Prepare Front Longitudinal Member To Passenger Compartment Floor Area - Ar62.20-D-1240-13HA
| The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases | Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system. | AS00.00-Z-0007-01A | |
| Risk of injury . Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | AS00.00-Z-0002-01A | |
| 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 body repair | AH60.00-N-0001-01A |
Model 906 up to 12/23/16
with code XL4 (Weight variant 5.500 kg)
except code CV1 (Pre-installation for winter service vehicle)
| Number | Designation | Model 906 | ||
|---|---|---|---|---|
| BA32.25-N-1004-02A | Nut, strut to support bushing | M16x1.5 | Nm | 90 |
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1056-07A | 1K-zinc dust paint | A 000 986 28 00 |
- Check whether dimension (a) on bracket (11) is identical or different on old front longitudinal member (1) and new front longitudinal member (1).
When repairing right front longitudinal member (1) with attachment point for SCR container on bracket (11)
Dimension (a) is identical.
↓
Continue with operation step 8.
- Measure dimension on front longitudinal member (1) and note.
When repairing right front longitudinal member (1) with attachment point for SCR container on bracket (11)
- Expose spot welds for bracket (11) on front longitudinal member (1) (areas J and K).
When repairing right front longitudinal member (1) with attachment point for SCR container on bracket (11)
- Cut out spot welds with
spot weld milling cutter (areas J and K) and remove bracket (11).
When repairing right front longitudinal member (1) with attachment point for SCR container on bracket (11)
- Grind mating surfaces on front longitudinal member (1) down to bare metal (areas J and K).
When repairing right front longitudinal member (1) with attachment point for SCR container on bracket (11)
- Drill new bracket (11) with Ø 6 mm bit (areas L and M).
When repairing right front longitudinal member (1) with attachment point for SCR container on bracket (11)
Transfer dimensions from removed bracket.
- Grind new bracket (11) around holes down to bare metal in crosshatched area (areas L and M).
When repairing right front longitudinal member (1) with attachment point for SCR container on bracket (11)
- Position new bracket (11) on front longitudinal member (1) (dimension b) and
(areas N and O).
When repairing right front longitudinal member (1) with attachment point for SCR container on bracket (11)
- Remove support bushing (2) on shock absorber strut (12) from front axle of vehicle side to be repaired.
- Install support bushing (2) on front longitudinal member (1).
- Mark both additional holes (5) on front longitudinal member (1).
- Remove support bushing (2).
- Drill holes (5) wit Ø10, 5 mm bit.
- Deburr holes (5) on both sides.
- Check whether weld nuts (6) are present on front longitudinal member (1).
Weld nuts (6) are present.
↓
Continue with operation step 26.
- Install support bushing (2) and brackets (3, 4) on front longitudinal member (1).
- Mark holes (7) on front longitudinal member (1).
- Remove bracket (4) from front longitudinal member (1).
- Center punch holes (7) and drill with Ø 12 mm bit.
- Deburr holes (7) on both sides.
- Grind front longitudinal member (1) around holes (7) down to bare metal in crosshatched area.
- Install bracket (4) on bracket (3) on front longitudinal member (1) with weld nuts (6).
- Weld nuts (6)
.
- Remove support bushing (2) and brackets (3, 4) from front longitudinal member (1).
- Coat both inner weld nuts (6) with zinc dust paint.
- Install support bushing (2) on shock absorber strut (12) on front axle.
- Punch holes on front longitudinal with Ø 6 mm bit (areas A, B, C, D and J).
- Drill holes on front longitudinal member with Ø 7 mm bit (areas E, F, G, H and I).
- Grind mating surfaces on front longitudinal member down to bare metal in crosshatched areas.
- Coat insides of spot weld flanges with zinc dust paint.
- Grind crosshatched areas on front longitudinal member down to bare metal around holes.
- Grind crosshatched areas on front longitudinal member (1) down to bare metal around holes.