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Set of cutting templates
Spot weld milling cutter
Spot weld milling cutter
201 589 00 51 00
221 589 03 23 00
Commercially available tools
Number | Designation | |
WH58.30-Z-1002-01A | Ball cutter, dia. 12 mm | |
WH58.30-Z-1006-01A | Vario Drill WS 91 spot weld removing tool | |
WH58.30-Z-1010-02A | Sheet metal crimping shears | |
WH58.30-Z-1001-03A | Round wire brush, braided, dia. 70 mm | |
WH58.30-Z-1024-04A | Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm) | |
WH58.30-Z-1004-20A | Hot-air gun | |
WH58.30-Z-1001-35A | Aluminum workshop vehicle |
Workshop equipment
WE58.40-Z-1001-03A | Drill (electric/pneumatic) |
WE58.40-Z-1003-03A | Angle grinder (electric/pneumatic) |
WE58.40-Z-1004-03A | Body saw (electric/pneumatic) |
WE58.40-Z-1005-03A | Wet/dry vacuum cleaner |
Repair materials
Number | Designation | Order number |
BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
P63.50-3408-09
1.1 Scribe separation line on rear fender (1) with cutting template (area A).
Position cutting template on Y-marking. Expose Y-marking if necessary (arrow).
1.2 If C-pillar is damaged, use separation line on rear fender (1) (area A1).
2 Scribe separation line on rear fender (1) with cutting template (area C).
Position cutting template on Y-marking. Expose Y-marking if necessary (arrow).
3.1 Cut rear fender (1) along separation line with body saw (area A).
Do not damage C-pillar below (area A).
3.2 If C-pillar is damaged, cut separation line on rear fender (1) with body saw (area A1).
4 Cut rear fender (1) along separation line with body saw (area C).
Do not damage outer side longitudinal member below (area C).
P63.50-3263-09
5 Expose spot welds on rear fender (1) (areas L, L1, L3 and M).
6 Cut out spot welds on rear fender (1) using spot weld milling cutter or Vario Drill spot weld removing tool (areas L, L1, L3 and M).
7 Expose stamping rivet on rear fender (1) (area L2).
8 Drill stamping rivet on rear fender (1) with dia. 6.5 mm drill bit (area L2).
Use rivet remover if available, to eliminate having to drill new rivet holes.
P63.50-3266-06
9 Expose spot welds on rear fender (1) (areas B and D).
10 Cut out spot welds on rear fender (1) using spot weld milling cutter or Vario Drill spot weld removing tool (areas B and D).
Cut out spot welds on rear fender (1) through two sheet metal layers (arrows).
P63.50-3421-09
11 Expose spot welds on rear fender (1) (areas G1 and N).
12 Cut out spot welds on rear fender (1) using spot weld milling cutter or Vario Drill spot weld removing tool (areas G1 and N).
13 Expose stamping rivets and clinch connections on rear fender (1) (areas G, H and I).
14 Cut out stamping rivet on rear fender (1) with spot weld milling cutter or Vario Drill spot weld removing tool (areas G and H).
Use rivet remover if available, to eliminate having to drill new rivet holes.
15 Drill dia. 6.5 mm clinch connections in rear fender (1) (area I).
P63.50-3418-09
16 Expose stamping rivet and clinch connections on rear fender (1) (area U).
17 Cut out stamping rivet on rear fender (1) with spot weld milling cutter or Vario Drill spot weld removing tool (area U).
Use rivet remover if available, to eliminate having to drill new rivet holes.
18 Drill dia. 6.5 mm clinch connections in rear fender (1) (areas T and V).
P63.50-3287-09
19 Heat rear fender (1) in cross-hatched areas using hot air gun.
Cross-hatched areas are foamed and bonded.
Damaged foam parts must be removed and replaced.
20 Remove damaged rear fender (1)
P63.50-3275-09
21 Remove adhesive residues in shaded areas using stainless steel round brush (areas P and P1).
22 Grind adhesive residues down to bare metal in cross-hatched areas using round wire brush (areas B1, D1, K and K1).
23 Grind mating surfaces down to bare metal in cross-hatched areas using round wire brush (areas B, C, D, O and Q).
Grind spot weld flanges down to bare metal on both sides.
Observe pretreatment of bonding surfaces.
P63.50-3416-09
24 Coat insides of spot weld flange and riveted joints with zinc dust paint (areas B and D).
To prevent adhesion problems, do not coat bonding surfaces with zinc dust paint. (area K).
P63.50-3280-09
25 Cut rear fender (1) to size in area of upper C-pillar (arrows) with body saw
26 Crimp rear fender (1) in area of C-pillar (arrows) with sheet metal crimping pliers to inside.
27 Grind mating surfaces down to bare metal in cross-hatched areas using round wire brush (areas A, W, X, Z, Z1, Z2 and AA).
28 Grind mating surfaces down to bare metal in shaded areas with stainless steel round brush (areas AB, AC, AD, AE, AF, AG, AH and AI).
29 Remove grinding and drill shavings using wet/dry vacuum cleaner.