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

WARNING: This page is about a different car, the 2011 Mercedes-Benz C300, 2010 Mercedes-Benz C300, 2009 Mercedes-Benz C300, and 2008 Mercedes-Benz C300. However, it is still accessible from the selected car via links, so may be relevant.

MODEL 204, 207

Shown on model 204.0

Fig 1: Locating Upper Front Longitudinal Member

Courtesy of MERCEDES-BENZ USA

Shown on model 207.4

Fig 2: Identifying Upper Front Longitudinal Member And A-Pillar Reinforcement

Courtesy of MERCEDES-BENZ USA

	Removing
	Risk of death caused by high voltage used for electric 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 fumes.	Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system.	AS00.00-Z-0007-01A
	Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes	Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only.	AS00.00-Z-0016-01A
	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 non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
	Measures for preventing damage to vehicles or components when performing electric welding work		AH00.00-N-0005-01A
	General information on repairs to body	Model 204.0/2/9, 207	AH60.00-N-0001-01A
	General information on repairs to body	Model 204.3	AH60.00-P-0001-01A
	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	General information on MB materials		AH98.00-P-9409-03A
1	Prepare required workshop equipment and commercially available tools for repair
2	Remove all detachable body components in area to be repaired.
3	Cover all detachable parts remaining in vehicle with welding protection blanket	Welding protective blanket gotis://K_60-65_23.0
4	Remove A-pillar reinforcement (2)	Type 207.4 If upper front longitudinal member (1) is damaged severely. Carbide cutter gotis://K_58.3_07.0
5.1	Separate upper front longitudinal member (1)	If upper front longitudinal member (1) is damaged severely.	AR62.20-P-1286-01CW
		Spot weld milling cutter Weld-spot milling machine gotis://K_58.1_02.0 Body jig saw gotis://K_58.1_01.0 Hot-air gun gotis://K_60-65_11.0 Round wire brush gotis://K_58.3_06.0 Wet and dry vacuum cleaner gotis://P_00.12_06.0	Figure
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
5.2	Partially separate upper front longitudinal member (1)	If upper front longitudinal member (1) is damaged slightly in front area.	AR62.20-P-1287-01EW
5.2	Partially separate upper front longitudinal member (1)	Spot weld milling cutter Weld-spot milling machine gotis://K_58.1_02.0 Body jig saw gotis://K_58.1_01.0 Hot-air gun gotis://K_60-65_11.0 Round wire brush gotis://K_58.3_06.0 Wet and dry vacuum cleaner gotis://P_00.12_06.0	Figure
6	Prepare A-pillar reinforcement (2) for installation	Model 207.4 If upper front longitudinal member (1) is damaged severely. Round wire brush gotis://K_58.3_06.0
7.1	Prepare upper front longitudinal member (1) for installation	If upper front longitudinal member (1) is damaged severely. Round wire brush gotis://K_58.3_06.0	AR62.20-P-1286-02CW
7.1		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
7.2	Partially prepare upper front longitudinal member (1) for installation	If upper front longitudinal member (1) is damaged slightly in front area. Body jig saw gotis://K_58.1_01.0 Round wire brush gotis://K_58.3_06.0	AR62.20-P-1287-02EW
	Install
8	Install welding device		AR62.20-P-1286-05CW
8	Install welding device	Welding device	Figure
9.1	Install upper front longitudinal member (1)	If upper front longitudinal member (1) is damaged severely.	AR62.20-P-1286-03CW
	General information on riveting		AH60.00-P-0003-01N
		Welding device Multifunction device (spot welding) gotis://K_60-65_15.0 Inert gas welder gotis://K_60-65_17.0 Hand riveting tool gotis://K_68-80_06.0 Vice grip pliers (standard) gotis://K_58.3_04.2 Manual temporary fastener gotis://K_58.3_10.0 Round wire brush gotis://K_58.3_06.0 Wet and dry vacuum cleaner gotis://P_00.12_06.0	Figure
		Adhesive	*BR00.45-Z-1092-02A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Rivet	*BR00.45-Z-1001-13A
		Polygrip countersunk head rivet, 6.4x14	*BR00.45-Z-1002-13A
9.2	Partially install upper front longitudinal member (1)	If upper front longitudinal member (1) is damaged slightly in front area.	AR62.20-P-1287-03EW
		Welding device Multifunction device (spot welding) gotis://K_60-65_15.0 Inert gas welder gotis://K_60-65_17.0 Vice grip pliers (standard) gotis://K_58.3_04.2 Round wire brush gotis://K_58.3_06.0 Wet and dry vacuum cleaner gotis://P_00.12_06.0	Figure
		Adhesive	*BR00.45-Z-1092-02A
10	Install A-pillar reinforcement (2)	Model 207.4 If upper front longitudinal member (1) is damaged severely. Inert gas welder gotis://K_60-65_17.0
11	Clean weld joints and sheet metal flanges with round wire brush	Round wire brush gotis://K_58.3_06.0
12	Clean area to be repaired	Wet and dry vacuum cleaner gotis://P_00.12_06.0
	Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.	No smoking! No open flames! Use respiratory protection, protective clothing, gloves, safety goggles and skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
13	Prime area to be repaired with primer filler	Use only primer filler approved by Daimler AG. See: ↓ http://portal.aftersales.i.daimler.com
	Notes on paintwork repairs		AH98.00-P-9408-02A
14	Carry out seam sealing after repairs	Model 204	AR97.10-P-4000CW
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
		Model 207	AR97.10-P-4000EC
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
	Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.	No smoking! No open flames! Use respiratory protection, protective clothing, gloves, safety goggles and skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
15	Paint area repaired and adjacent surfaces
	Notes on paintwork repairs		AH98.00-P-9408-02A
16	Apply additional cavity preservation	Model 204	AR97.20-P-1500CW
		Model 207	AR97.20-P-1500EC
	Notes on cavity preservation		AH97.20-P-0001-01B
		Cavity preservation gun gotis://K_91-97_01.0
		Preservation agent	*BR00.45-Z-1003-05A
17	Remove welding protection blanket	On all covered parts remaining in vehicle.
18	Install all detachable body components in area to be repaired.

Fig 3: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Welding Device (204 589 01 23 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	Sealant, white, 310 ml, DB supply specification 6069.20	A 001 989 63 20
BR00.45-Z-1041-01A	Seam sealant, sprayable 310 ml	A 002 989 84 20
BR00.45-Z-1092-02A	Adhesive kit, body, 2-component adhesive	A 009 989 36 71
BR00.45-Z-1003-05A	Cavity preservation, solvent-free (1 l container)	A 000 986 72 70 05
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42
BR00.45-Z-1001-13A	Blind rivet 6.4x14	A 003 990 35 97
BR00.45-Z-1002-13A	Polygrip countersunk head rivet, 6.4x14	A 003 990 86 97 05