Replace front section of longitudinal member - AR62.20-P-1260P
MODEL 203.0 /2 /7, 209.3 /4
Shown on model 203.0
| Remove | |||
| Risk of death caused by high voltage used for arc welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding spatter and UV-light while welding. Risk of poisoning caused by inhaling welding vapors. | Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor. | AS00.00-Z-0007-01A | |
| Risk of death cased by vehicle slipping or toppling off of the lifting platform. | Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and undeburred vehicle parts. Deburr replacement panels. |
AS00.00-Z-0017-01A | |
| Measures for preventing damage to vehicles or components during electro-welding | AH00.00-N-0005-01A | ||
| General information on body repair | AH60.00-N-0001-01A | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1 | Remove complete front end assembly with front reinforcement | AR62.30-P-1570P | |
| 2 | Remove detachable parts in area to be repaired | ||
| 3 | Cover all detachable body components that remain in the area to be repaired | Tarpaulin (fireproof) | *WH58.30-Z-1001-40A |
| 4 | Equip Celette or Car-Bench straightening bench with modular members or cross members and straightening set | ||
| Celette straightening bench M8S | *WE58.40-Z-1001-01E | ||
| Celette straightening bench Sevenne | *WE58.40-Z-1001-01E | ||
| Set of Celette modular members 955.940 | *WE58.40-Z-1007-01E | ||
| Celette additional member 955.908 | *WE58.40-Z-1008-01E | ||
| Celette straightening bench 7203.300 (for model 203) | *WE58.40-Z-1029-01A | ||
| Car-Bench straightening bench BT 17 | *WE58.40-Z-1003-01E | ||
| Car-Bench straightening bench BT 43/1 | *WE58.40-Z-1003-01E | ||
| Celette straightening bracket set 7203.309 (for model 203), as supplement to 7203.300 | *WE58.40-Z-1031-01A | ||
| Celette straightening set 7203.310 (for model 203), only for new orders, includes supplement 7203.309 | *WE58.40-Z-1032-01A | ||
| Celette 7203.308 supplementary straightening set for Celette straightening bracket set 7203.310 (for model 203 4MATIC) | *WE58.40-Z-1047-01A | ||
| Car-Bench universal cross member set A 296 | *WE58.40-Z-1010-01E | ||
| Car-bench straightening set 82434 (for model 203) | *WE58.40-Z-1030-01A | ||
| Car-Bench 82445 supplementary straightening set for Car-Bench straightening bracket set 82434 (for model 203 4MATIC) | *WE58.40-Z-1048-01A | ||
| Multi-Z straightening set system MZ 450.000 | *WE58.40-Z-1006-01E | ||
| 5 | Place vehicle on straightening bench using two-column lift | Two-column lift | *WE58.40-Z-1001-05A |
| 6 | Attach vehicle to straightening bench | ||
| 7 | Separate longitudinal member front section (1) | AR62.20-P-1260-01P | |
| Figure | |||
| *WH58.30-Z-1006-01A | |||
| *WH58.30-Z-1001-03A | |||
| *WH58.30-Z-1024-04A | |||
| Drill (electric/pneumatic) | *WE58.40-Z-1001-03A | ||
| Angular grinder (electric/pneumatic) | *WE58.40-Z-1003-03A | ||
| Body saw (electric/pneumatic) | *WE58.40-Z-1004-03A | ||
| Wet/dry vacuum cleaner | *WE58.40-Z-1005-03A | ||
| Zinc dust paint which can be spot welded | *BR00.45-Z-1001-07A | ||
| 8 | Prepare longitudinal member front section (1) | AR62.20-P-1260-05P | |
| *WH58.30-Z-1001-03A | |||
| *WH58.30-Z-1002-02A | |||
| Drill (electric/pneumatic) | *WE58.40-Z-1001-03A | ||
| Zinc dust paint which can be spot welded | *BR00.45-Z-1001-07A | ||
| Install | |||
| 9 | Install and weld in longitudinal member front section (1) | AR62.20-P-1260-07P | |
| *WH58.30-Z-1001-03A | |||
| *WH58.30-Z-1024-04A | |||
| *WH58.30-Z-1003-02A | |||
| Two-column lift | *WE58.40-Z-1001-05A | ||
| Inert gas welder | *WE58.40-Z-1001-02A | ||
