Install And Weld In Wheel Well - Ar62.20-P-1200-17LFS

Model 222 

with code Z07 (B7 armoring on special protection version) 

When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Tack weld weld seams at start and end. Weld seam gap should not be greater than 1 mm, if required, preweld.

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Shown on MODEL 222 with CODE Z07 (Top protection) 

1. Install wheel well (1) with straightening tool, fit and fix in place.
2. Install pedal floor panel (3) and connecting carrier (2), fit and fix in place.
3. Drill Ø 6.7 mm rivet holes in connecting carrier (2) (areas A).

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4. Drill Ø 6.7 mm rivet holes in pedal floor panel (3) (areas B).
5. Grind mating surfaces down to bare metal in the cross-hatched inner C-pillar sidewall.
6. Remove pedal floor panel (3).
7. Deburr rivet holes on pedal floor panel (3) and body on both sides.
8. Remove grinding dust and drill chips.

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9. Drill Ø 6.7 mm rivet holes in wheel (1) (areas C₁ , C₂ , D₁ and D₂ ).

   Drill rivet hole through main floor reinforcement so that the rivet can be inserted completely (area D₂ ).

10. Mark rivet holes on lower longitudinal member, drill with Ø 6.7 mm bit and countersink (areas D₃ ).

    To fit the mounting console on the lower front longitudinal member optimally, countersink the rivet holes so that the countersunk rivet head is flush with the surface.

11. Mark position of rivet hole on wheel well (1) (area C₃ ).

    Dimensions  :

    c₁ = approx. 16 mm

12. Drill Ø 6.7 mm rivet holes on wheel well (1) (area C₃ ).
13. Grind mating surfaces down to bare metal in crosshatched area.
14. Remove grinding dust and drill chips.

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15. Drill Ø 6.7 mm rivet holes in wheel well (1) (areas E₁ , E₂ , F₁ and F₂ ).
16. Mark rivet holes on lower longitudinal member, drill with Ø 6.7 mm bit and countersink (areas D3).

    To fit the mounting console on the lower front longitudinal member optimally, countersink the rivet holes so that the countersunk rivet head is flush with the surface.

17. Mark positions of rivet holes on wheel well (1) (area E₃ ).

    Dimensions  :

    e₁ = approx. 47 mm

    e₂ = approx. 100 mm

18. Drill Ø 6.7 mm rivet holes on wheel well (1) (area E₃ ).
19. Grind connection surfaces down to bare metal in cross-hatched area.
20. Remove grinding dust and drill chips.

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21. Mark positions of rivet holes on wheel well (1) (area G).

    When working on wheel well (1) on driver side.

    Dimensions  :

    g₁ = approx. 45 mm

    g₂ = approx. 77 mm

    g₃ = approx. 106 mm

    g₄ = approx. 140 mm

    Perform operation step analogously on driver side on right-hand drive vehicle.

22. Drill Ø 6, 7 mm rivet holes on wheel well (1) on driver side (area G).

    When working on wheel well (1) on driver side.

    Perform operation step analogously on driver side on right-hand drive vehicle.

23. Remove drilling chips.

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24. Use dimensions x₁ and y₁ previously transferred to the firewall from points (X₁ and Y₁ ) on the new wheel well (1) and drill with Ø 6.7 mm bit (area F₁ ).

    When working on wheel well (1) on passenger side.

    Perform operation step analogously on passenger side on right-hand drive vehicle.

25. Remove drilling chips.

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26. Mark positions of rivet holes on wheel well (1) (area F₂ ).

    When working on wheel well (1) on passenger side.

    Dimensions  :

    f₁ = approx. 45 mm

    f₂ = approx. 85 mm

    f₃ = approx. 34 mm

    Perform operation step analogously on passenger side on right-hand drive vehicle.

27. Drill Ø 6.7 mm rivet holes on wheel well (1) on passenger side (area F₂ ).

    When working on wheel well (1) on passenger side.

    Perform operation step analogously on passenger side on right-hand drive vehicle.

28. Remove drilling chips.
29. Drill Ø 6.7 mm rivet holes in wheel well (1) (area H₁ ).

    Only if a riveter for punching and flow form rivets is not used for installation.

