cutter (areas V, W and Y).

    Cut out through two sheet metal thicknesses (area V).

15. Bend open partition wall (2) (arrows).

    Bend open partition wall (2) in this area (arrows) to facilitate removal and installation of front wheelhouse (1).

16. Remove insulating cover (3) from main floor (4).
17. Expose spot welds on main floor (4) (area Z).
18. Drill dia. 6.5 mm spot welds in main floor (4) (area Z).
    Fig 7: Identifying Main Floor Spot Welding Area (Z)

    Courtesy of MERCEDES-BENZ USA
    Fig 8: Identifying Front Wheelhouse Cross-Hatched Areas

    Courtesy of MERCEDES-BENZ USA
19. Heat front wheelhouse (1) in cross-hatched areas with hot air gun.

    Cross-hatched areas are glued in addition.

20. Remove damaged front wheelhouse (1).
    Fig 9: Identifying Grinding Surfaces In Cross-Hatched Areas

    Courtesy of MERCEDES-BENZ USA
21. 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.

22. Remove grinding and drill shavings using wet/dry vacuum cleaner.
23. Using zinc dust paint, coat insides of spot weld flanges and riveted joints that were not additionally bonded.

    Do not coat bonding surfaces with zinc dust paint to prevent adhesion problems (areas AA, AB, AC, AD, AE and AF).

    Observe pretreatment of bonding surfaces.