Front End Weld In - Ar62.10-P-1000-05RG

	000 588 12 84 00 Welder		WS00.00-P-0318K
	000 588 04 39 00 Rivet press tool		WS60.00-P-0440B

Model 190 

Further information can be found in the superordinate service document. Comply with safety information in superordinate customer service document.

Always  maintain welding sequence according to operation steps.

Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

1. Install front-end assembly (1) and fit and fix in place with straightening set.

   Slide new part under remaining section on body.

2. Check weld seam gaps.

   When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

3. Tack weld front-end assembly (1) with welder ( ) (area A1re).

   When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush.

   Weld seams must  be tack welded at start, end and every approx. 4 cm.

4. Weld front-end assembly (1) with welder ( ) (area A1re).

   When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

   Shown on model 190.3 

   Courtesy of MERCEDES-BENZ USA

5. Tack weld front-end assembly (1) with welder ( ) (areas B1li, A2re, B2li, A3re and B3li).

   When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam. Welding sequence (B1li, A2re, B2li, A3re and B3li) must  be complied with.

6. Weld front-end assembly (1) with welder ( ) (areas B1li, A2re, B2li, A3re and B3li).

   When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam. Welding sequence (B1li, A2re, B2li, A3re and B3li) must  be complied with.

   Shown on model 190.3 

   Courtesy of MERCEDES-BENZ USA

7. Tack weld front-end assembly (1) with welder ( ) (areas A4re, B4li, A5re, B5li, A6re and B6li).

   When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam. Welding sequence (A4re, B4li, A5re, B5li, A6re and B6li) must  be complied with.

8. Weld front-end assembly (1) with welder ( ) (areas A4re, B4li, A5re, B5li, A6re and B6li).

   When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam. Welding sequence (A4re, B4li, A5re, B5li, A6re and B6li) must  be complied with.

   Shown on model 190.3 

   Courtesy of MERCEDES-BENZ USA

   The following operation steps 9 and 10 are shown on the left side of the vehicle. Perform in same manner on right side of vehicle.

9. Tack weld front-end assembly (1) with welder ( ) (area B7li).

   When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

10. Weld front-end assembly (1) with welder ( ) (area B7li).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

    The following operation steps 11 and 12 are shown on the left side of the vehicle. Perform in same manner on right side of vehicle.

11. Tack weld front-end assembly (1) with welder ( ) (areas B8li, B9li and B10li).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam. Welding sequence (B8li, B9li and B10li) must  be complied with.

12. Weld front-end assembly (1) with welder ( ) (areas B8li, B9li and B10li).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam. Welding sequence (B8li, B9li and B10li) must  be complied with.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

13. Tack weld front-end assembly (1) with welder ( ) (areas C1re, D2li, C3re, D3li, C2re and D1li).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam. Welding sequence (C1re, D2li, C3re, D3li, C2re and D1li) must  be complied with.

14. Weld front-end assembly (1) with welder ( ) (areas C1re, D2li, C3re, D3li, C2re and D1li).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam. Welding sequence (C1re, D2li, C3re, D3li, C2re and D1li) must  be complied with.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

15. Install, fit and fix in place left inner end plate (2).
16. Drill rivet holes in left inner end plate (2) and in front-end assembly (1) at inside and outside with ø 6.7 mm (areas A).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

17. Remove left inner end plate (2).
18. Deburr rivet holes in left inner end plate (2) and in front-end assembly (1) on both sides.

    Observe pretreatment of bonding surfaces.

19. Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

20. On left inner striker plate (2) and front-end assembly (1), apply 2- component adhesive (crosshatched areas).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

21. Install, fit and fix in place left inner end plate (2).
22. Rivet left inner striker plate (2) and inside and outside of front-end assembly (1) with rivet press tool and blind rivets or blind rivets (areas A₁ ).

    Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

23. Fit, install and fix in place left lower firewall section (3b).

    Bond left lower firewall section (3b) so that overlapping with remaining firewall (3a) and rivet.