30. Drill Ø 6.7 mm rivet holes in wheel well (1) (area H₂ ).
31. Remove straightening tool and wheel well (1).
32. Deburr rivet holes on wheel well (1) and body on both sides.
33. Remove drilling chips.

    Shown on MODEL 222 with CODE Z07 (Top protection) 

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34. Apply 2-component adhesive to body in crosshatched areas.

    Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive.

    Shown on MODEL 222 with CODE Z07 (Top protection) 

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35. Apply 2-component adhesive to body in crosshatched areas.

    Observe pretreatment of bonding surfaces Observe manufacturer's specifications for drying and processing time of adhesive.

    Shown on MODEL 222 with CODE Z07 (Top protection) 

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36. Install wheel well (1) with straightening tool, fit and fix in place.
37. Rivet wheel well (1) with Ø with 6.5x12.5 blind rivet (area I₁ ).

    Flow form rivets with a clamping range of 3.35 mm to 4.1 "S2" can be used, if a riveter for punching and flow form rivets is used for installation (area H2).

38. Rivet wheel well (1) with Ø with 6.5x12.5 blind rivet (area I₂ ).

    Shown on MODEL 222 with CODE Z07 (Top protection) 

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39. Rivet wheel well (1) with Ø with 6.5x12.5 blind rivet (area K).

    When working on wheel well (1) on driver side.

    Perform operation step analogously on driver side on right-hand drive vehicle.

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40. Rivet wheel well (1) with Ø with 6.5x14.5 blind rivet (area K₁ ).

    When working on wheel well (1) on passenger side.

    Perform operation step analogously on passenger side on right-hand drive vehicle.

41. Rivet wheel well (1) with Ø with 6.5x12.5 blind rivet (areas L₁ ).
42. Rivet wheel well (1) with Ø with 6.5x14.5 blind rivet (area L₂ ).
43. Rivet wheel well (1) with blind rivet with Ø 6.4x15.5 countersunk head (area L₄ ).
44. Adapter plate (5) (areas S).
45. Coat point not easily accessible later with zinc dust paint (area L₂ ).

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46. Rivet wheel well (1) with Ø with 6.5x12.5 blind rivet (areas M₁ ).
47. Rivet wheel well (1) with Ø 6.5x14.5 blind rivet (areas M₂ ).
48. Rivet wheel well (1) with blind rivet with Ø 6.4x15.5 counstersunk head (area M₃ ).
49. Adapter plate (4) (areas T).

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50. Apply 2-component adhesive to body in crosshatched areas.

    Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive.

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51. Install pedal floor panel (3) and fix in place.
52. Rivet pedal floor panel (3) with 6.5x12.5 blind rivet (areas N).
53. Pedal floor panel (3) (areas O₁ ).

    Inert gas weld in intervals and allow to cool down in between. Reduces heat distortion.

54. Pedal floor panel (3) (areas O₂ ).

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    Shown on MODEL 222 with CODE Z07 (Top protection) 

55. Drill Ø 6.7 mm rivet holes in connecting carrier (2) (areas P).
56. Mark cutouts on connecting carrier (2) (areas Q).

    Rivets for installation of the wheel well are present in the area of the cutouts.

57. Remove connecting carrier (2).
58. Deburr rivet holes on connecting carrier (2) and body on both sides.
59. Make cutouts on connecting carrier (2) (areas Q).
60. Remove grinding dust and drill chips.
61. Apply 2-component adhesive to body in crosshatched areas.

    Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive.

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

62. Install connecting carrier (2) and fix in place.
63. Rivet connecting carrier (2) with Ø 6.5x12.5 blind rivets (areas R₁ ).
64. Rivet connecting carrier (2) with Ø 6.5x14.5 blind rivets (area R₂ ).
65. Lay guard plate down on frame in pedal floor panel.
66. Grind down rivet heads until guard plate makes flush contact with frame (6) (areas L₃ ).
67. Remove grinding dust.

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68. Apply 2-component adhesive to guard plate (4) in crosshatched areas.

    Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive.

69. Install guard plate (4) and fix in place.

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