215 589 00 51 00
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-1021-04A | Cutting disk, dia. 65 mm, 80 m/s (max. 23,500 rpm) | |
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-1002-03A | Straight grinder (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
Shown on model 221 without code Z07 Top protection
1.1 Scribe separation line on rear fender (1) with cutting template (area A).
1.2 If C-pillar is damaged, scribe separation line on rear fender (1) with cutting template (area A1).
Position cutting template on Y-marking. Expose Y-marking if necessary (arrow).
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) on separation point using body saw
(area A).
Do not damage C-pillar below (area A).
3.2 If C-pillar is damaged, cut rear fender (1) on separation point in area (A1) using body saw.
4 Cut rear fender (1) on separation point using body saw
(area C).
Do not damage outer side longitudinal member below
(area C).
P63.50-3446-09
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 weld seams between rear fender (1) and guard plate (2) (area M1).
8 Separate weld seams between rear fender (1) and guard plate (2) (area M1).
9 Expose stamping rivet on rear fender (1) (area L2).
10 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.
P63.50-3442-09
11 Expose spot welds on rear fender (1) (areas B and D).
12 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).
13 Expose weld seams between rear fender (1) and guard plate (2) (area B2).
14 Separate weld seams between rear fender (1) and guard plate (2) (area B2).
P63.50-3421-09
Shown on model 221 without code Z07 Top protection
15 Expose spot welds on rear fender (1) (areas G1 and N).
16 Cut out spot welds on rear fender (1) using spot weld milling cutter or Vario Drill spot weld removing tool (areas G1 and N).
17 Expose stamping rivets and clinch connections on rear fender (1) (areas G, H and I).
18 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.
19 Drill dia. 6.5 mm clinch connections in rear fender (1) (area I).
P63.50-3418-09
Shown on model 221 without code Z07 Top protection
20 Expose stamping rivet and clinch connections on rear fender (1) (areas T, U and V).
21 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.
22 Drill dia. 6.5 mm clinch connections in rear fender (1)
(areas T and V).
P63.50-3287-09
Shown on model 221 without code Z07 Top protection
23 Heat rear fender (1) in cross-hatched areas using heat gun.
Cross-hatched areas are foamed and bonded.
Damaged foam parts must be removed and replaced.
24 Remove damaged rear fender (1)
P63.50-3275-09
Shown on model 221 without code Z07 Top protection
25 Remove adhesive residues in cross-hatched areas using stainless steel round wire brush (areas P and P1).
26 Grind adhesive residues down to bare metal in cross-hatched areas using round wire brush (areas B1, D1, K and K1).
27 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
Shown on model 221 without code Z07 Top protection
28 Coat insides of riveted joints with zinc dust paint (area D).
To prevent adhesion problems, do not coat bonding surfaces with zinc dust paint. (area K).
P63.50-3280-09
Shown on model 221 without code Z07 Top protection
29 Cut rear fender (1) to size in area of upper C-pillar (arrows) using body saw
30 Crimp rear fender (1) in area of C-pillar (arrows) with sheet metal crimping pliers to inside.
31 Grind mating surfaces down to bare metal in cross-hatched areas using stainless steel round wire brush (areas AB, AC, AD, AE, AF, AG, AH and AI).
32 Grind mating surfaces down to bare metal in cross-hatched areas using round wire brush (areas A, W, X, Z, Z1, Z2
and AA).
Grind spot weld flanges down to bare metal on both sides.
33 Remove grinding and drill shavings using wet/dry vacuum cleaner.