Prepare inner section of rear wheel well for installation - AR63.10-P-0610-02CW

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MODEL 204, 212.0, 218.3 (except, 212.041)

The following steps are shown on components for model 204.0.

Fig 1: Complete Wheel Well Separation Points

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Scribe separation points on complete wheel well (2) (areas A, B and C).
Cut complete wheel well (2) at separation points (areas A, B and C).
Drill Ø 6.7 mm spot welds on complete wheel well (2) (area D).
Drill spot weld at bottom in area of front crossmember.
Grind mating surfaces on complete wheel well (2) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.
Coat insides of spot weld flanges with zinc dust paint.
Only perform on model 218.3. Observe pretreatment of bonding surfaces.

Do not coat bonding surfaces with zinc dust paint (areas XX₁ and XX₂ ). Adhesion problems can occur.

Fig 2: Complete Wheel Well Crosshatched Areas
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Drill Ø 7 mm hole in complete wheel well (2) (area D₁ ).
Grind mating surfaces on complete wheel well (2) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.
Coat insides of spot weld flanges with zinc dust paint.

Fig 3: Rear Axle Crossmember Rivet Hole Areas

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Perform operation steps 9, 10 and 11 only on model 204.

Scribe holes in rear axle crossmember (6) (areas F₁ and F₂ ).
Drill dia. 6.7 mm rivet holes in rear axle crossmember (6) (areas F₁ and F₂ ).
Debur holes on both sides.

Fig 4: Rear Axle Crossmember Crosshatched Areas

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Punch Ø 6 mm holes in rear axle crossmember (6) areas F and G).
Grind mating surfaces on rear axle crossmember (6) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces (area E).
Grind crosshatched areas on rear axle crossmember (6) down to bare metal around holes (areas F and G).
Coat insides of spot weld flange on rear axle crossmember (6) with zinc dust paint.
Do not apply zinc dust paint to bonding surfaces (area E). Adhesion problems can occur.

Fig 5: Spare Wheel Well Locking Lug And Upper Rear Axle Crossmember Crosshatched Areas

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Grind mating surfaces on spare wheel well locking lug (4) and upper rear axle crossmember (5) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.
Coat insides of spot weld flanges with zinc dust paint.
Do not coat bonding surfaces with zinc dust paint (area H). Adhesion problems can occur. Observe pretreatment of bonding surfaces (area H).

Fig 6: Loading Floor Crossmember Spot Weld Areas

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1. 18.1) Cut Ø 6.7 mm spot welds in loading floor crossmember (3) (areas I and J).
  On Model 204.
2. 18.2) Cut out spot welds on loading floor crossmember (3) (areas I and J).
  With model 212.0, 218.3. The loading floor crossmember (3) is located below the loading floor crossmember remaining section (3.1)
Remove loading floor crossmember remaining section (3.1).
Debur holes on both sides.
Grind loading floor crossmember (3) down to bare metal in crosshatched areas.
Loading floor crossmember (3) _{SG ««««} (area M).

Fig 7: Loading Floor Crossmember Crosshatched Areas (1 Of 2)

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Perform operation steps 23 only on model 218.3.

Grind mating surfaces on loading floor crossmember (3) down to bare metal in crosshatched areas.
Observe pretreatment of bonding surfaces (areas XY₁ , XY₂ , XY₃ and XY₄ .

Fig 8: Loading Floor Crossmember Crosshatched Areas (2 Of 2)

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Grind mating surfaces on loading floor crossmember (3) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.
Coat insides of spot weld flanges with zinc dust paint.

Perform operation steps 26, 27, 28, 29, 30 and 31 only on model 204.

Fig 9: Inner Longitudinal Member Separation Point

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Scribe separation points on inner longitudinal member (8) (area K).
Transfer separation point from vehicle.
Cut inner longitudinal member (8) at separation point (area K).
Drill Ø 7 mm holes in inner longitudinal member (8) (area L).
Grind mating surfaces on inner longitudinal member (8) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.
Grind crosshatched areas on inner longitudinal member (8) down to bare metal around holes (area L).
Coat insides of spot weld flanges with zinc dust paint.

Fig 10: Inner Longitudinal Member And Offset Reinforcement Separation Points

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Perform operation steps 32, 33, 34 and 35 only on model 212.0, 218.3.

Scribe separation points on inner longitudinal member (8) and offset reinforcement (9) (areas M and N).
Take separation points from vehicle
Cut inner longitudinal member (8) and offset reinforcement (9) at separation points (areas M and N).
Grind mating surfaces on inner longitudinal member (8) and offset reinforcement (9) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.
Coat insides of spot weld flanges with zinc dust paint.

Fig 11: Outer Longitudinal Member At Separation Point

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Scribe separation points on outer longitudinal member (1) (area O).
Transfer separation point from vehicle.
Cut outer longitudinal member (1) at separation point (area O).
Grind mating surfaces on outer longitudinal member (1) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.
Coat insides of spot weld flanges with zinc dust paint.