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Replace wheelhouse with front longitudinal member - AR62.20-P-1856V: Notes

MODEL 171 

Fig 1: Identifying Wheelhouse With Front Longitudinal Member
G05027975Courtesy of MERCEDES-BENZ USA
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. 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. -
DANGER Risk of death  caused 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. -
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 undeburred vehicle parts. -
    Deburr replacement panels.  
1 Remove front bumper   AR88.20-P-2000V
2 Remove front lamp unit When removing left and right front headlamp unit   AR82.10-P-4730V
3 Remove front fender   AR88.10-P-1000V
4 Remove engine hood   AR88.40-P-3000V
5 Remove engine    
    Engine 272.963 in model 171.456 with transmission 722.906 AR01.10-P-2400VA
    Engine 272.963 in model 171.456 with transmission 716.664 AR01.10-P-2400VB
6 Remove detachable parts in area to be repaired    
7 Cover all attached parts remaining in vehicle Tarpaulin (fireproof) *WH58.30-Z-1001-40A 
8 Equip straightening bench with modular members, crossmembers and straightening bracket set. IMPORTANT Observe body plans provided.  
    Celette straightening bench M8S *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 
    Car-Bench straightening bench BT 17 *WE58.40-Z-1003-01E 
    Car-Bench universal crossmember set A 296 *WE58.40-Z-1010-01E 
    Celette straightening bench Sevenne *WE58.40-Z-1001-01E 
    Car-Bench straightening bench BT 43/1 *WE58.40-Z-1003-01E 
    Multi-Z straightening set system MZ 450.000 *WE58.40-Z-1006-01E 
    Celette straightening set 7171.300 (for model 171) *WE58.40-Z-1052-01A 
    Car-Bench straightening bracket set 82452 (for model 171) *WE58.40-Z-1053-01A 
9 Raise vehicle.   AR00.60-P-1000V
10 Place vehicle on straightening bench    
11 Remove stop plug from jack tubes    
12 Attach vehicle to straightening bench    
13 Remove front reinforcement   AR62.30-P-1400V 
14 Completely remove front crossmember   AR62.30-P-1300V 
15 Remove wheelhouse with front longitudinal member (1)   AR62.20-P-1856-01V 
    SPECIAL TOOL Spot weld milling cutter Figure
    SPECIAL TOOL Drilling template Figure
    COMMERCIALLY AVAILABLE TOOLS Spherical milling cutter, dia. 12 mm *WH58.30-Z-1002-01A 
    COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot weld removing tool *WH58.30-Z-1006-01A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
    COMMERCIALLY AVAILABLE TOOLS Cutting disk, dia. 65 mm, 80 m/s (max. 23, 500 RPM) *WH58.30-Z-1021-04A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
    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 
    Bi-metal HSS keyhole saw set dia. 16 -67 mm *WH58.30-Z-1009-34A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
16 Prepare wheelhouse with front longitudinal member (1) for installation   AR62.20-P-1856-02V 
    COMMERCIALLY AVAILABLE TOOLS Hole punching pliers, dia. 7 mm *WH58.30-Z-1002-02A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install     
17 Install wheelhouse with front longitudinal member (1)   AR62.20-P-1856-03V 
    SPECIAL TOOL Welding device Figure
    SPECIAL TOOL Welding device Figure
    COMMERCIALLY AVAILABLE TOOLS Electrode miller *WH58.30-Z-1003-01A 
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    COMMERCIALLY AVAILABLE TOOLS Manual temporary fastener, dia. 6.4 mm, clamping area 0 to 15 mm, identification color silver *WH58.30-Z-1038-02A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
    COMMERCIALLY AVAILABLE TOOLS Taurus 3 blind rivet tool with 100 mm long extension unit *WE58.40-Z-1003-14A 
    Inert gas welder *WE58.40-Z-1001-02A 
    Spot welder *WE58.40-Z-1002-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
    Polygrip flat/round head rivet, 6.4x14 *BR00.45-Z-1001-13A 
    Polygrip countersunk rivet, 6.40x10 *BR00.45-Z-1002-13A 
    Sealing washer *BR00.45-Z-1002-15A 
18 Completely install front crossmember   AR62.30-P-1300V 
19 Install front reinforcement   AR62.30-P-1400V 
20 Unfasten vehicle from straightening bench    
21 Install stop plug on jack tubes    
22 Raise vehicle.   AR00.60-P-1000V
23 Remove straightening bench.    
24 Clean welds and sheet metal flange with round wire brush COMMERCIALLY AVAILABLE TOOLS Drill (electric/pneumatic) *WH58.30-Z-1001-03A 
    Round wire brush, braided, dia. 70 mm *WE58.40-Z-1001-03A 
25 Clean area to be repaired    
26 Prime area to be repaired with priming filler    
27 Carry out seam sealing after repairs IMPORTANT Supplement standard sealing with MB body sealant. AR97.10-P-4000V
    Sealant *BR00.45-Z-1003-01A 
    Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
28 Paint are to be repaired and adjacent surfaces    
29 Apply additional cavity preservation   AR97.20-P-1500V
    Cavity preservation gun Sata HRS no. 11072 *WE58.40-Z-1006-08A 
    MB cavity wax preservation, 1 | *BR00.45-Z-1003-05A 
30 Remove tarpaulin IMPORTANT On all covered parts remaining in vehicle. *WH58.30-Z-1001-40A 
31 Install engine    
    Engine 272.963 in model 171.456 with transmission 722.906 AR01.10-P-2400VA
    Engine 272.963 in model 171.456 with transmission 716.664 AR01.10-P-2400VB
32 Install engine hood   AR88.40-P-3000V
33 Install front fender   AR88.10-P-1000V
34 Install front bumper   AR88.20-P-2000V
35 Install front lamp unit When removing left and right front lamp unit AR82.10-P-4730V
36 Install all removed detachable body components    
Fig 2: Identifying Weld In Device (171 589 01 23 00)
G05027976Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Weld In Device (171 589 02 23 00)
G05027977Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G05027978Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Drilling Template (171 589 07 23 00)
G05027979Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1002-01A Ball cutter, dia. 12 mm
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-1038-02A Manual temporary fastener, dia.6.4 mm - clamping range 0 -15 mm, identification color silver
Firma Hausmann GmbH D-34346 Hann. Munden, Germany
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-1009-34A HSS bimetal keyhole saw set 16 Ø- 67 mm
WH58.30-Z-1001-40A Tarp (fire-resistant)
WORKSHOP EQUIPMENT

WE58.40-Z-1052-01A Celette straightening bracket set 7171.300 (model 171)
WE58.40-Z-1053-01A Car bench straightening bracket set 82452, (model 171)
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-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
WE58.40-Z-1006-08A Cavity preservation gun
WE58.40-Z-1003-14A Blind rivet tool
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1041-01A Seam sealant, sprayable 310 ml A 002 989 84 20
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
BR00.45-Z-1001-13A Rivet A 003 990 35 97
BR00.45-Z-1002-13A Polygrip countersunk head rivet, 6.4 x 14 A 003 990 86 97 05
BR00.45-Z-1002-15A Sealing washer A 116 987 02 44
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