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Home >> Mercedes Benz >> 2021 >> E450 Base, 2D Convertible >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Collision - Front End And Fire Wall (238 Chassis) >> Front End And Fire Wall Body Repair >> Remove/Install Headlamp Support With CROSSMEMBER And Upper Frame CROSSMEMBER - Ar62.30-P-2200LWO

Remove/Install Headlamp Support With CROSSMEMBER And Upper Frame CROSSMEMBER - Ar62.30-P-2200LWO

Model 238 

MODIFICATION NOTES

03.05.2022 Document reference added Operation step 23  
Fig 1: Headlamp Support, Crossmember, Upper Frame Crossmember And Adjacent Component Locations (Model 238)
G15378328Courtesy of MERCEDES-BENZ USA
G15378329Courtesy of MERCEDES-BENZ USA
G15378330Courtesy of MERCEDES-BENZ USA
G15378331Courtesy of MERCEDES-BENZ USA
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
CAUTION Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.		 AS00.00-Z-0017-01A
REMOVING Remove     
1 Remove detachable parts in area of repair point.    
2 Unscrew bolts (11, 12) on left and right at upper crossmember (1).    
3 Remove expansion rivet (15) on left and right at upper crossmember (1).    
4 Unscrew bolts (14) on left and right at lower impact absorbers (7).    
5 Unscrew bolts (13) on left and right at upper impact absorbers (5).    
6.1 Remove upper crossmember (1) with lower crossmember (3), headlamp mounts (4), upper impact absorbers (5), lower impact absorbers (7), cross strut (2), struts (9), struts (6) and lock striker (8). Model 238 except code 239 (Adaptive cruise control Pro (DISTRONIC PRO)) except code 23P (Drive package)
IMPORTANT Aid of helper required.		  
6.2 Remove upper crossmember (1) with lower crossmember (3), headlamp mounts (4), upper impact absorbers (5), lower impact absorbers (7), cross strut (2), struts (9), struts (6), bracket (10) and lock striker (8). Model 238 with code 239 (Adaptive cruise control Pro (DISTRONIC PRO))
Model 238 with code 23P (Drive package)
IMPORTANT Aid of helper required.		  
INSTALLING Install     
7 Install lower impact absorbers (7) on left and right and screw in bolts (14) until in contact. IMPORTANT Do not yet tighten bolts (14).  
8 Install upper impact absorbers (5) on left and right and screw in bolts (13) until in contact. IMPORTANT Do not yet tighten bolts (13).  
9 Install lower crossmember (3).    
10 Install upper crossmember (1) and screw in bolts (11, 12 and 19) on left and right until in contact. IMPORTANT Do not yet tighten bolts (11, 12 and 19).  
11 Install expansion rivet (15) on left and right at upper crossmember (1).    
12 Install struts (6) on left and right and screw in bolts (16) until in contact. IMPORTANT Do not yet tighten bolts (16).  
13 Tighten bolts (14) on left and right. TORQUE SPECIFICATION Bolt, soundproofing to front axle carrier *BA62.30-P-1006-01H 
14 Tighten bolts (13) on left and right. TORQUE SPECIFICATION Bolt, insulation to longitudinal member *BA62.30-P-1005-01H 
15 Tighten bolts (11, 12 and 19) on left and right. TORQUE SPECIFICATION Bolt, front module carrier to cross member *BA62.30-P-1010-01H 
    TORQUE SPECIFICATION Bolt, cross member to soundproofing *BA62.30-P-1001-01H 
    TORQUE SPECIFICATION Screw, front module carrier/cross strut to body/angle bracket for front module carrier *BA62.30-P-1007-01H 
16 Tighten bolts (16) on left and right. TORQUE SPECIFICATION Bolt, strut to cross member *BA62.30-P-1003-01H 
    TORQUE SPECIFICATION Bolt, strut to soundproofing *BA62.30-P-1004-01H 
17 Install struts (9) on left and right and tighten bolts (17).    
18 Install cross strut (2) and tighten screw (20) on left and right.    
19 Install lock striker (8) and tighten bolts (18). TORQUE SPECIFICATION Bolt, lock striker to cross member/front-module carrier *BA62.30-P-1008-01H 
20 Install headlamp mounts (4) on left and right and tighten bolts (21). TORQUE SPECIFICATION Bolt, headlamp support to cross member *BA62.30-P-1002-01H 
21 Install bracket (10) and tighten screws (22). Model 238 with code 239 (Adaptive cruise control Pro (DISTRONIC PRO))
Model 238 with code 23P (Drive package)		  
22 Adjust height of hood via nuts (23) at left and right hood catch upper part (24) so that flush with left and right fender.    
23 Apply wax at connections to body.   AR97.20-P-1500LWO
24 Reinstall all detachable parts in area of repair point.    
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 238
BA62.30-P-1001-01H Bolt, cross member to soundproofing M10 Stage 1 Left side Nm 28
Right side Nm 35
Stage 2 ∠° 135
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 238
BA62.30-P-1002-01H Bolt, headlamp support to cross member M6 Nm 8
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 238
BA62.30-P-1003-01H Bolt, strut to cross member M8 Nm 20
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 238
BA62.30-P-1004-01H Bolt, strut to soundproofing M8 Nm 23
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 238
BA62.30-P-1005-01H Bolt, insulation to longitudinal member M12 Stage 1 Nm 90
Stage 2 ∠° 90
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 238
BA62.30-P-1006-01H Bolt, soundproofing to front axle carrier M8 Nm 23
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 238
BA62.30-P-1007-01H Screw, front module carrier/cross strut to body/angle bracket for front module carrier Nm 11
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 238
BA62.30-P-1008-01H Bolt, lock striker to cross member/front-module carrier Nm 10
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 238
BA62.30-P-1010-01H Bolt, front module carrier to cross member M6 Nm 8
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