24. Drill rivet holes in left lower firewall section (3b) and in firewall (3a) with ø 6.7 mm (area B).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

25. Remove left lower firewall section (3b).
26. Deburr rivet holes at left lower firewall section (3b) and at firewall (3a) on both sides.

    Observe pretreatment of bonding surfaces (cross-hatched areas).

27. Remove shavings using wet/dry vacuum cleaner.

    Courtesy of MERCEDES-BENZ USA

28. On left lower firewall section (3b) and firewall (3a), apply 2- component adhesive (crosshatched areas).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

29. Fit, install and fix in place left lower firewall section (3b).
30. Rivet left lower firewall section (3b) and firewall (3a) with rivet press tool and blind rivets or blind rivets (area B₁ ).

    Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

31. Install, fit and fix in place right cover plate (4).
32. Drill rivet holes in right cover plate (4) and in front-end assembly (1) with ø 6.7 mm (areas C and D).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

33. Remove right cover plate (4).
34. Deburr rivet holes at right cover plate (4) and at front-end assembly (1) on both sides.

    Observe pretreatment of bonding surfaces (cross-hatched areas).

35. Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

36. On right cover plate (4) and frontend assembly (1), apply 2- component adhesive (crosshatched areas).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

37. Install, fit and fix in place right cover plate (4).
38. Rivet right cover plate (4) and frontend assembly (1) with rivet press tool and blind rivets or blind rivets (areas C₁ and D₁ ).

    Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

39. Install, fit and fix in place right lower end plate (12).
40. Drill rivet holes in right lower end plate (12) and in front-end assembly (1) with ø 6.7 mm (crosshatched areas).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

41. Remove right lower end plate (12).
42. Drill rivet holes in right lower end plate (12) and in front-end assembly (1) on both sides (crosshatched areas).

    Observe pretreatment of bonding surfaces.

43. Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

44. Apply 2-component adhesive to right lower end plate (12) and frontend assembly (1) (cross-hatched areas).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

45. Install, fit and fix in place right lower end plate (12).
46. Rivet right lower end plate (12) and front-end assembly (1) using rivet press tool and blind rivets or blind rivets (area K₁ ).

    Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

47. Install, fit and fix in place left upper firewall (5).
48. Drill rivet holes in left upper firewall (5) and in front-end assembly (1) with ø 6.7 mm (areas E1, E2 and E3).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

49. Remove left upper firewall (5).
50. Deburr rivet holes at left upper firewall (5) and front-end assembly (1) on both sides.

    Observe pretreatment of bonding surfaces.

51. Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

52. On left upper firewall (5) and frontend assembly (1), apply 2-component adhesive (crosshatched areas).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

53. Install, fit and fix in place left upper firewall (5).

    Courtesy of MERCEDES-BENZ USA

54. Rivet left upper firewall (5) and front-end assembly (1) with rivet press tool and blind rivets (areas E₄ and E₅ ) and blind rivet (area E₆ ).

    Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

55. Tack weld left upper firewall (5) with welder ( ) (see depiction in picture).

    When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Weld seams must  be tack welded at start, end and every approx. 4 cm.

56. Weld left upper firewall (5) with welder ( ) (see depiction in picture).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

57. Install, fit and fix in place right lower end plate (6).
58. Drill rivet holes in right lower end plate (6) and in front-end assembly (1) with ø 6.7 mm (area F).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

59. Remove right lower end plate (6).
60. Deburr rivet holes at right lower end plate (6) and front-end assembly (1) on both sides.

    Observe pretreatment of bonding surfaces (cross-hatched areas).

61. Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

62. On right lower striker plate (6) and front-end assembly (1), apply 2-component adhesive (crosshatched area).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

63. Install, fit and fix in place right lower end plate (6).
64. Rivet right lower striker plate (6) and front-end assembly (1) with rivet press tool and blind rivets or blind rivets (area F₁ ).

    Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

65. Install, fit and fix in place right lower partition (7).
66. Tack weld right lower partition (7) with welder ( ) (see depiction in picture).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

67. Weld right lower partition (7) with welder ( ) (see depiction in picture).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

68. Install, fit and fix in place left lower partition (8).
69. Tack weld left lower partition (8) with welder ( ) (see depiction in picture).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

70. Weld left lower partition (8) with welder ( ) (see depiction in picture).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

    The following operation steps 71 to 74 are shown on the left side of the vehicle. Perform in same manner on right side of vehicle.

71. Install, fit and fix in place outer longitudinal member end plate (9).
72. Drill rivet holes in outer longitudinal member end plate (9) and in frontend assembly (1) with ø 6.7 mm (areas G).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

73. Remove outer longitudinal member end plate (9).
74. Deburr rivet holes at outer longitudinal member end plate (9) and front-end assembly (1) on both sides.

    Observe pretreatment of bonding surfaces (cross-hatched areas).

75. Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

    The following operation steps 76 to 78 are shown on the left side of the vehicle. Perform in same manner on right side of vehicle.

76. On outside longitudinal member striker plate (9) and front-end assembly (1), apply 2-component adhesive (cross-hatched areas).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

77. Install, fit and fix in place outer longitudinal member end plate (9).
78. Rivet outside longitudinal member striker plate (9) and front-end assembly (1) with rivet press tool and blind rivets or blind rivets (areas G₁ ).

    Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

    The following operation step 79 is shown on the left side of the vehicle. Perform in same manner on right side of vehicle.

79. Mark installation position of strut (10) on front-end assembly (1).

    Measure dimension (g) from edge of front-end assembly (1) downward. Measure dimension (h) from rear edge of front-end assembly (1) toward front.

    The following operation steps 80 to 82 are shown on the left side of the vehicle. Perform in same manner on right side of vehicle.

80. Install, fit and fix in place strut (10).
81. Tack weld strut (10) with welder to front-end assembly (1) ( ) (see depiction in picture).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

    Courtesy of MERCEDES-BENZ USA

82. Weld strut (10) with welder to frontend assembly (1) ( ) (see depiction in figure).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

    The following operation steps 83 to 88 are shown on the left side of the vehicle. Perform in same manner on right side of vehicle.

83. Fit, install and fix in place A-pillar section (11a).
84. Drill rivet holes in A-pillar section (11a) with ø 6.7 mm (area H).

    Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt them and drill through together.

85. Remove A-pillar section (11a).
86. Deburr rivet holes at A-pillar section (11a) on both sides (cross-hatched area).

    Observe pretreatment of bonding surfaces.

87. Prepare mating surfaces at A-pillar section (11a) and A-pillar (11) for weld joints (area I).
88. Prepare welds by grind down to bare metal with stainless steel brush.
89. Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

    The following operation steps 89 to 95 are shown on the left side of the vehicle. Perform in same manner on right side of vehicle.

90. On A-pillar section (11a) and frontend assembly (1), apply 2-component adhesive (crosshatched area).

    Observe manufacturer's specification for drying and processing time of 2-component adhesive.

91. Install, fit and fix in place A-pillar section (11a).
92. Rivet A-pillar section (11a) and front-end assembly (1) with rivet press tool and blind rivets or blind rivets (area H₁ ).

    Replace flow drill screws installed in vehicle by high-strength blind rivets according to clamping range.

93. Tack weld A-pillar section (11a) with welder ( ) area (I1).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

94. Weld A-pillar section (11a) with welder ( ) area (I1).

    When MIG welding ( ), prepare welds by grinding down to bare metal with stainless steel brush directly before welding. Tack weld seams at start, end and approx. every 4 cm. Weld seam gap should not be greater than 1 mm; if required, create a pre-seam.

95. Clean and level weld seams on Apillar section (11a) and A-pillar (11), and create surface (area I₁ ).
96. Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

    The following operation step 96 is shown on the left side of the vehicle. Perform in same manner on right side of vehicle.

97. Foam front-end assembly (1) via openings (area J) on front longitudinal member with 2Kcomponent filler foam.

Fill one spray can of 2K filler foam into each side of the vehicle.

Shown on model 190.3