Remove rear wheel well inner section - AR63.10-P-0610-01CW

WARNING: This page does not describe the selected car, but rather 33 other vehicles, including the 2016 Mercedes-Benz E63 S AMG, 2016 Mercedes-Benz E400, 2016 Mercedes-Benz E350, 2016 Mercedes-Benz E300, and 2016 Mercedes-Benz E250. However, it is still accessible from the selected car via links, so may be relevant.

MODEL 204, 212.0, 218.3 (except, 212.041)

The following steps are shown on model 204.0.

Fig 1: Longitudinal Member Separation Point

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Scribe separation point on side longitudinal member (1) at Y-marking (arrow) (area A).
Cut side longitudinal member (1) at separation point (area A).
Expose spot welds on side longitudinal member (1) (areas B, C and D).
Cut out spot welds on side longitudinal member (1) (areas B, C und D).

Fig 2: Wheel Well Inner Section Separation Point

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Coarsely scribe separation points on wheel well inner section (2) (areas E and F).
Coarsely cut wheel well inner section (2) at separation point (areas E and F).
Expose spot welds on wheel well inner section (2) (area G).
Cut out spot welds on wheel well inner section (2) (area G).

Fig 3: Loading Floor Crossmember Spot Weld Areas (1 Of 2)

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Expose spot welds on loading floor crossmember (3) (areas H, I and J).
Cut out spot welds on loading floor crossmember (3) (areas H, I and J).
Remove section from loading floor crossmember (3).

Fig 4: Loading Floor Crossmember Spot Weld Areas (2 Of 2)

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Expose spot welds and brazed MIG seams on load compartment crossmember (3) (areas K, K₁ , L, M, M₁ , N and O).
Cut out spot welds on loading floor crossmember (3) (areas K, M, N and O).
1. 14.1) Cut out spot welds on loading floor crossmember (3) (areas K₁ and M₁ ).
  On model 204.
2. 14.2) Drill Ø 6.7 mm spot welds in loading floor crossmember (3) (areas K₁ and M₁ ).
  On model 212.0, model 218.3. The loading floor crossmember (3) is located below the connecting flange (arrows).
Cut brazed MIG seams on loading floor crossmember (3) (area L).
Spot welds may be present in area L depending on the vehicle variant. Cut out.
Remove loading floor crossmember (3)

Fig 5: Front Rear Axle Crossmember Spot Weld Areas

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Expose spot welds on front rear axle crossmember (7) and vehicle floor (7.1) (areas R, S, S₁ , S₂ , S₃ and S₄ ).
Cut out spot welds on front rear axle crossmember (7) (areas R, S and S₂ ).
Mill off spot weld through two sheet metal thicknesses (arrow).
Drill Ø 6.7 mm spot welds on front rear axle crossmember (7) and vehicle floor (7.1) (areas S₁ and S₃ ).
Remove front rear axle crossmember (7).
Drill Ø 8 mm holes in vehicle floor (7.1) (area S₄ ).

Fig 6: Upper Rear Axle Crossmember Spot Weld Areas

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Expose spot welds and brazed MIG seams on upper rear axle crossmember (5) (areas P, Q, T, U and arrows).
Cut brazed MIG seams on upper rear axle crossmember (5) (area Q and arrows).
Cut out spot welds on upper rear axle crossmember (5) (areas P, T and U).
Remove upper rear axle crossmember (5).

Fig 7: Rear Axle Crossmember And Spare Wheel Well Locking Lug Spot Weld Areas

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Expose spot welds on brazed MIG seams on rear axle crossmember (6) and spare wheel well locking lug (4) (areas V, W, X, Y, Z, AA, AB, AC, AD and arrow).
On model 212.0, 218.3 spot welds are not present in area W on the spare wheel well locking lug (4) due to the structural shape.
Cut brazed MIG seams on rear axle crossmember (6) (areas Y, Z and AA).
Cut out spot welds on rear axle crossmember (6) and spare wheel well locking lug (4) (areas V, W, X, AB, AC, AD and arrow).
Cut out spot welds from bottom (arrow).

On model 212.0, 218.3 spot welds are not present in area W on the spare wheel well locking lug (4) due to the structural shape.
Remove rear axle crossmember (6).

Fig 8: Wheel Well Inner Section Spot Weld Areas

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Expose spot welds on wheel well inner section remaining sections (9 and 10) and vehicle floor (11) (areas AH, AI, AJ, AK and AL).
Cut out spot welds on wheel well inner section remaining sections (9 and 10) and vehicle floor (11) (areas AH, AI, AJ, AK and AL).

Fig 9: Inner Side Longitudinal Member Separation Points

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Scribe separation point on inner side longitudinal member (8) (area AE).
On model 212.0, 218.3 scribe offset reinforcement (12) in area AE.
Cut inner side longitudinal member (8) at separation point (area AE).
On model 212.0, 218.3 cut offset reinforcement (12) in area AE in addition.

Perform operation steps 34 and 35 only on model 204.

Expose spot welds on inner side longitudinal member (8) (areas AF and AG).
Cut out spot welds on inner side longitudinal member (8) (areas AF and AG).
Remove inner side longitudinal member remaining section (8.1) and wheel well inner section remaining section.

Perform operation steps 37, 38 and 39 only on model 212.0, 218.3.

Scribe separation point on offset reinforcement (12) (area AM).
Scribe separation point on offset reinforcement (12) according to Y-markings (arrows).
Cut offset reinforcement (12) at separation point (area AM).
Remove offset reinforcement section (12.1).

Fig 10: Grinding Mating Surfaces In Cross-Hatched Areas (1 Of 2)

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Grind mating surfaces on body down to bare metal in cross-hatched areas.
On model 212.0, 218.3 additionally grind offset reinforcement down to bare metal in crosshatched areas.

Fig 11: Grinding Mating Surfaces In Cross-Hatched Areas (2 Of 2)

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Grind mating surfaces on body down to bare metal in cross-hatched areas.
Grind spot weld flanges down to bare metal on both sides.
Remove shavings and drill chips.
Coat insides of spot weld flanges with zinc dust paint.