Install upper front longitudinal member - AR62.20-P-1286-03SX

Fig 1: Identifying Welding Device (221 589 01 23 00)

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Fig 2: Identifying Upright (221 589 07 23 00)

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Fig 3: Identifying Upper Front Longitudinal Member And Gas-Operated Spring Console Rivet Holes Areas (A And B)

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The following operation steps are shown on model 221 on the left side of the vehicle and must be performed analogously on the right side in the event of damage.

1. Install new parts with welding device, fit and fasten with clamping pliers.
2. Drill rivet holes in upper front longitudinal member (1) and gas-operated spring console (2) with dia. 6.5 mm bit (areas A and B).
   Fig 4: Identifying Rivet Hole Areas (C, D, E And F)

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3. Drill rivet holes in gas-operated spring console (2), suspension strut console bottom reinforcement (4) and suspension strut console top reinforcement (5) with dia. 6.5 mm bit (areas C, D, E and F).
4. Tack weld suspensions strut console bottom reinforcement (4) and suspension strut console top reinforcement (5) (area F₁ .
   Fig 5: Identifying Side Reinforcement And Suspension Strut Console Top Reinforcement Rivet Hole Areas (G, H, I And L)

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5. Drill rivet holes in side reinforcement (3) and suspension strut console top reinforcement (5) with dia. 6.5 mm bit (areas G, H, I and L).
6. Partially remove welding device.
7. Drill rivet holes in side reinforcement (3) with dia. 6.5 mm bit (areas J and K).
8. Remove new parts.
9. Deburr rivet holes on both sides
10. Remove drill shavings using wet/dry vacuum cleaner
11. Coat insides of riveted joints with zinc dust paint.
12. Suspension strut console reinforcement (8) (area F₂ ).
13. Grind welds down flat (area F ₂ ).
14. Coat insides of spot weld flanges with zinc dust paint.
    Fig 6: Identifying Suspension Strut Console Reinforcement Grinding Area (F2)

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    Fig 7: Identifying 2-Component Adhesive In Cross-Hatched Area

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15. Apply 2-component adhesive in cross-hatched area.

    Observe preliminary treatment of bonding surface.

    Refer to manufacturer specifications for adhesive curing and application times.

16. Install side reinforcement (3), inner front longitudinal member (7) and upper front longitudinal member (1) with welding device, fit and fasten with clamping pliers and manual temporary fastener.
17. Tack weld inner front longitudinal member (7) (areas M and N).
18. Partially remove welding device.
19. Remove upper front longitudinal member (1)
    Fig 8: Identifying Inner Front Longitudinal Member Tack Weld Areas (M And N)

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    Fig 9: Identifying Inner Front Longitudinal Member Drill Hole Area (Q)

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20. Drill holes in inner front longitudinal member (7) with dia. 7 mm bit (area Q).
21. Inner front longitudinal member (7) (area Q).
22. Inner front longitudinal member (7) (areas O, P, R and S).
    Fig 10: Identifying Side Reinforcement Polygrip Flat/Round Head Rivet Areas (G, H, I, J And K)

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23. Side reinforcement (3) (area T).
24. Rivet side reinforcement (3) with Polygrip flat/round head rivet, dia. 6.4x14 (areas G, H, I, J and K).

    Blind rivet tool.

    Fig 11: Identifying Inner Front Longitudinal Member

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25. Apply 2-component adhesive in cross-hatched area.

    Observe preliminary treatment of bonding surface.

    Refer to manufacturer specifications for adhesive curing and application times.

    Fig 12: Identifying Suspension Strut Console Reinforcement Polygrip Flat/Round Head Rivet Areas (E, F And L)

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26. Install suspension strut console reinforcement (8), fit and fasten with clamping pliers and manual temporary fasteners.
27. Suspension strut console reinforcement (8) (areas E₁ , U and U₁ ).
28. Rivet suspension strut console reinforcement (8) with Polygrip flat/round head rivet, dia. 6.4X14 (areas E, F and L).

    Blind rivet tool.

29. Grind spot welds down flat (areas E ₁ and U₁ ).
30. Coat insides of spot weld flanges with zinc dust paint (area U ₁ ).
    Fig 13: Identifying Inner Front Longitudinal Member And Side Reinforcement

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31. Apply 2-component adhesive in cross-hatched areas.

    Observe pretreatment of bonding surfaces.

    Refer to manufacturer specifications for adhesive curing and application times.

    Fig 14: Identifying Upper Front Longitudinal Member Areas (V, W, X, Y And Y1)

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32. Install upper front longitudinal member (1) and gas-operated spring console (2) with welding device, fit and fasten with clamping pliers and manual temporary fastener.
33. Upper front longitudinal member (1) (areas V, W, X, Y and Y₁ .
34. Rivet upper front longitudinal member (1) and gas-operated spring console (2) with Polygrip flat/round head rivet, dia. 6.4 X 14 (areas A, B, C and D).

    Blind rivet tool.

    Fig 15: Identifying Upper Front Longitudinal Member Area (Z)

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35. Remove welding device.
36. Upper front longitudinal member (1) (area Z).