Replace Complete Front End Assembly Together With Reinforcement - AR62.30-P-1570GQ
MODEL 166, 292
MODIFICATION NOTES
| 12.04.2016 | New operation steps added | Operation steps 2 and 18 |
Shown on model 166
| 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 | |
| General information on body repair | AH60.00-P-0001-01A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| Disassemble | |||
| 1 | Remove all detachable parts in repair area | ||
| Remove | |||
| 2 | Remove radiator for low-temperature water circuit | Model 166 with engine 157, 276, 278 Model 292 with engine 157, 276, 278 |
AR09.41-P-6935MLJ |
| 3 | Unscrew bolts (13) and remove right, left struts (11.1, 11.2) with spacer sleeves (12.1, 12.2) | ||
| 4 | Secure cooler with fastening strap against falling down | Figure | |
| Figure | |||
| 5 | Unscrew bolts (10.1, 10.2) and remove cross strut (10) | ||
| 6 | Unscrew bolts (4.1, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6) and remove impact absorber (9) | ||
| 7 | Unscrew bolts (5.1, 6.1) and remove right, left supports (7, 8) | ||
| 8 | Unscrew bolts (5.2, 6.2) and remove right, left lamp frame (5, 6) | ||
| 9 | Unscrew bolts (3.1) and remove lock wedge (3) and mounting console (4) | ||
| 10 | Unscrew bolts (2.1, 2.2) and remove crossmember (2) | ||
| Install | |||
| 11 | Fit crossmember (2) and screw in bolts (2.1, 2.2) | ||
| 12 | Fit lock wedge (3) and mounting console (4) and screw in bolts (3.1) | ||
| 13 | Fit right, left lamp frame (5, 6) and screw in bolts (5.2, 6.2) | ||
| 14 | Fit right, left supports (7, 8) and screw in bolts (5.1, 6.1) | ||
| 15 | Fit impact absorber (9) and screw in bolts (4.1, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6) | ||
| 16 | Fit cross strut (10) and screw in bolts (10.1, 10.2) | ||
| 17 | Fit right, left struts (11.1, 11.2) with spacer sleeve (12.1, 12.2) and screw in bolts (13) | ||
| 18 | Install radiator for low-temperature water circuit | Model 166 with engine 157, 276, 278 Model 292 with engine 157, 276, 278 |
AR09.41-P-6935MLJ |
| Adjust | |||
| 19 | Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01GQ | |
| Gap dimension | *BE60.00-P-1001-01Z | ||
| Gap dimension | *BE60.00-P-1002-01Z | ||
| Fig 1 | |||
| 20 | Adjust front end with reinforcement and fit | *BA62.30-P-1001-02I | |
| *BA62.30-P-1002-02I | |||
| *BA62.30-P-1003-02I | |||
| *BA62.30-P-1004-02I | |||
| Apply preservation agent | |||
| 21 | Add cavity preserving agent | AR97.20-P-1500GQ | |
| Assemble | |||
| 22 | Install detachable parts in area to be repaired |
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 166 | Model 292 | |||
|---|---|---|---|---|---|---|
| BE60.00-P-1001-01Z | Gap dimension | Engine hood to fender | Dimension "A" | mm | 3, 8 (± 1) | 3, 0 (± 0, 5) |
| Engine hood to headlamp | Dimension "B" | mm | 3, 9 (± 1) | 3, 5 (± 1) | ||
| Engine hood to bumper | Dimension "C" | mm | 5, 4 (± 1, 5) | 4, 5 (± 1, 5) | ||
| Fender to A-pillar | Dimension "D" | mm | 3, 5 (± 1) | 3, 0 (± 0, 5) | ||
| Front door to fender | Dimension "E" | mm | 4, 3 (± 0, 7) | 4, 0 (+1/-0, 5) | ||
| Front door to rear door | Dimension "F" | mm | 4, 8 (± 0, 7) | 4, 5 (+1/-0, 5) | ||
| Rear door to rear fender | Dimension "I" | mm | 4, 3 (± 0, 7) | 3, 5 (+1/-0, 5) | ||
| For picture, see | AR60.00-P-0700-01GQ | AR60.00-P-0700-01GQ | ||||
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 166 | Model 292 | |||
|---|---|---|---|---|---|---|
| BE60.00-P-1002-01Z | Gap dimension | Bumper to headlamp | Dimension "S1" | mm | 3, 0 (± 0, 5) | 2, 0 (± 1) |
| Dimension "S2" | mm | 3, 0 (± 0, 5) | 2, 0 (± 1) | |||
| Dimension "S3" | mm | 3, 0 (± 0, 5) | 3, 0 (± 1) | |||
| Fender to headlamp | Dimension "R" | mm | 3, 9 (± 1) | 3, 0 (± 1) | ||
| Engine hood to A-pillar | Dimension "Q" | mm | 3, 5 (± 1) | 4, 0 (+1, 5/-1, 0) | ||
| For picture, see | AR60.00-P-0700-01GQ | AR60.00-P-0700-01GQ | ||||
FROND END WITH REINFORCEMENT
| Number | Designation | Model 166 | Model 292 | |
|---|---|---|---|---|
| BA62.30-P-1001-02I | Screw/bolt, impact absorber to longitudinal member/longitudinal member to impact absorber | Nm | 55 | 55 |
FROND END WITH REINFORCEMENT
| Number | Designation | Model 166 | Model 292 | |
|---|---|---|---|---|
| BA62.30-P-1002-02I | Screw/bolt, cross strut to impact absorber | Nm | 25 | 25 |
FROND END WITH REINFORCEMENT
| Number | Designation | Model 166 | Model 292 | |
|---|---|---|---|---|
| BA62.30-P-1003-02I | Screw/bolt, crossmember to longitudinal member on outside | Nm | 10 | 10 |
FROND END WITH REINFORCEMENT
| Number | Designation | Model 166 | Model 292 | |
|---|---|---|---|---|
| BA62.30-P-1004-02I | Bolt, impact absorber to cross member | Nm | 20 | 20 |