P63.50-3536-09
In principle replacement parts required for this repair can be replaced completely. Ensure that the standard joining and bonding connections are observed or are coordinated with the responsible Daimler departments in individual cases. On cut panels also ensure that the joints to the present paneling are accessible for later cavity preservation and that the minimum distance between foam-protected areas and connection points is approx. 100 mm.
1 Position metal needle template at Y-markings and scribe orientation line on rear fender (1) (area C).
Transfer separation line from new part (area C).
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2 Position metal needle template at Y-markings and scribe orientation line on rear fender (1) (areas A and B).
Metal needle template.
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Scribe separation line for crimping flange approx. 10 mm offset from Y-markings (arrows). If necessary, expose Y-markings.
3 Cut rear fender (1) at separation line with jig saw (area C).
Keyhole saw
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Do not damage components below (area C).
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4 Cut rear fender (1) at separation point with jig saw (areas A and B).
Keyhole saw
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Do not damage C-pillar below (areas A and B).
5 Expose spot welds on rear fender (1) (areas D, D1, D2, E, F and G).
6 Cut out spot welds on rear fender (1) with spot weld milling cutter or Vario Drill spot welding removing tool (areas D, D1, D2, E, F and G).
Weld-spot milling machine
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Cut out spot weld on rear fender (1) through two panel thicknesses (arrow).
P63.50-3537-06
7 Expose spot welds on rear fender (1) (areas I and J).
8 Cut out spot welds on rear fender (1) with spot weld milling cutter or Vario Drill spot welding removing tool (areas I and J).
Weld-spot milling machine
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9 Cut adhesive bead between wheelhouse and rear fender (1) with window removal tool.
Window removal tool (FSC 1.6)
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Glue rear fender (1) to rear wheelhouse from outside.
10 Remove damaged rear fender (1)
11 Remove remaining adhesive material in area of rear wheelhouse with flat scraper.
Do not leave more than 2 mm of remaining adhesive material. Pull off loose adhesive material (remaining pieces which are not completely cut off).
12 Repair bare parts with touchup applicator.
P63.50-3540-08
13 Grind mating surfaces down to bare metal in crosshatched areas with round wire brush.
Round wire brush
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Grind spot weld flanges down to bare metal on both sides.
Damaged foam rubber parts must be removed and replaced (arrows).
14 Remove grinding and drill shavings using wet/dry vacuum cleaner.
Wet and dry vacuum cleaner
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15 Coat insides of spot weld flanges with zinc dust paint.
Do not coat bonding surfaces with zinc dust paint to prevent adhesion problems (area K and K1).
Observe pretreatment of bonding surfaces.
16 Crimp connecting flange toward inside using sheet metal crimping pliers (area L).
Beading pliers
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Use sheet metal crimping pliers for heavily accessible areas.