Separate rear fender - AR63.50-P-1400-02SC

Fig 1: Identifying Rear Fender Cutting Area

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Position metal needle template (2) offset on Y-markings (arrows) approx. 10 mm toward rear and scribe (area A).
When the C-pillar is damaged, transfer Y-marking (arrows) upward according to dimension (a), position metal needle template (2) and scribe cut (area A₁ ).

Dimension (a) is 120 mm.
Cut along broken line using body saw (area A or A₁ ).
Observe sheet metal below.
Expose spot welds on rear fender (1) and cut out (area B).
Expose MIG weld seam on rear fender (1) and grind open (area C).
Scribe cut on rear fender (1) using cutting template and according to dimensions (b, c) (area E).
Dimension (b) is approx. 82 mm and dimension (c) is approx. 329 mm.
Cut on rear fender (1) using body saw (area E).
Observe sheet metal below.
Expose spot welds on rear fender (1) and cut out (areas D and F).

Fig 2: Identifying Spot Welds On Rear Fender And Cut Out (Areas D And F)
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Expose clinch connections on rear fender (1) and drill with 6.0 mm dia. bit (areas G and I).
Expose punch rivets on rear fender (1) and cut out (area H).
Expose spot welds on rear fender (1) and cut out (areas J₁ , J₂ and J₃ ).

Fig 3: Identifying Spot Welds On Rear Fender Cutting Areas
Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Clinch Connections And Resistance Spot Welds Rear Fender And Cutting Areas (K, L, M And Q)
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Expose clinch connections and resistance spot welds on rear fender (1) and cut out (areas K, L, M and Q).
Expose punch rivet and clinch connections on rear fender (1) and drill with 6.0 mm dia. bit (areas N, O, P and R).

Fig 5: Identifying Outer Rear Wheelhouse And Rear Fender Cutting Area (S)
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Cut bonded connection between outer rear wheelhouse and rear fender (1) using multicutter (area S).

Fig 6: Identifying Rear Fender Cross-Hatched Areas
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Heat rear fender in cross-hatched areas with hot air gun and remove.
The rear fender is foam-protected and bonded in cross-hatched areas. Damaged foam parts must be removed and replaced.

Fig 7: Identifying Adhesive Residues In Cross-Hatched Areas (T, U, V, V1, W, X1, X2, X3 and X4)
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For all other operation steps, observe information on pretreatment of bonding surfaces.
Remove adhesive residues in cross-hatched areas using round wire brush (areas T, U, V, V₁ , W, X₁ , X₂ , X₃ and X₄ ).
Grind mating surfaces down to bare metal in cross-hatched areas on both sides using round wire brush (areas U, X₂ , V₁ and W₁ ).
Grind mating surfaces down to bare metal in other cross-hatched areas on one side using round wire brush.
Cut off adhesive residues using scraper (area Y).
A maximum of 2 mm of adhesive residue may be left. Pull off loose adhesive material (remaining pieces which are not completely cut off).
Remove grinding and drill shavings using wet/dry vacuum cleaner.
Coat insides of spot weld flange with zinc dust paint (area V₁ ).
Cut upper C-pillar to size using body saw and crimp toward inside using sheet metal crimping pliers (area AA).
Use shop-made sheet metal crimping pliers for areas difficult to be accessed.
Remove adhesive residues in cross-hatched areas using stainless steel round wire brush and grind mating surfaces down to bare metal on one side (area AB).
Remove adhesive residues in cross-hatched areas using round wire brush and grind mating surfaces down to bare metal on one side (area AF).

Fig 8: Identifying Insides Of Spot Weld Flange With Zinc Dust Paint Areas (AC, AD And AE)
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Grind mating surfaces down to bare metal in cross-hatched areas using round wire brush on one side (areas AC, AD and AE).
Remove grinding and drill shavings using wet/dry vacuum cleaner.
Coat insides of spot weld flange with zinc dust paint (areas AC, AD and AE).
Remove adhesive residues in cross-hatched areas using stainless steel round wire brush and grind mating surfaces down to bare metal (areas Z, Z₁ and Z₂ ).
Remove grinding and drill shavings using wet/dry vacuum cleaner.

Fig 9: Identifying Adhesive Residues In Cross-Hatched Areas (Z, Z1 and Z2).
Courtesy of MERCEDES-BENZ USA