Replace Upper Front Longitudinal Member - Ar62.20-P-1286LWO

Model 238 

Fig 1: Upper Front Longitudinal Member, Strut, Reinforcement, Bracket And Locations (Model 238)

Courtesy of MERCEDES-BENZ USA

	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	See AS00.00-Z-0010-01A .
	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.	See AS00.00-Z-0017-01A .
	Risk of explosion  from aluminum grinding dust, risk of injury to respiratory system from inhaling dust	Wear dust filter mask, safety glasses and protective gloves. Use a suitable, grounded dust extraction system.	See AS60.00-Z-0007-01N .
	General information on body repair		See AH60.00-N-0001-01A .
	Information on preventing damage to electronic components due to electrostatic discharge		See AH54.00-P-0001-01A .
	Pretreatment of bonding surfaces		See AH60.00-P-0008-01SX .
	Note on working on aluminum components and vehicles		See AH60.00-P-0034-01LW .
	General information on MB materials		See AH98.00-P-9409-03A .
	Remove
1	Remove detachable parts in area to be repaired
2	Cover all detachable parts remaining on vehicle with spark protection blankets
3	Remove upper front longitudinal member (1), strut (2), reinforcement (3) and bracket (4)		AR62.20-P-1286-01LWO
	000 588 00 84 00 Heat gun	Commercially available devices/tools  Round wire brush Body power jigsaw Spot weld milling machine Torx EPL 12, Wet/dry vacuum cleaner Aluminum workplace Aluminum tools	See WS54.00-P-0049B .
		1K-zinc dust paint	See *BR00.45-Z-1056-07A .
4	Remove upper front longitudinal member (1), strut (2), reinforcement (3) and bracket (4)	Commercially available devices/tools  Round wire brush Body power jigsaw Aluminum workplace Aluminum tools	AR62.20-P-1286-02LWO
		1K-zinc dust paint	See *BR00.45-Z-1056-07A .
	Install
	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.	See AS00.00-Z-0007-01A .
	Measures for preventing damage to components when performing electric welding and soldering work		See AH60.00-P-0001-02A .
	General information on riveting		See AH60.00-P-0003-01N .
5	Install welding device		See AR62.20-P-1286-05LW .
		Welding device	See Figure.
		Adapter kit	See Figure.
6	Install upper front longitudinal member (1), strut (2), reinforcement (3) and bracket (4)		AR62.20-P-1286-03LWO
	000 588 01 84 00 Welder		See WS60.00-P-0021K .
	000 588 02 84 00 Welder	Commercially available devices/tools  Round wire brush Manual temporary fastener 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Wet/dry vacuum cleaner Aluminum workplace Aluminum tools	See WS60.00-P-0022K .
		1K-zinc dust paint	See *BR00.45-Z-1056-07A .
		Parts kit for 2-component adhesive for body	See *BR00.45-Z-1162-02A .
		Blind rivet 6.4 x 12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN)	See *BR00.45-Z-1035-13A .
		Blind rivet 6.5 x 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	See *BR00.45-Z-1012-13A .
		Blind rivet 6.5 x 14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)	See *BR00.45-Z-1016-13A .
		Adapter kit	See Figure.
		Welding device	See Figure.
7	Clean welds and sheet metal flanges	Commercially available devices/tools  Round wire brush
8	Remove spark protection blankets
9	Clean repair area	Commercially available devices/tools  Wet/dry vacuum cleaner
10	Prime repair area using primer filler Notes on paintwork repairs	Use only primer filler approved by Daimler AG:	AH98.00-P-9408-02A
11	Seal seam following repairs		AR97.10-P-4000LWO
12	Paint repair areas and adjacent surfaces Notes on paintwork repairs	Use only paints approved by Daimler AG:	See AH98.00-P-9408-02A .
13	Add cavity preserving agent		AR97.20-P-1500LWO
14	Install all detachable body components in area to be repaired

Fig 2: Identifying Adapter Kit (213 589 00 23 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Welding Device (253 589 00 23 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1012-13A	Blind rivet 6.5 x 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	A 004 990 16 97
BR00.45-Z-1016-13A	Blind rivet 6.5 x 14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)	A 004 990 17 97
BR00.45-Z-1035-13A	Blind rivet 6.4 x 12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN)	A 000 991 76 32
BR00.45-Z-1056-07A	1K-zinc dust paint	A 000 986 28 00
BR00.45-Z-1162-02A	Parts kit for 2-component adhesive for body	A 012 989 17 71