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Replace front section of longitudinal member - AR62.20-P-1260V: Notes

MODEL 171 

Fig 1: Identifying Longitudinal Member
G05027936Courtesy 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 headlamp unit When removing left and right front headlamp unit   AR82.10-P-4730V
3 Remove front fender   AR88.10-P-1000V
4 Remove detachable parts in area to be repaired    
5 Cover all attached parts remaining in vehicle Tarpaulin (fireproof) *WH58.30-Z-1001-40A 
6 Equip straightening bench with modular members, cross members and straightening bracket set. IMPORTANT Observe body plans provided.  
    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 
    Car-Bench straightening bench BT 17 *WE58.40-Z-1003-01E 
    Car-Bench straightening bench BT 43/1 *WE58.40-Z-1003-01E 
    Car-Bench universal cross member set A 296 *WE58.40-Z-1010-01E 
    Multi-Z straightening set system MZ 450.000 *WE58.40-Z-1006-01E 
    Celette straightening bench 7171.300 (for model 171) *WE58.40-Z-1052-01A 
    Car-Bench straightening bracket set 82452 (for model 171) *WE58.40-Z-1053-01A 
7 Raise vehicle.   AR00.60-P-1000V
8 Place vehicle onto straightening bench    
9 Remove plugs from jack tube    
10 Attach vehicle to straightening bench    
11 Remove front reinforcement   AR62.30-P-1400V 
12 Completely remove front cross member   AR62.30-P-1300V 
13 Separate longitudinal member front section (1)   AR62.20-P-1260-01V 
    COMMERCIALLY AVAILABLE TOOLS Spot weld milling cutter Figure
    COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot-weld loosening 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 disc, dia. 115 mm, 80 m/s (max. 13.250 RPM) *WH58.30-Z-1024-04A 
    COMMERCIALLY AVAILABLE TOOLS Cutting disc, 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 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
14 Prepare longitudinal member front section (1)   AR62.20-P-1260-05V 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disc, dia. 115 mm, 80 m/s (max. 13.250 RPM) *WH58.30-Z-1024-04A 
    COMMERCIALLY AVAILABLE TOOLS Cutting disc, 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 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install     
15 Weld in longitudinal member front section (1)   AR62.20-P-1260-03V 
    COMMERCIALLY AVAILABLE TOOLS Electrode miller *WH58.30-Z-1003-01A 
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disc, dia. 115 mm, 80 m/s (max. 13.250 RPM) *WH58.30-Z-1024-04A 
    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 
    Steel/steel blind rivet, 6.5x 12.5 *BR00.45-Z-1012-13A 
16 Completely install front cross member   AR62.30-P-1300V 
17 Install front reinforcement   AR62.30-P-1400V 
18 Unfasten vehicle from straightening bench    
19 Install plugs for jack tube    
20 Raise vehicle.   AR00.60-P-1000V
21 Remove straightening bench.    
22 Clean welds and sheet metal flange with round wire brush COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
23 Clean area to be repaired    
24 Prime area to be repaired with priming filler    
25 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 
26 Paint repair areas and adjacent surfaces    
27 Apply additional cavity preservation   AR97.20-P-1500V
    Cavity preservation gun Sata HRS no. 11072 *WE58.40-Z-1006-08A 
    Preservation agent *BR00.45-Z-1003-05A 
28 Remove tarpaulin IMPORTANT On parts covered remaining in vehicle  
29 Install front fender   AR88.10-P-1000V
30 Install front bumper   AR88.20-P-2000V
31 Install front lamp unit When removing left and right front headlamp unit AR82.10-P-4730V
32 Install all detachable body components in area to be repaired    
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G05027937Courtesy of MERCEDES-BENZ USA
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-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-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
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-1012-13A Rivet A 004 990 16 97
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