Rear Inner Wheel Well Installation - Ar63.10-P-0670-04RG

Notice	Notes on bolted connections with self tapping screws		AH00.00-P-0007-01SF
	000 588 04 39 00 Rivet press tool		WS60.00-P-0440B
	000 588 12 84 00 Welder		WS00.00-P-0318K

Model 190 

Fig 1: Templates (190 589 01 23 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Drilling Fixture (197 589 01 23 00)

Courtesy of MERCEDES-BENZ USA

Further information can be found in the superordinate service document. Comply with safety information in superordinate customer service document.

The following operation steps are shown on the left side of the vehicle. This must be similarly performed for damage to the right side of the vehicle.

Always  maintain welding sequence according to operation steps.

Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

1. Install inner rear wheel well (1) and fit and fix in place with straightening set.
2. Check weld seam gaps.

   Before the start of welding, check all weld seam gaps. The weld seam gap must not be larger than 1 mm; if necessary, make an add-on seam weld.

3. Tack weld inner rear wheel well (1) with welder ( ) (area A1).

   When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Weld seams must  be tack welded at start, end and every approx. 4 cm.

4. Weld inner rear wheel well (1) with welder ( ) (area A1).

   When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

   Shown on model 190.3 

   Courtesy of MERCEDES-BENZ USA

5. Tack weld inner rear wheel well (1) with welder ( ) (area A2L).

   When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Weld seams must  be tack welded at start, end and every approx. 4 cm.

6. Weld inner rear wheel well (1) with welder ( ) (area A2L).

   When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

   Shown on model 190.3 

   Courtesy of MERCEDES-BENZ USA

7. Tack weld inner rear wheel well (1) with welder ( ) (area A2R).

   When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Weld seams must  be tack welded at start, end and every approx. 4 cm.

8. Weld inner rear wheel well (1) with welder ( ) (area A2R).

   When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

   Shown on model 190.3 

   Courtesy of MERCEDES-BENZ USA

9. Tack weld inner rear wheel well (1) with welder ( ) (areas A3 and A4).

   When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Weld seams must  be tack welded at start, end and every approx. 4 cm. Welding sequence (A3 and A4) must  be complied with.

10. Weld inner rear wheel well (1) with welder ( ) (areas A3 and A4).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

    Welding sequence (A3 and A4) must  be complied with.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

11. Tack weld inner rear wheel well (1) with welder ( ) (areas A5 and A6).

    When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Weld seams must  be tack welded at start, end and every approx. 4 cm. Welding sequence (A5 and A6) must  be complied with.

12. Weld inner rear wheel well (1) with welder ( ) (areas A5 and A6).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

    Welding sequence (A5 and A6) must  be complied with.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

13. Tack weld inner rear wheel well (1) with welder ( ) (areas A7 and A8).

    When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Weld seams must  be tack welded at start, end and every approx. 4 cm. Welding sequence (A7 and A8) must  be complied with.

14. Weld inner rear wheel well (1) with welder ( ) (areas A7 and A8).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

    Welding sequence (A7 and A8) must  be complied with.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

15. Tack weld inner rear wheel well (1) with welder ( ) (areas A9, A11 and A10).

    When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Weld seams must  be tack welded at start, end and every approx. 4 cm. Welding sequence (A9, A11 and A10) must  be complied with.

16. Weld inner rear wheel well (1) with welder ( ) (areas A9, A11 and A10).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

    Welding sequence (A9, A11 and A10) must  be complied with.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

17. Tack weld inner rear wheel well (1) with welder ( ) (areas A12, A13 and A14).

    When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Weld seams must  be tack welded at start, end and every approx. 4 cm. Welding sequence (A12, A13 and A14) must  be complied with.

18. Weld inner rear wheel well (1) with welder ( ) (areas A12, A13 and A14).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam. Welding sequence (A12, A13 and A14) must  be complied with.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

19. Model 190.3

    Install, fit and fix in place C-pillar supports (11 and 12).

20. Model 190.3

    Tack weld C-pillar supports (11 and 12) with welder ( ) (areas B1, B2, B4, B6, B3, B5 and B7).

    When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Weld seams must  be tack welded at start, end and every approx. 4 cm. Welding sequence (B1, B2, B4, B6, B3, B5 and B7) must  be complied with.

21. Model 190.3

    Weld C-pillar supports (11 and 12) with welder ( ) (areas B1, B2, B4, B6, B3, B5 and B7).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

    Welding sequence (B1, B2, B4, B6, B3, B5 and B7) must  be complied with.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

22. Model 190.3

    Install, fit and fix in place left rear window frame (10).

23. Model 190.3

    Drill rivet holes in left rear window frame (10) with ø 6.7 mm (areas C2, C3 and C4).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

24. Model 190.3

    Drill rivet holes in left rear window frame (10) with ø 6.0 mm (area C1).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

    Courtesy of MERCEDES-BENZ USA

25. Model 190.3

    Remove left rear window frame (10).

26. Model 190.3

    Deburr rivet holes on left rear window frame (10) on both sides.

    Observe pretreatment of bonding surfaces (cross-hatched areas).

