Front Longitudinal Member Section Replacement - Ar62.20-P-1260RG
Model 190
Shown on model 190.3
| 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. |
AS60.00-Z-0007-01N | |
| 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 | |
| Notice | General information on body repair | AH60.00-P-0001-01S | |
| Notice | General information on crack diagnosis of aluminum parts | AH60.00-P-0014-01N | |
| Note on working on aluminum components and vehicles | AH60.00-P-0034-01RG | ||
| Remove | |||
| 1 | Prepare all workshop equipment and commercially available devices/tools required for the repair. | ||
| 2 | Remove detachable parts in area of repair point. | ||
| 3 | Cover all detachable parts that remain in the vehicle with fire-resistant welding protection blankets. | ||
| 4 | Set up straightening bench with module members, crossmembers, and straightening set. | ||
| 5 | Place vehicle on straightening bench and fasten. | ||
| 000 588 50 23 00 Body straightening system | WS60.00-P-0439K | ||
| 6 | Remove front crossmember support (4) and cut off longitudinal member front section (1). | AR62.20-P-1260-01RG | |
| 000 588 15 84 00 Heat gun | Vacuum unit suitable for aluminum dusts Round wire brush Spot weld milling machine Drill bit and milling cutter for ultra-high-strength steels Hand drill Body saw Wet/dry vacuum cleaner |
WS54.00-P-0125B | |
| Preparation | |||
| Notice | Notes on processing of 2-K structural foam adhesive during body repairs | AH60.00-P-0040-01A | |
| Notice | Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | |
| 7 | Prepare longitudinal member front section (1) and front crossmember support (4). | Vacuum unit suitable for aluminum dusts Round wire brush Drill bit and milling cutter for ultra-high-strength steels Hand drill Body saw Wet/dry vacuum cleaner |
AR62.20-P-1260-05RG |
| 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. | AS00.00-Z-0007-01A | |
| Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes | Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only. | AS00.00-Z-0016-01A | |
| Notice | Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | |
| General notes on welding | AH60.00-P-0005-01N | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| 8 | Install and weld in longitudinal member front section (1) and front crossmember support (4). | AR62.20-P-1260-07RG | |
| 000 588 12 84 00 Welder | WS00.00-P-0318K | ||
| 000 588 04 39 00 Rivet press tool | Vacuum unit suitable for aluminum dusts Round wire brush Drill bit for ultra-high-strength steels Hand drill Manual temporary fastener 6.35 mm Wet/dry vacuum cleaner |
WS60.00-P-0440B | |
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A | ||
| Blind rivet Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1016-13A | ||
| 9 | Release vehicle from straightening bench, lift and remove straightening bench. | ||
| Clean | |||
| 10 | Clean weld joints and sheet metal flange. | Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner |
|
| 11 | Remove fire-resistant welding protection blankets. | ||
| 12 | Clean repair area. | Wet/dry vacuum cleaner |
|
| Paint | |||
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents | Never spray corrosion protection on flames or hot, glowing objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection. | AS97.00-Z-0001-01A | |
| Notice | Notes on cavity preservation | AH97.20-P-0001-01B | |
| Notice | Notes on sprayable joint sealant | AH97.10-P-0002-01A | |
| Notice | Notes on paintwork repairs | AH98.00-P-9408-02A | |
| General information on operation items and work procedures for painting | AH98.00-P-0003-01A | ||
| General note on use of 2-component acoustic filler foam following repairs | AH60.00-P-0033-01RQ | ||
| Notes on seam seal | AH97.10-P-0002-02A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 13 | Treat repair areas with primer filler. | ||
| 14 | Seal seam after repair. | AR97.10-P-4000RG | |
| 15 | Paint repair areas and adjacent surfaces. | ||
| 16 | Supplement cavity preservation. | AR97.20-P-1500RG | |
| Assemble | |||
| 17 | Install detachable parts in the area of the repair point. |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1012-13A | Blind rivet Y2 6.5x12.5 (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 Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | A 004 990 17 97 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |