Rear Longitudinal Member Section Installation - Ar64.20-P-1260-03RG

	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.

The following operation steps are shown on the left side of the vehicle. In case of damage, these steps must be similarly performed on the right side of the vehicle. Replace flow drill bolts and self-tapping fillister head bolts installed in vehicle by high-strength rivets according to clamping range. Always  maintain welding sequence according to operation steps.

1. Insert inner shoe (2) into remaining section of rear longitudinal member (1) present on vehicle.

   Measure insertion depth (b) from edge toward front.

   Courtesy of MERCEDES-BENZ USA

2. Install new rear longitudinal member part (1a) and fit with straightening set.
3. Check weld seam gaps.

   Check all weld seam gaps before start of welding. The individual weld seam gap may not be greater than 1 mm, where required use a body weld.

4. Fix new rear longitudinal member part (1a).
5. Drill rivet hole in front floor (7) with ø 6.7 mm (area O).

   Transfer holes present in vehicle for flow drill bolts and selftapping fillister head bolts to new part.

   Shown on model 190.3 

   Courtesy of MERCEDES-BENZ USA

6. Adapt rear bottom end plate (6) to rear longitudinal member (1) and fix in place.
7. Drill rivet holes in rear longitudinal member (1) with ø 6.7 mm (area I).

   Transfer holes present in vehicle for flow drill bolts and selftapping fillister head bolts to new part. In the case of new part to new part connections, adapt these and drill together.

8. Remove drilling shavings with wet/dry vacuum cleaner.

   Shown on model 190.3 

   Courtesy of MERCEDES-BENZ USA

9. Install front floor section (7a), fit and fix in place.
10. Drill rivet holes in front floor section (7a) with ø 6.7 mm (area J).

    Transfer holes present in vehicle for flow drill bolts and selftapping fillister head bolts to new part. In the case of new part to new part connections, adapt these and drill together.

11. Remove front floor section (7a).

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

12. Remove new rear longitudinal member part (1a) and straightening set.
13. Remove inner shoe (2).
14. Deburr rivet holes at rear longitudinal member (1), front floor section (7a), inner shoe (2) and body on both sides.

    Observe pretreatment of bonding surfaces.

15. Remove shavings using wet/dry vacuum cleaner.
16. In inner shoe beading (2) apply the 2-component adhesive.

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

17. Insert inner shoe (2) into remaining section of rear longitudinal member (1) present on vehicle.

    Remove escaping 2-component adhesive. Otherwise, weld seam cannot be carried out in area.

    Measure insertion depth (b) from edge toward front.

    Courtesy of MERCEDES-BENZ USA

18. Install new rear longitudinal member part (1a), fit with straightening set and fix.

    Remove escaping 2-component adhesive. Otherwise, weld seam cannot be carried out in area.

19. Rivet remaining section of rear longitudinal member (1) and inner shoe (2) with rivet press tool and blind rivet or blind rivet (area Q).

    Use 6.5x12.5 (Klemmbereich 2 mm up to 5 mm, mi n. draw-off strength 19 kN) or 6.5x14.5 blind rivets (Klemmbereich 4 mm up to 7 mm, mi n. draw-off strength 19 kN).

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

20. On rear longitudinal member (1), apply the 2-component adhesive (cross-hatched areas).

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

21. Fix rear bottom end plate (6) to rear longitudinal member (1).
22. Rivet lower rear end plate (6) with rivet press tool and blind rivets or blind rivet (area I1).

    Use 6.5x12.5 (Klemmbereich 2 mm up to 5 mm, min. draw-off strength 19 kN) or 6.5x14.5 blind rivets (Klemmbereich 4 mm up to 7 mm, mi n. draw-off strength 19 kN).

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

23. On front floor section (7a) apply the 2-component adhesive (crosshatched areas).

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

24. Install front floor section (7a), fit and fix in place.
25. Rivet front floor section (7a) with rivet press tool and blind rivets or blind rivet (area J1).

    Use 6.5x12.5 (Klemmbereich 2 mm up to 5 mm, min. draw-off strength 19 kN) or 6.5x14.5 blind rivets (Klemmbereich 4 mm up to 7 mm, min. draw-off strength 19 kN).

26. Tack weld front floor section (7a) to crossmember with welder ( ) (area K).

    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.

27. Tack weld front floor section (7a) to front floor (7) with welder ( ) (area L).

    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.

28. Weld front floor section (7a) with welder ( ) (areas K and L).

    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

29. Tack weld rear longitudinal member (1) with welder ( ) (area A).

    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.

30. Weld rear longitudinal member (1) all the way around with welder ( ) (area A).

    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

31. Tack weld rear longitudinal member (1) with welder ( ) (areas B and 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.

32. Weld rear longitudinal member (1) with welder ( ) (areas B and 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.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

33. Tack weld rear longitudinal member (1) with welder ( ) (areas D and 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.

34. Weld rear longitudinal member (1) with welder ( ) (areas D and 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.

    Shown on model 190.3 

    Courtesy of MERCEDES-BENZ USA

35. Tack weld rear longitudinal member (1) with welder ( ) (areas F to H).

    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.

36. Weld rear longitudinal member (1) with welder ( ) (areas F to H).

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