Prepare Front Longitudinal Member To Passenger Compartment Floor Area - Ar62.20-D-1240-13HB
| 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 5/27/16
with code CV1 (Pre-installation for winter service vehicle)
except code XL4 (Weight variant 5.500 kg)
FRONT AXLE DAMPER STRUT
| 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 |
- Scribe holes according to drawing on front longitudinal member (1) on right and left, center punch and drill Ø 6 mm pilot hole and then drill with Ø 10 mm. Deburr holes.
Mark dimensions from references edges (0).
- Scribe dimensions according to drawing on front longitudinal member (1) on at bottom, center punch and drill Ø 6 mm pilot hole and then drill with Ø 10 mm.
- Deburr holes.
- 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) with Ø10, 5 mm bit.
- Deburr holes (5) on both sides.
- Install support bushing (2) and brackets (3 and 4) on front longitudinal member (1).
- Mark holes (7) on front longitudinal member (1).
- Remove bracket (4) from front longitudinal member (1).
- Drill holes (7) with Ø12 mm bit.
- Deburr holes (7) on both sides.
- Install bracket (4) and reinforcement (8) on front longitudinal member (1) and bracket (3).
- Mark position of reinforcement (8) on front longitudinal member (1) (areas P, Q, R, S)
- Remove bracket (4) and reinforcement (8) from front longitudinal member (1).
- Grind front longitudinal member (1) around holes (7) down to bare metal in crosshatced area.
- Grind front longitudinal member (1) down to bare metal in marked area (areas P, Q, R, S).
- Screw bracket (4) with weld nuts (6) and reinforcement (8) to front longitudinal member (1) and bracket (3).
- Weld nuts (6) and reinforcement (8)
(areas Q, R, S).
- Reinforcement (8)
(area P).
- Remove support bushing (2) and brackets (3 and 4) from front longitudinal member (1).
- Coat both weld nuts (6) and adjacent area with zinc dust paint.
- Install support bushing (2) on shock absorber strut (12) on front axle.
- Punch holes on front longitudinal member 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.