Install rear wheel well inner section and weld in - AR63.10-P-0610-03CW

MODEL 204, 212.0, 218.3 (except, 212.041) 

The following steps are shown on model 204.0.

Fig 1: Fitting Wheel Well Inner Section Into Place With Straightening Tool

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1. Install wheel well inner section (2), loading floor crossmember (3), front spare wheel well locking lug (4), upper rear axle crossmember (5), rear axle crossmember (6), front rear axle crossmember (7), partial rear longitudinal member (10), fit with straightening tool and fix in place.

   On model 204.9 front rear axle spacers and rear axle spacers are required additionally for fitting and installing

Fig 2: Front Spare Wheel Well Locking Lug Rivet Holes Area
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2. Drill Ø 6.7 mm rivet holes in front spare wheel well locking lug (4) (areas A, B and C).

   On model 212.0, 218.3 do not drill rivet holes in front spare wheel well locking lug (4) in areas A, B and C due to construction design.

Fig 3: Loading Floor Crossmember Rivet Hole Areas
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3. Drill Ø 6.7 mm rivet holes in loading floor crossmember (3) (areas D, E and F).
Fig 4: Wheel Well Inner Section Rivet Hole Areas
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4. Drill Ø 6.7 mm rivet holes in wheel well inner section (2) (area G).
5. Scribe connecting flange for wheel well inner section (2) on rear-end floor (arrows).
Fig 5: Front Rear Axle Crossmember Rivet Hole Areas
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6. Drill Ø 6.7 mm rivet holes in front rear axle crossmember (7) (areas H and I).
Fig 6: Front Spare Wheel Well Locking Lug And Rear Axle Crossmember Rivet Hole Areas
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7. Drill Ø 6.7 mm rivet holes in front spare wheel well locking lug (4) and rear axle crossmember (6) (areas J, K and L).

   Due to construction design on model 212 rivet holes are not drilled on spare wheel well locking lug (4) in area K.

   Fig 7: Loading Floor Crossmember Rivet Holes (Areas M, M1, N, O₁ And O₂ )

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8. Drill Ø 6.7 mm rivet holes in loading floor crossmember (3) (areas M, M₁ , N, O₁ and O₂ ).

   On model 212.0, 218.3 the loading floor crossmember (3) is located below the connecting flange (area M₁ ).

9. Remove inner wheel well, loading floor crossmember (3), front spare wheel well locking lug, upper rear axle crossmember, rear axle crossmember, front rear axle crossmember and partial rear longitudinal member.
10. Deburr rivet holes on both sides
Fig 8: Rear-End Floor Separation Points
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11. Scribe separation points on rear-end floor (area AM).

    Measure connecting flange scribed previously on rear floor.

12. Cut rear-end floor at separation point (area AM).
Fig 9: Rear Axle Crossmember Crosshatched Areas
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13. Apply 2-component adhesive to rear axle crossmember (6) in crosshatched areas.

    Observe pretreatment of bonding surfaces. Refer to the manufacturer's information for the curing and working times of 2-component adhesive.

14. Install inner wheel well, loading floor crossmember, front spare wheel well locking lug, rear axle crossmember (6), front axle crossmember and partial rear longitudinal member and fix in place.
Fig 10: Rear Axle Crossmember Steel Blind Rivet Areas
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15. Rivet rear axle crossmember (6) with 6.5 X 12.5 steel blind rivet (area X).
Fig 11: Rear Axle Crossmember Weld Areas
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16. Rear axle crossmember (6)_{SG ««««} (areas AE and AF).
17. Rear axle crossmember (6) _{SG ⓧ} (area AG).
18. Grind MIG plug welds down flat (area AG).
Fig 12: Upper Rear Axle Crossmember Steel Blind Rivet Areas
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19. Rivet upper rear axle crossmember (5) with 6.5 X 12.5 steel blind rivet (area AT).
20. Upper rear axle crossmember (5) (area AS).
21. Upper rear axle crossmember (5) _{SG ««««} (areas AV and VA).
22. Rear axle crossmember (6) _{SG ⓧ} (areas AW and AX).
Fig 13: Front Rear Axle Crossmember Steel Blind Rivet Areas
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23. Rivet front rear axle crossmember (7) with 6.5 X 12.5 steel blind rivet (areas U and V).
Fig 14: Wheel Well Inner Section Steel Blind Rivet Areas
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24. Rivet wheel well inner section (2) with 6.5 X 12.5 steel blind rivet (area T).
Fig 15: Wheel Well Inner Section Adhesive Application Areas
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25. Apply 2-component adhesive to wheel well inner section (2) in crosshatched areas.

