Separate longitudinal member front section - AR62.20-P-1260-01CW

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.

Fig 1: Identifying Front End Assembly Spot Welds & Separation Points

Courtesy of MERCEDES-BENZ USA

Illustrated on model 204.0

Expose spot welds on front end assembly bracket (2) (areas D and E).
Cut spot welds on front end bracket (2) (areas D and E)
Remove damaged front end assembly bracket (2).
Expose spot welds on front cover (3) (areas F and G).
Cut out spot welds on front cover (3) (areas F and G).
Scribe separation line on front cover (3) (area C).
Transfer separation line from new part (area C).
Separate front cover (3) from separation point (area C).
Do not damage reinforcing bracket (4) below (area C 1).

8.1 Mark separation line on longitudinal member front section (1) (area A).
8.2 Scribe separation on longitudinal member front section (1) (area B).
If damaged severely, cut longitudinal member front (1) in area (B).

Transfer separation line from new part (area B).
9.1 Separate longitudinal member front section (1) at separation point (area A).
9.2 Separate longitudinal member front section (1) at separation point (area B).
Do not damage sheet metal panels beneath.
10 Remove damaged longitudinal member front section (1).
If damaged severely, replace reinforcing bracket (4).
11 Expose spot welds on reinforcing bracket (4) (area H).
12 Drill spot welds on reinforcing bracket (4) with ø 6.7 mm bit (area H).
13 Remove damaged reinforcing bracket (4).
14 Sand connection surfaces down to bare metal in the cross-hatched areas.
Grind spot weld flanges down to bare metal on both sides.
15 Remove drill shavings.
16 Coat insides of spot weld flanges with zinc dust paint.

Fig 2: Identifying Connection Surfaces
Courtesy of MERCEDES-BENZ USA