- Install inner shoe (2) in longitudinal member (3).
- Install longitudinal member front section (1), fit with straightening tool set and fix in place.
- Check weld seam gap.
The weld seam gap must not be larger than 1 mm; if necessary, make an add-on seam weld.
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- Tack weld longitudinal member front section (1) at top and bottom with welder to longitudinal member (
) (areas A1, A2, A3 and A4).
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. Welding sequence (A1, A2, A3 and A4) must
be complied with.
 Courtesy of MERCEDES-BENZ USA
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 Courtesy of MERCEDES-BENZ USA
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- Tack weld longitudinal member front section (1) outside to inner boot (2) with welder (
) (areas B).
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.
- Tack weld longitudinal member (3) inside to inner boot (2) with welder (
) (areas C).
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.
- Tack weld longitudinal member (3) outside to inner boot (2) with welder (
) (areas D).
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.
- Tack weld longitudinal member front section (1) inside to inner boot (2) with welder (
) (areas E).
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.
- Weld longitudinal member front section (1) outside to inner boot (2) with welder (
) (areas B).
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.
- Weld longitudinal member (3) inside to inner boot (2) with welder (
) (areas C).
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.
- Weld longitudinal member (3) outside to inner boot (2) with welder (
) (areas D).
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.
- Weld longitudinal member front section (1) inside to inner boot (2) with welder (
) (areas E).
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
|
- Weld longitudinal member front section (1) to longitudinal member (3) all the way around with welder (
) (area F).
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.
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|
- Install front crossmember support (4) and fit.
- Transfer holes of front crossmember support (4) to longitudinal member front section (1) (area J).
- Drill rivet holes in longitudinal member front section (1) with drill bit ø 6.5 mm (area J).
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.
- Remove front crossmember support (4).
- Deburr rivet holes on front crossmember support (4) and longitudinal member front section (1) on both sides.
Observe pretreatment of bonding surfaces.
- Remove shavings using wet/dry vacuum cleaner.
- On front crossmember support (4) and longitudinal member front section (1), apply 2-component adhesive (area J).
Observe manufacturer's specification for drying and processing time of 2-component adhesive.
- Install and fix in place front crossmember support (4).
- Rivet front crossmember support (4) with rivet press tool and blind rivet (5) or blind rivet (5).
Replace self-tapping fillister head screws installed in vehicle by high-strength blind rivets (5) according to clamping range.
- Check weld seam gap.
The weld seam gap must not be larger than 1 mm; if necessary, make an add-on seam weld.
- Tack weld front crossmember support (4) with welder (
) (areas G1, I, G2, G3, G4, H1 and H2).
When MIG welding (
) prepare welds by grinding down to bare metal with stainless steel brush.
 Courtesy of MERCEDES-BENZ USA
|
Weld seams must
be tack welded at start, end and every approx. 4 cm. Welding sequence (G1, I, G2, G3, G4, H1 and H2) must
be complied with.
- Weld front crossmember support (4) with welder (
) (areas G1, I, G2, G3, G4, H1 and H2).