Prepare upper front longitudinal member - AR62.20-P-1286-02SX

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1006-01A	Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1001-03A	Round wire brush, braided, dia. 70 mm
WH58.30-Z-1024-04A	Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm)

WORKSHOP EQUIPMENT

WE58.40-Z-1001-03A	Drill (electric/pneumatic)
WE58.40-Z-1003-03A	Angle grinder (electric/pneumatic)

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42

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

Grind mating surfaces on upper front longitudinal member (1) down to bare metal in cross-hatched areas with round wire brush.
Grind spot weld flanges down to bare metal on both sides.
Using zinc dust paint, coat insides of spot weld flanges that were not additionally bonded.

Fig 2: Not Applying Zinc Dust Paint To Surfaces To Be Bonded (Areas A, B And C)
Courtesy of MERCEDES-BENZ USA

Do not apply zinc dust paint to surfaces to be bonded (areas A, B and C).

Observe pretreatment of bonding surfaces.

Fig 3: Identifying Inner Front Longitudinal Member Spot Welding Area (D)
Courtesy of MERCEDES-BENZ USA
Expose spot welds on inner front longitudinal member (2) (area D).
Cut out spot welds on inner front longitudinal member (2) with spot weld milling cutter or Vario Drill spot weld removing tool (area D).
Grind mating surfaces on upper front longitudinal member (2) down to bare metal in cross-hatched areas with round wire brush.
Grind spot weld flanges down to bare metal on both sides.
Using zinc dust paint, coat insides of spot weld flanges that were not additionally bonded.
Observe pretreatment of bonding surfaces.

Do not coat bonding surfaces with zinc dust paint (areas E, F and G).

Fig 4: Not Applying Zinc Dust Paint To Surfaces To Be Bonded Areas (E, F And G)
Courtesy of MERCEDES-BENZ USA
Drill holes in side reinforcement (4) with dia. 7 mm bit (area H).
Grind cross-hatched areas down to bare metal around holes with round wire brush.
Grind connection surfaces on side reinforcement (4) down to bare metal in cross-hatched areas with round wire brush.
Grind spot weld flanges down to bare metal on both sides.
Coat insides of spot weld flanges with zinc dust paint.

Fig 5: Identifying Grinding Surfaces On Side Reinforcement (Cross-Hatched Areas)
Courtesy of MERCEDES-BENZ USA
Grind mating surfaces on suspension strut console bottom reinforcement (5) and suspension strut console top reinforcement (6) down to bare metal in cross-hatched area with round wire brush.
Grind spot weld flanges down to bare metal on both sides.
Using zinc dust paint, coat insides of spot weld flanges that were not additionally bonded.
Observe pretreatment of bonding surfaces.

Do not coat surfaces to be bonded with zinc dust paint (area I).

Fig 6: Not Applying Zinc Dust Paint To Surfaces To Be Bonded Area (I)
Courtesy of MERCEDES-BENZ USA