| Drill (electric/pneumatic) | *WE58.40-Z-1001-03A | ||
| Body saw (electric/pneumatic) | *WE58.40-Z-1004-03A | ||
| Angular grinder (electric/pneumatic) | *WE58.40-Z-1003-03A | ||
| Wet/dry vacuum cleaner | *WE58.40-Z-1005-03A | ||
| Cavity preservation gun Sata HRS no. 11072 | *WE58.40-Z-1006-08A | ||
| Zinc dust paint which can be spot welded | *BR00.45-Z-1001-07A | ||
| Sealant | *BR00.45-Z-1003-01A | ||
| Preservation agent | *BR00.45-Z-1003-05A | ||
| 10 | Weld in longitudinal member cover (2) | AR62.20-P-1260-04P | |
| *WH58.30-Z-1001-03A | |||
| *WH58.30-Z-1003-02A | |||
| *WH58.30-Z-1003-01A | |||
| Inert gas welder | *WE58.40-Z-1001-02A | ||
| Spot welder | *WE58.40-Z-1002-02A | ||
| Drill (electric/pneumatic) | *WE58.40-Z-1001-03A | ||
| Two-column lift | *WE58.40-Z-1001-05A | ||
| Wet/dry vacuum cleaner | *WE58.40-Z-1005-03A | ||
| Cavity preservation gun Sata HRS no. 11072 | *WE58.40-Z-1006-08A | ||
| Zinc dust paint which can be spot welded | *BR00.45-Z-1001-07A | ||
| Sealant | *BR00.45-Z-1003-01A | ||
| Preservation agent | *BR00.45-Z-1003-05A | ||
| 11 | Unfasten vehicle from straightening bench | ||
| 12 | Lift vehicle with two-column lift | Two-column lift | *WE58.40-Z-1001-05A |
| 13 | Remove straightening bench. | ||
| 14 | Clean repair areas | ||
| 15 | Prime area to be repaired with priming filler | ||
| 16 | Carry out seam sealing after repairs | Model 203 | AR97.10-P-4000P |
| Model 209 |
AR97.10-P-4000Q | ||
| Sealant | *BR00.45-Z-1003-01A | ||
| 17 | Paint repair areas and adjacent surfaces | ||
| 18 | Install front end with front stiffeners complete | AR62.30-P-1570P | |
| 19 | Apply additional cavity preservation | ||
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| 20 | Install all removed detachable body components |
COMMERCIALLY AVAILABLE TOOLS
| Number | Designation |
|---|---|
| WH58.30-Z-1003-01A | Electrode miller |
| WH58.30-Z-1006-01A | Vario Drill WS 91 spot weld removing tool |
| WH58.30-Z-1002-02A | Hole punching pliers, dia. 7 mm |
| WH58.30-Z-1003-02A | Clamping pliers |
| 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-1001-40A | Tarp (fire-resistant) |
WORKSHOP EQUIPMENT
| WE58.40-Z-1029-01A | Celette straightening bracket set 7203.300 (model 203) |
| WE58.40-Z-1030-01A | Car bench straightening bracket set 82434, (model 203) |
| WE58.40-Z-1031-01A | Celette straightening bracket set 7203.309 (model 203), as supplement to 7203.300 |
| WE58.40-Z-1032-01A | Celette straightening bracket set 7203.310 (model 203), only with new ordering contains addition 7203.309 |
| WE58.40-Z-1047-01A | Celette 7203.308 supplementary straightening set for Celette straightening bracket set 7203.310 (model 203 4MATIC) |
| WE58.40-Z-1048-01A | Car-Bench 82445 supplementary straightening set for Car Bench straightening bracket set 82434 (model 203 4MATIC) |
| WE58.40-Z-1001-01E | Celette straightening bench |
| WE58.40-Z-1003-01E | Car-Bench straightening bench |
| WE58.40-Z-1006-01E | Celette Multi-Z straightening set system |
| WE58.40-Z-1007-01E | Celette module crossmember set 955.940 |
| WE58.40-Z-1008-01E | Celette additional member 955.908 |
| WE58.40-Z-1010-01E | Car-Bench universal cross member set A 296 |
| WE58.40-Z-1001-02A | Inert gas welder |
| WE58.40-Z-1002-02A | Spot welder |
| 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 |
| WE58.40-Z-1001-05A | Two-post lifting platform |
| WE58.40-Z-1006-08A | Cavity preservation gun |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | Sealant | A 001 989 63 20 |
| BR00.45-Z-1003-05A | Preservation agent | A 000 986 72 70 05 |
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |