Outer Longitudinal Member Shell On Entrance Installation - Ar63.30-P-1102-03RG

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

Model 190 

Fig 1: Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

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 and self-tapping fillister head screws as well as self-pierce rivets installed on the vehicle with high-strength rivets in accordance with the clamping range.

1. Install and fit new outer side longitudinal member part (1) and longitudinal member panel.
2. Check and adjust gap dimension using feeler gauge.
3. Fix in place new outer side longitudinal member part (1).
4. Remove longitudinal member panel.
5. Drill rivet holes in outer side longitudinal member (1) with ø 6.5 mm (areas C1 and D1).

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

6. Drill rivet holes in outer side longitudinal member (1) with ø 6.5 mm (area F1).

   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.

7. Prepare the outer side longitudinal member (1) with a rivet press tool (area E1).

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

8. Remove the outer side longitudinal member (1).
9. Deburr rivet holes at outer side longitudinal member (1) and body on both sides (areas C1, D1 and F1).

   Observe pretreatment of bonding surfaces and weld joints.

10. Remove shavings using wet/dry vacuum cleaner.
11. On outer side longitudinal member (1), apply the 2-component adhesive (cross-hatched areas).

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

    Courtesy of MERCEDES-BENZ USA

12. Install the outer side longitudinal member (1), fit and fix in place.
13. Rivet outer side longitudinal member (1) using rivet press tool and flow-form rivets or flow-form rivets (area E2).

    Use flow-form rivets with structure 5.0 mm to 6.1 mm clamping range (S48) or flow-form rivets with structure 7.1 mm to 8.3 mm clamping range (S68).

14. Rivet outer side longitudinal member (1) using rivet press tool and Riveting the blind rivets (areas C2, D2 and F2).

    Use blind rivets with 6.4x15.5 countersunk head (Klemmbereich 3 mm up to 5 mm, mi n. draw-off strength 15.5 kN).

15. Tack weld outer side longitudinal member (1) with welder ( ) (areas A2 and B2).

    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.

16. Check weld seam gaps.

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

17. Weld outer side longitudinal member (1) with welder ( ) (areas A2 and B2).

    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.

18. Level welds at outer side longitudinal member (1) and restore surface (areas A2 and B2).
19. Remove shavings using wet/dry vacuum cleaner.

    Shown on model 190.4 

    Courtesy of MERCEDES-BENZ USA

20. Foam B-pillar above opening (area K) with 2K-filler foam.

    Fill half of a spray can of 2K-filler foam into each side of the vehicle.

    Courtesy of MERCEDES-BENZ USA