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Side Longitudinal Member Installation - Ar63.30-P-0800-03RG

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

Model 190 

GAP DIMENSIONS

Number Designation Model 190.3 Model 190.4
BE60.00-P-1007-01EA Gap dimension, fender to door paneling Dimension "G" mm 4 (±0, 5) 4 (±0, 5)
See   AR60.00-P-0700-01RG AR60.00-P-0700-01RG
GAP DIMENSIONS

Number Designation Model 190.3 Model 190.4
BE60.00-P-1008-01EA Gap dimension, sidewall panel to door paneling Dimension "H" mm 3, 5 (±0, 5) 3, 5 (±0, 5)
See   AR60.00-P-0700-01RG AR60.00-P-0700-01RG
GAP DIMENSIONS

Number Designation Model 190.3 Model 190.4
BE60.00-P-1009-01EA Gap dimension, longitudinal member panel to fender/sidewall panel Dimension "I" mm 0 (+0, 5) 0, 5 (±0, 5)
See   AR60.00-P-0700-01RG AR60.00-P-0700-01RG
Fig 1: Feeler Gauge (129 589 03 21 00)
G07469060Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1045-13A Blind rivet Y7 6.4x14 (clamping range 2.6 mm to 6 mm, draw-off strength min. 15.5 kN) A 000 991 55 32
BR00.45-Z-1046-13A Blind rivet Y8 6.4x17 (clamping range 4.5 mm to 7 mm, draw-off strength min. 15.5 kN) A 000 991 53 32
BR00.45-Z-1054-13A Flow-form rivet structure 7.1 mm up to 8.3 mm clamping range (S68) A 000 991 29 33
BR00.45-Z-1162-02A Parts kit for 2-component adhesive for body A 012 989 17 71

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

IMPORTANT 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 align the new side longitudinal member part (1) and A-pillar reinforcement with the straightening set.
  2. Install new parts B-pillar with lock wedge, A-pillar outer section with door, fender and longitudinal member panel and fit.
  3. Check gaps using SPECIAL TOOL feeler gauge and adjust. HAND-HELD TESTERHAND-HELD TESTERHAND-HELD TESTER
  4. Check weld seam gaps.

    IMPORTANT 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.

  5. Fix the new side longitudinal member part (1).
  6. Remove the longitudinal member panel, fender, door, A-pillar outer section, lock wedge, B-pillar and A-pillar reinforcement.
    G16678192Courtesy of MERCEDES-BENZ USA

    Shown on model 190.3 

  7. Drill rivet holes on the side longitudinal member (1) with a diameter of ø 6.5 mm (areas A1 to A5).

    IMPORTANT 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. Prepare side longitudinal member (1) with rivet press tool (area A6).

    IMPORTANT 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.

  9. Remove drilling shavings with wet/dry vacuum cleaner.
    G16678193Courtesy of MERCEDES-BENZ USA

    Shown on model 190.3 

  10. Install rear longitudinal member striker plate (4), fit and fix in place.
  11. Drill rivet holes on the rear longitudinal member striker plate (4) with a diameter of ø 6.5 mm (area A13).

    IMPORTANT Transfer the existing holes for the flow drill and self-tapping fillister head screws and the riveted joints in the vehicle to the new part. In the case of new part to new part connections, adapt these and drill together.

  12. Remove rear longitudinal member striker plate (4).
  13. Remove side longitudinal member (1).
  14. Deburr rivet holes on rear longitudinal member striker plate (4), side longitudinal member (1) and body on both sides.

    IMPORTANT Observe pretreatment of bonding surfaces.

  15. Remove shavings using wet/dry vacuum cleaner.
  16. On body apply the 2-component adhesive (cross-hatched areas).

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

    Shown on model 190.3 

    G16678194Courtesy of MERCEDES-BENZ USA
    G16678195Courtesy of MERCEDES-BENZ USA
  17. Install side longitudinal member (1), fit with straightening tool and fix in place.
  18. Rivet side longitudinal member (1) using rivet press tool and flow-form rivets (area A7).

    IMPORTANT Use flow-form rivet with structure 7, 1 mm to 8.3 mm clamping range (S68).

  19. Rivet side longitudinal member (1) using rivet press tool and Rivet the blind rivet (areas A8 to A12).

    IMPORTANT Use blind rivets 6.4x17 (Klemmbereich 4.5 mm up to 7 mm, draw-off strength min. 15.5 kN).