27. Model 190.3

    Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

28. Model 190.3

    On left rear window frame (10) apply the 2-component adhesive (cross-hatched areas).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

29. Model 190.3

    Install, fit and fix in place left rear window frame (10).

30. Model 190.3

    Rivet left rear window frame (10) with rivet press tool and blind rivets or blind rivets (areas C₅ , C₆ , and C₇ ).

    Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

31. Model 190.3

    Rivet left rear window frame (10) with rivet press tool and flow-form rivets (area C₈ ).

    Use flow form rivet structure 4 mm up to 5.15 mm clamping range (S3).

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

    Shown on model 190.4 

32. Model 190.4

    Install, fit and fix in place soft top compartment beltline reinforcement (19).

33. Model 190.4

    Drill rivet holes in soft top compartment beltline reinforcement (19) with ø 6.7 mm (area U₄ ).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

34. Model 190.4

    Drill rivet holes in soft top compartment beltline reinforcement (19) with ø 5.2 mm (area V₅ ).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

35. Model 190.4

    Remove soft top compartment beltline reinforcement (19).

36. Model 190.4

    Deburr rivet holes on soft top compartment beltline reinforcement (19) on both sides.

    Observe pretreatment of bonding surfaces (cross-hatched areas).

37. Model 190.4

    Remove shavings using wet/dry vacuum cleaner.

    Courtesy of MERCEDES-BENZ USA

    Shown on model 190.4 

38. Model 190.4

    On soft top compartment beltline reinforcement (19), apply the 2-component adhesive (cross-hatched areas).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

39. Model 190.4

    Install, fit and fix in place soft top compartment beltline reinforcement (19).

40. Model 190.4

    Rivet soft top compartment beltline reinforcement (19) with rivet press tool and flow-form rivets (area V4).

    Use flow form rivet structure 4 mm up to 5.15 mm clamping range (S3).

41. Model 190.4

    Rivet soft top compartment beltline reinforcement (19) with rivet press tool and blind rivets or blind rivet (area U3).

    Replace flow drill screws installed in vehicle by high strength blind rivets according to clamping range.

42. Model 190.4

    Rivet soft top compartment beltline reinforcement (19) with rivet press tool and blind rivet (area V3).

    Use blind rivet 5x10.

43. Install, fit and fix in place lower rear end plate (18).
44. Drill rivet holes in lower rear end plate (18) with ø 6.7 mm (area R₁ ).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

45. Remove lower rear end plate (18).
46. Deburr rivet holes on lower rear end plate (18) on both sides.

    Observe pretreatment of bonding surfaces (cross-hatched areas).

47. Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.4 

    Courtesy of MERCEDES-BENZ USA

48. On lower rear striker plate (18) apply the 2-component adhesive (cross-hatched areas).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

49. Install, fit and fix in place lower rear end plate (18).
50. Rivet lower rear striker plate (18) with rivet press tool and blind rivets or blind rivets (area R).

    Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

    Shown on model 190.4 

    Courtesy of MERCEDES-BENZ USA

51. Install, fit and fix in place front left wheel well (9).
52. Drill rivet holes in front left wheel well (9) with ø 6.7 mm (areas D1, D2 and D3).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

53. Remove front left wheel well (9).
54. Deburr rivet holes on front left wheel well (9) on both sides.

    Observe pretreatment of bonding surfaces (cross-hatched areas).

55. Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

56. Front left wheel well (9) apply the 2- component adhesive (crosshatched areas).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

57. Install, fit and fix in place front left wheel well (9).
58. Rivet front left wheel well (9) with rivet press tool and blind rivets or blind rivets (areas D₄ , D₅ , and D₆ ).

    Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

59. Install, fit and fix in place front wheel well end plate (8).
60. Drill rivet holes in front wheel well end plate (8) with ø 6.7 mm (areas E₁ , E₂ and E₃ ).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

61. Remove front wheel well end plate (8).
62. Deburr rivet holes on front wheel well end plate (8) on both sides.

    Observe pretreatment of bonding surfaces (cross-hatched areas except areas F₁ , F₂ and F₃ ). Prepare welds by grinding down to bare metal with stainless steel brush (areas F₁ , F₂ and F₃ ).

63. Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

64. On front wheel well striker plate (8), apply the 2-component adhesive (cross-hatched areas).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

65. Install, fit and fix in place front wheel well end plate (8).
66. Rivet front wheel well striker plate (8) with rivet press tool and blind rivets or blind rivets (areas E₄ , E₅ , and E₆ ).

    Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

67. Tack weld front wheel well end plate (8) with welder ( ) (areas F₄ , F₅ and F₆ ).

    When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Weld seams must  be tack welded at start, end and every approx. 4 cm.

    Courtesy of MERCEDES-BENZ USA

    Shown on model 190.3 

    Welding sequence (F₄ , F₅ and F₆ ) must  be complied with.

68. Weld front wheel well end plate (8) with welder ( ) (areas F₄ , F₅ and F₆ ).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

    Welding sequence (F₄ , F₅ and F₆ ) must  be complied with.

