Remove Longitudinal Member Outer Shell On Entrance - Ar63.30-P-1102-01CLW

Model 205.3 

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

The longitudinal member outer shell can be separated at the specified separating points by observing the foam parts and reinforcement.

Observe standard series production joining and bonded connections.

Fig 1: Longitudinal Member Outer Shell Removal Measurement Locations (Model 205.3)

Courtesy of MERCEDES-BENZ USA

1. Mark separation points on longitudinal member outer shell (1) and cut (according to damage in area A, area B or areas A and B).

   Do not make the cuts too deep.

   Otherwise the components below can be damaged and weakened.

   Dimensions: 

   a = approx. 60 mm

   b = approx. 43 mm

   Fig 2: Longitudinal Member Reinforcement Removal Measurement Locations (Model 205.3)

   Courtesy of MERCEDES-BENZ USA
2. Expose spot welds on reinforcement (2) and cut out (areas C and D).

   Cut out spot welds through two sheet metal thicknesses (area D).

   Courtesy of MERCEDES-BENZ USA

3. Heat reinforcement (2) in crosshatched areas.

   Cross-hatched areas are bonded with adhesive.

4. Remove reinforcement (2).
   Fig 3: Longitudinal Member Outer Shell Removal Cut Lines And Locations (Model 205.3)

   Courtesy of MERCEDES-BENZ USA
5. Expose spot welds on longitudinal member outer shell (1) and cut out (areas E).

   Courtesy of MERCEDES-BENZ USA

6. Heat longitudinal member outer shell (1) in crosshatched areas.

   Cross-hatched areas are bonded with adhesive.

7. Remove outer longitudinal member shell (1).

   Courtesy of MERCEDES-BENZ USA

8. Sand down mating surfaces to bare metal in cross-hatched areas.

   Sand down spot weld flanges to bare metal on both sides.

9. Remove grinding dust and drill chips.
10. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust (areas F).

    Otherwise adhesion problems may occur.