    On model 218.3.

    Observe pretreatment of bonding surfaces. Refer to the manufacturer's information for the curing and working times of 2-component adhesive.

Fig 16: Loading Floor Crossmember Steel Blind Rivets (Areas Y, Y1, Z, Z₁ and Z₂ )
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26. Rivet loading floor crossmember (3) with 6.5 X 12.5 steel blind rivet (areas Y, Y₁ , Z, Z₁ and Z₂ ).

    On model 212.0 the loading floor crossmember (3) is located below the connecting flange (area Y₁ ).

Fig 17: Locating MIG Plug Welds On Loading Floor Crossmember And Vehicle Floor
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27. Drill MIG plug welds on loading floor crossmember (3) and vehicle floor (areas AA, AB, AC and AD).
28. Loading floor crossmember (3) _{SG ⓧ} (areas AA, AB, AC and AD).
29. Grind MIG plug welds down flat (areas AB and AD).
Fig 18: Loading Floor Crossmember Steel Blind Rivets (Areas R, R1 and S)
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30. Rivet loading floor crossmember (3) with 6.5 X 12.5 steel blind rivet (areas R, R₁ and S).
Fig 19: Loading Floor Crossmember And Front Spare Wheel Well Locking Lug
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31. Loading floor crossmember (3) and front spare wheel well locking lug (4) (areas AH and AI).
Fig 20: Loading Floor Crossmember And Wheel Well Inner Section
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32. Loading floor crossmember (3) (area AJ).
33. Wheel well inner section (2) _{SG ⓧ} (area AK).
Fig 21: Front Spare Wheel Well Locking Lug Steel Blind Rivets (Areas W and X1)
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34. Rivet front spare wheel well locking lug (4) with 6.5 X 12.5 steel blind rivet (areas W and X₁ ).

    On model 212.0, 218.3 rivets are not required on front spare wheel well locking lug (4) in area X1 due to construction design.

Fig 22: Front Spare Wheel Well Locking Lug Steel Blind Rivets (Areas P and Q)
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35. Rivet front spare wheel well locking lug (4) with 6.5 X 12.5 steel blind rivet (areas P and Q).

    On model 212.0, 218.3 rivets are not required on front spare wheel well locking lug (4) in areas P and Q due to construction design.

Fig 23: Brake Line Brackets On Rear Axle Crossmember
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36. Brake line brackets (9) on rear axle crossmember (6) _{SG ««««} (areas AL and AM).

    Only on model 204.0/2.

    It is only necessary to install the rear axle mount reinforcement first on model 204.9. On model 212, 218.3 the brake line brackets (9) are already present on the new part. Position new brake line bracket (9) in same position as old brake line bracket.

Fig 24: Inner Longitudinal Member, Longitudinal Member Section And Offset Reinforcement
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Perform operation steps 37 and 38 only on model 204.

37. Inner longitudinal member (8) and longitudinal member section (8.1) _{SG ««««} (area AY).

    Inert gas weld in intervals, allow to cool down in between to minimize heat distortion (area AY).

38. Inner longitudinal member (8) and longitudinal member section (8.1) _{SG ⓧ} (areas AZ, BA and BB).

Perform operation step 39 only on model 212.0, 218.3.

39. Inner longitudinal member (8), longitudinal member section (8.1) and offset reinforcement (9) _{SG ««««} (areas AT, AU and AV).

    Inert gas weld inner longitudinal member (8) and longitudinal member section (8.1) in area AU at inside.

40. Wheel well inner section (2) _{SG ⓧ} (area BC).
41. Grind inert gas weld on mating surfaces down flat (arrow).
Fig 25: Outer Longitudinal Member Install, Fit And Fix
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42. Install, fit and fix in place outer longitudinal member (1).
43. Outer longitudinal member (1)_{SG ««««} (area AO).

    Inert gas weld in intervals, allow to cool down in between to minimize heat distortion (area AO).

44. Outer longitudinal member (1) (areas AN, AP and AS).
45. Grind inert gas weld on mating surfaces down flat (arrows).
Fig 26: Loading Floor Crossmember Crosshatched Areas
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46. Grind loading floor crossmember (3) down to bare metal in crosshatched areas (areas AQ and AR).
47. Loading floor crossmember (3) _{SG ««««} (areas AQ₁ and AR₁ ).
48. Clean all weld joints.
49. Remove shavings and drill chips.