ar6350p140002lf

Cut off rear fender

Type ar · topic 63.50 · version 0104 · 2018-09-14

Applies to: Model 222

Where it sits

Function group 3 Body › 63 Side wall › 63.50 Rear fenders — Series 222

EinPAS 35 Body/frame/detachable parts › 35.34 Sidewall › 35.34.35 Fender/sidewall — Series 222

EinPAS 35 Body/frame/detachable parts › 35.37 Fender › 35.37.31 Rear fender — Series 222

AR63.50-P-1400-02LF

Cut off rear fender

Model

222

The following steps are shown on the left side of the vehicle and must be accomplished analogously on the right side in the event of damage.

Cut off rear fender

P63.50-3909-09

Shown on model 222.0

1

Model 222.0/1
Mark separating points on rear fender (1) and cut (areas A and B).

Do not make the cuts too deep.
Otherwise the components below can be damaged and weakened.

Separation point can be selected freely according to damage in consideration of foam parts and structural foam parts (area A).

If connections are to be offset in area B, observe overlapping of approx. 10 mm.

Dimensions:
a = approx. 120 mm
b1 = approx. 570 mm
b2 = approx. 60 mm (measured from Y-marking)

2

Model 222.0/1
Separate adhesive bead between outer rear wheel well and rear fender (1) (area C).

The rear fender (1) is bonded to the outer rear wheel well.

Cut off rear fender

P63.50-4004-09

Shown on model 222.9

3

Model 222.9
Mark separating points on rear fender (1) and cut (areas P, R1 and R2).

Do not make the cuts too deep.
Otherwise the components below can be damaged and weakened.

Separating points can be selected freely according to damage in consideration of foam parts and structural foam parts (area P).

If connection in area R2 is to be crimped, observe overlap of approx. 10 mm.

Dimensions:
p = approx. 485 mm
r1 = approx. 130 mm
r2 = approx. 40 mm (measured from Y-marking)

4

Model 222.9
Separate adhesive bead between outer rear wheel well and rear fender (1) (area S).

The rear fender (1) is bonded to the outer rear wheel well.

Cut off rear fender

P63.50-3910-09

Shown on model 222.0

5

Model 222.0/1
Drill through clinch connections on rear fender (1) with Ø 6 mm bit (area D).

The clinch connections can also be separated with a riveter for self-piercing and flow-form rivets.

6

Model 222.0/1
Expose spot welds on rear fender (1) and cut out (areas E and F).

Cut out spot welds through two panel thicknesses (area F).

Cut off rear fender

7

Model 222.9
Drill through clinch connections on rear fender (1) with Ø 6 mm bit (area V).


The clinch connections can also be separated with a riveter for self-piercing and flow-form rivets.



8

Model 222.9
Expose spot welds on rear fender (1) and cut out (areas R, T and U).


Cut out weld spots through two sheet metal thicknesses (area U).


Shown on model 222.9

P63.50-4005-06

Cut off rear fender

9

Drill out clinch connections on rear fender (1) (areas G1).


The clinch connections can also be separated with a riveter for self-piercing and flow-form rivets.



10

Drill through clinch connections on rear fender (1) with Ø 6 mm bit (area G2).


The clinch connections can also be separated with a riveter for self-piercing and flow-form rivets.



11

Expose self-piercing riveting on rear fender (1) and drill out with Ø 6 mm (areas H1 and H2).


The self-piercing rivets can also be separated with a riveter for self-piercing and flow-form rivets (areas H2).


P63.50-3911-06

Cut off rear fender

12

Drill through clinch connections on rear fender (1) with Ø 6 mm bit (areas J).


The clinch connections can also be separated with a riveter for self-piercing and flow-form rivets.



13

Expose self-piercing riveting on rear fender (1) and drill with Ø 6 mm bit (area I).


The self-piercing rivets can also be separated with a riveter for self-piercing and flow-form rivets.



14

Expose spot welds on rear fender (1) and cut out (areas K and L).


Cut out weld spots through two sheet metal thicknesses (area L).


Shown on model 222.0

P63.50-3912-06

Cut off rear fender

P63.50-3913-09

Shown on model 222.0

15

Heat rear fender (1) in crosshatched areas.

Cross-hatched areas are bonded.

16

Remove rear fender (1).

Cut off rear fender

P63.50-3914-09

Shown on model 222.0

17

Remove remaining adhesive material in area of outer rear wheel well (area N).

A maximum of 2 mm of adhesive residue may be left. Remove loose adhesive material.

18

Repair bare parts with primer stick (area N).

19

Sand bonding surfaces on structural foam part with fine-grit abrasive paper (area O).

Observe pretreatment of bonding surfaces.

20

Grind mating surfaces down to bare metal in the cross-hatched inner C-pillar sidewall .

Sand down spot weld flanges to bare metal on both sides.

21

Remove grinding dust and drill chips.

22

Coat insides of spot weld flanges with zinc dust paint.

Do not coat bonding surfaces with zinc dust paint (areas M).
Otherwise adhesion problems may occur.

Observe pretreatment of bonding surfaces.