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Replace upper front longitudinal member - AR62.20-P-1286P

MODEL 203.0/ 2/ 7, 209 

Illustrated on Model 203.0 

Fig 1: Identifying Upper Front Longitudinal Member
G04735151
REMOVING Remove     
DANGER Risk of death  caused by high voltage used for arc welding. Risk of explosion  caused by welding in the area of highly inflammable materials. Injury hazard  from 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 danger zone. Use air extractor. AS00.00-Z-0007-01A
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between the columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
DANGER 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 non-deburred vehicle parts.
Deburr repair panels.		 AS00.00-Z-0017-01A
NOTES Measures for preventing damage to vehicles or components when performing arc welding work   AH00.00-N-0005-01A
NOTES General information on repairs to body   AH60.00-N-0001-01A
NOTES Notes on paintwork repairs   AH98.00-P-9408-02A
IMPORTANT General information on MB materials   AH98.00-P-9409-03A
1 Remove engine hood Model 203 AR88.40-P-3000P
    Model 209 AR88.40-P-3000Q
2 Remove left front fender Model 203 AR88.10-P-1000P
    Model 209 AR88.10-P-1000Q
3 Remove detachable parts in area to be repaired    
4 Cover all attached parts remaining in vehicle Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
5 Set up straightening bench with module or crossmembers and straightening bracket set IMPORTANT Observe setup plans enclosed!  
    Celette straightening bench M8S *WE58.40-Z-1001-01E 
    Celette straightening bench Sevenne *WE58.40-Z-1001-01E 
    Set of Celette module members 955.940 *WE58.40-Z-1007-01E 
    Celette additional member 955.908 *WE58.40-Z-1008-01E 
    Celette straightening bracket set 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 bracket set 7209.309 (for model A 209), as supplement to 7203.300 (model 203), as well as 7203.310 (model C 209) *WE58.40-Z-1042-01A 
    Celette straightening bracket set 7203.310 (for model 203), only for new orders, includes supplement 7203.309 *WE58.40-Z-1032-01A 
    Celette 7203.308 supplementary straightening bracket set for Celette straightening bracket set 7203.310 (for model 203 4MATIC) *WE58.40-Z-1047-01A 
    Car-Bench universal crossmember set A296 *WE58.40-Z-1010-01E 
    Car-bench straightening bracket 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 
6 Place vehicle on straightening bench using two-post lift Two-post lift *WE58.40-Z-1001-05A 
7 Attach vehicle to straightening bench    
8 Remove top front longitudinal member   AR62.20-P-1286-01P 
    SPECIAL TOOL Spot weld milling cutter Figure
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot weld removing tool *WH58.30-Z-1006-01A 
    COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm) *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 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
9 Prepare upper front longitudinal member   AR62.20-P-1286-02P 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install     
10 Installing inspection and welding device Model 203.0/2/7 except model 203.08/28, model 209.3/4 spring strut removed AR62.20-P-1286-04PA 
    Model 203.0/2/7 except model 203.08/28, model 209.3/4 spring strut installed AR62.20-P-1286-04PE 
    Model 203.08/28 spring strut removed AR62.20-P-1286-04PAA 
    Model 203.08/28 spring strut installed AR62.20-P-1286-04PEA 
    SPECIAL TOOL Inspection and welding gauge, model 209, model 203 except model 203.08/28 Figure
    SPECIAL TOOL Inspection and welding gauge, model 209, model 203 except model 203.08/28 Figure
    SPECIAL TOOL Inspection and welding gauge, model 203.08/28 Figure
    SPECIAL TOOL Inspection and welding gauge, model 203.08/28 Figure
    TORQUE SPECIFICATION Model 203 without 4MATIC
Nut, rebound stop to piston rod		 *BA32.25-P-1006-01B 
    TORQUE SPECIFICATION Model 203 with 4MATIC
Nut, rebound stop to piston rod		 *BA32.25-P-1006-01B 
11 Install upper front longitudinal member   AR62.20-P-1286-03P 
    COMMERCIALLY AVAILABLE TOOLS Electrode miller *WH58.30-Z-1003-01A 
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm) *WH58.30-Z-1024-04A 
    Inert gas welder *WE58.40-Z-1001-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Spot welder *WE58.40-Z-1002-02A 
    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 
    Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
    Cavity preservation gun Sata HRS no. 11072 *WE58.40-Z-1006-08A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
    Sealant *BR00.45-Z-1003-01A 
    Preservation agent *BR00.45-Z-1003-05A 
12 Unfasten vehicle from straightening bench    
13 Lift vehicle with two-post lift Two-post lift *WE58.40-Z-1001-05A 
14 Remove straightening bench.    
15 Clean repair areas    
16 Prime area to be repaired with priming filler    
17 Carry out seam sealing after repairs Model 203 AR97.10-P-4000P
    Model 209
IMPORTANT Supplement standard seals with MB body sealant.		 AR97.10-P-4000Q
    Sealant *BR00.45-Z-1003-01A 
18 Paint top front longitudinal member and adjacent surfaces    
19 Perform cavity preservation after repair work Model 203.0 AR97.20-P-1500P
    Model 203.2 AR97.20-P-1500PA
    Model 203.7 AR97.20-P-1500PB
    Model 209 AR97.20-P-1500Q
NOTES Notes on cavity preservation   AH97.20-P-0001-01B
20 Install engine hood Model 203 AR88.40-P-3000P
    Model 209 AR88.40-P-3000Q
21 Install left front fender Model 203 AR88.10-P-1000P
    Model 209 AR88.10-P-1000Q
22 Install all removed detachable body components    
TORQUE SPECIFICATION FRONT AXLE SHOCK ABSORBER

Number Designation Model 203 without 4MATIC Model 203 with 4MATIC
BA32.25-P-1006-01B Nut, rebound stop to piston rod Nm 60 -
Fig 2: Identifying Inspection And Welding Device (203 589 05 23 00)
G04735152
Fig 3: Identifying Inspection And Welding Device (203 589 04 23 00)
G04735153
Fig 4: Identifying Inspection And Welding Device (203 589 15 23 00)
G04735154
Fig 5: Identifying Inspection And Welding Device (203 589 14 23 00)
G04735155
Fig 6: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G04735156
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-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-1042-01A Celette straightening bracket set 7209.309 (model A 209), as supplement to 7203.300 (model 203), as well as 7203.310 (model C209)
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
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