69. Install, fit and fix in place front floor end plate (3).
70. Drill rivet holes in front floor end plate (3) with ø 6.7 mm (area G).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

71. Remove front floor end plate (3).
72. Deburr rivet holes on front floor end plate (3) on both sides.

    Observe pretreatment of bonding surfaces (cross-hatched area G). Prepare welds by grinding down to bare metal with stainless steel brush (areas H₁ and H₂ ).

73. Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

74. On front floor striker plate (3), apply 2-component adhesive (crosshatched area G₁ ).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

75. Install, fit and fix in place front floor end plate (3).
76. Rivet front floor striker plate (3) with rivet press tool and blind rivets or blind rivets (area G₁ ).

    Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

77. Tack weld front floor end plate (3) with welder ( ) (areas H3 and H₄ ).

    When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Weld seams must  be tack welded at start, end and every approx. 4 cm. Welding sequence (H₃ and H₄ ) must  be complied with.

78. Weld front floor end plate (3) with welder ( ) (areas H₃ and H₄ ).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

    Welding sequence (H₃ and H₄ ) must  be complied with.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

79. Install, fit and fix in place end plate (6).
80. Drill rivet holes in end plate (6) with ø 6.7 mm (areas I1, I2, J1, J2, K and L).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

81. Remove end plate (6).
82. Deburr rivet holes on end plate (6) on both sides.

    Observe pretreatment of bonding surfaces (cross-hatched areas).

83. Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

84. On striker plate (6), apply the 2-component adhesive (crosshatched areas).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

85. Install, fit and fix in place end plate (6).
86. Rivet striker plate (6) with rivet press tool and blind rivets or blind rivets (areas I₃ , I₄ , J₃ , J₄ , K₁ , and L₁ ).

    Replace flow drill screws installed in vehicle by high strength blind rivets according to clamping range.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

87. Install, fit and fix in place end plates (4 and 5).
88. Drill rivet holes in end plates (4 and 5) with ø 6.7 mm (areas M₁ , M₂ , M₃ , N₁ and N₂ ).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

89. Remove end plates (4 and 5).
90. Deburr rivet holes on end plates (4 and 5) on both sides.

    Observe pretreatment of bonding surfaces (cross-hatched areas except areas O₁ and O₂ ). Prepare welds by grinding down to bare metal with stainless steel brush (areas O₁ and O₂ ).

91. Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

92. On striker plates (4 and 5), apply the 2-component adhesive (crosshatched areas).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

93. Install, fit and fix in place end plates (4 and 5).
94. Rivet striker plates (4 and 5) with rivet press tool and blind rivets or blind rivets (areas M₄ , M₅ , M₆ , N₃ , and N₄ ).

    Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

95. Tack weld end plates (4 and 5) with welder ( ) (areas O₃ and O₄ ).

    When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Weld seams must  be tack welded at start, end and every approx. 4 cm.

    Courtesy of MERCEDES-BENZ USA

    Welding sequence (O₃ and O₄ ) must  be complied with.

96. Weld end plates (4 and 5) with welder ( ) (areas O₃ and O₄ ).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

    Welding sequence (O₃ and O₄ ) must  be complied with.

    Shown on model 190.3 

97. Load drilling jig (14) with templates.
98. Attach drilling jig (14) with straightening set (13) to inner rear wheel well (1) and fix in place.
99. Insert pilot bushings (15) with ø 7.5 mm into drilling jig (14) in diagonal area (areas P1, P2, P3 and P4).
100. Drill core hole ø 7.5 mm through pilot bushings (15) with a drill depth of 25 mm (areas P1, P2, P3 and P4).
101. Remove pilot bushings (15).
102. Insert pilot bushings (16) with ø 8.2 mm into drilling jig (14) in diagonal area (areas P1, P2, P3 and P4).
103. Preform new thread with thread forming screws located in the set and in doing so fix in place drilling jig (14) (areas P1, P2, P3 and P4).

     Preform new thread with 4 to 6 thread turns. The screw length is selected so that approx. 8 mm of thread protrudes beyond pilot bushings (16). Approx. 4 to 6 thread turns are thus preformed in inner rear wheel well (1).

     Courtesy of MERCEDES-BENZ USA

104. Insert pilot bushings (15) with ø 7.5 mm in drilling jig (14) (areas P5).
105. Drill remaining core hole bores ø 7.5 mm in pilot bushings (15) with a drill depth of 25 mm (areas P5).
106. Remove pilot bushings (15).
107. Insert pilot bushings (16) with ø 8.2 mm in drilling jig (14) (areas P5).
108. Preform remaining new threads in inner rear wheel well (1) with thread forming screws located in set (areas P5).

     Preform new thread with 4 to 6 thread turns. The screw length is selected so that approx. 8 mm of thread protrudes beyond pilot bushings (16). Approx. 4 to 6 thread turns are thus preformed in inner rear wheel well (1).

109. Unscrew all thread forming screws and remove pilot bushings (16) (areas P1 to P5).
110. Remove drilling jig (14) with straightening set (13).
111. Tighten new mounting supports for transverse control arms (17) with new genuine screws .

Observe prescribed tightening torque of new genuine screws, threads are subsequently fully formed.

Courtesy of MERCEDES-BENZ USA