    G16678196Courtesy of MERCEDES-BENZ USA

    Shown on model 190.3 

  20. Tack the side longitudinal member (1) with the welder (SHIELDED GAS PLUG WELD ) (areas B1 and B2).

    IMPORTANT When MIG welding (SHIELDED GAS PLUG WELD ) 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.

  21. Check weld seam gaps.

    IMPORTANT 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.

  22. Weld the side longitudinal member (1) with the welder (SHIELDED GAS SEAM WELD ) (areas B1 and B2).

    IMPORTANT When MIG welding (SHIELDED GAS SEAM WELD ), 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.

    G16678197Courtesy of MERCEDES-BENZ USA

    Shown on model 190.3 

  23. Tack the side longitudinal member (1) with the welder (SHIELDED GAS PLUG WELD ) (areas B3, B4 and B5).

    IMPORTANT When MIG welding (SHIELDED GAS PLUG WELD ) 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.

  24. Check weld seam gaps.

    IMPORTANT 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.

  25. Weld the side longitudinal member (1) with the welder (SHIELDED GAS SEAM WELD ) (areas B3, B4 and B5).

    IMPORTANT When MIG welding (SHIELDED GAS SEAM WELD ), 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.

    G16678198Courtesy of MERCEDES-BENZ USA

    Shown on model 190.3 

  26. Tack the side longitudinal member (1) with the welder (SHIELDED GAS PLUG WELD ) (areas B6 to B9).

    IMPORTANT When MIG welding (SHIELDED GAS PLUG WELD ) 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. Check weld seam gaps.

    IMPORTANT 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.

  28. Weld the side longitudinal member (1) with the welder (SHIELDED GAS SEAM WELD ) (areas B6 to B9).

    IMPORTANT When MIG welding (SHIELDED GAS SEAM WELD ), 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.

    G16678199Courtesy of MERCEDES-BENZ USA

    Shown on model 190.3 

  29. Tack the side longitudinal member (1) with the welder (SHIELDED GAS PLUG WELD ) (areas B10 to B13).

    IMPORTANT When MIG welding (SHIELDED GAS PLUG WELD ) 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. Check weld seam gaps.

    IMPORTANT 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.

  31. Weld the side longitudinal member (1) with the welder (SHIELDED GAS SEAM WELD ) (areas B10 to B13).

    IMPORTANT When MIG welding (SHIELDED GAS SEAM WELD ), 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.

  32. Level the welds on the side longitudinal member (1) (areas B10 to B13).
  33. Remove shavings using wet/dry vacuum cleaner.
    G16678200Courtesy of MERCEDES-BENZ USA

    Shown on model 190.3 

  34. Tack the side longitudinal member (1) with the welder (SHIELDED GAS PLUG WELD ) (areas B14 and B15).

    IMPORTANT When MIG welding (SHIELDED GAS PLUG WELD ) 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.

  35. Check weld seam gaps.

    IMPORTANT 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.

  36. Weld the side longitudinal member (1) with the welder (SHIELDED GAS SEAM WELD ) (areas B14 and B15).

    IMPORTANT When MIG welding (SHIELDED GAS SEAM WELD ), 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.

  37. Level welds on side longitudinal member (1) (area B15).
  38. Remove shavings using wet/dry vacuum cleaner.
  39. Install bracket (6), fit and fix in place.
  40. Tack the holder (6) with the welder (SHIELDED GAS PLUG WELD ) (areas C1, C2 and C3).

    IMPORTANT When MIG welding (SHIELDED GAS PLUG WELD ) 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.

  41. Check weld seam gaps.

    IMPORTANT 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.

    G16678201Courtesy of MERCEDES-BENZ USA
  42. Weld the holder (6) with the welder (SHIELDED GAS SEAM WELD ) (areas C1, C2 and C3).

    IMPORTANT When MIG welding (SHIELDED GAS SEAM WELD ), 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 

  43. On the rear longitudinal member striker plate (4), apply the 2- component adhesive (crosshatched areas).

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

  44. Rivet rear longitudinal member striker plate (4) with rivet press tool and blind rivets (area D).

IMPORTANT Use blind rivets 6.4x14 (Klemmbereich 2.6 mm up to 6 mm, d raw-off strength min. 15.5 kN).

Shown on model 190.3 

G16678202Courtesy of MERCEDES-BENZ USA
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