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Rear Longitudinal Member Installation - Ar64.20-P-1200-24ME

Model 167 

IMPORTANT The following operation steps are shown on the left side of the vehicle. In case of damage on the right side of the vehicle, these steps must be performed analogously.

The higher-level service document as well as the safety information in the service document must be observed.

G14791743Courtesy of MERCEDES-BENZ USA
  1. Transfer positions of existing holes in body to rear longitudinal member (1) using drill hole finder (areas A).
  2. Install rear longitudinal member (1), fit and fix in place with straighteners.

    IMPORTANT Helper required.

  3. Drill rivet holes from inside with Ø 6.7 mm through existing holes in body (areas B).
  4. Mark rivet holes through existing holes in body (areas C).
  5. Remove straighteners and rear longitudinal member (1).

    IMPORTANT Helper required.

  6. Predrill rivet holes at positions transferred with drill hole finder in rear longitudinal member (1) with Ø 5 mm (areas A).
  7. Predrill marked rivet holes in rear longitudinal member (1) with Ø 5 mm (areas C).
  8. Install rear longitudinal member (1) and fix in place.

    IMPORTANT Helper required.

  9. Drill predrilled rivet holes in rear longitudinal member (1) with Ø 6.7 mm (areas A, C).
  10. Remove rear longitudinal member (1).

    IMPORTANT Helper required.

  11. Deburr rivet holes on longitudinal member (1) and body on both sides.
  12. Remove drilling chips.
    G14791744Courtesy of MERCEDES-BENZ USA
  13. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and the manufacturer's specifications for the curing and processing time of 2-component adhesive.

    G14791745Courtesy of MERCEDES-BENZ USA
  14. Install rear longitudinal member (1) and fix in place.

    IMPORTANT Helper required.

  15. Rivet rear longitudinal member (1) with rivets Ø 6.5x12.5 (areas D1 ).
  16. Rivet rear longitudinal member (1) with rivets Ø 6.5x14.5 (areas E1 ).
  17. Rivet rear longitudinal member (1) with rivets Ø 6.4 M6 (area F).
  18. Rivet rear longitudinal member (1) from inside with rivets Ø 6.5x12.5 (areas D2 ).
  19. Rivet rear longitudinal member (1) from inside with rivets Ø 6.5x14.5 (areas E2 ).
    G14791746Courtesy of MERCEDES-BENZ USA
  20. Apply 2-component adhesive in cross-hatched areas to longitudinal member connecting part (3).

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G14791747Courtesy of MERCEDES-BENZ USA
  21. Fit mounting support (4) and bracket (5) on longitudinal member connecting part (3) and fix in place.

    IMPORTANT Take over precise positions from old part.

  22. Mounting support (4) and bracket (5) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas H).
    G14791748Courtesy of MERCEDES-BENZ USA
  23. Install, fit and fix in place longitudinal member connecting part (3).
  24. Drill rivet holes with Ø 6.7 mm (areas I1 ).
  25. Drill rivet holes from inside through existing holes in body with Ø 6.7 mm (areas I2 ).
  26. Drill rivet holes with Ø 6.7 mm through existing holes in body (area J1 ).
  27. Drill hole in body for plug welding through one panel thickness with Ø 8 mm (area J2 ).
  28. Remove longitudinal member connecting part (3).
  29. Deburr rivet holes on longitudinal member connecting part (3) and body on both sides.
  30. Remove drilling chips.

    IMPORTANT Observe pretreatment of bonding surfaces.

  31. Coat insides of riveted joints on which no adhesive is applied with zinc dust paint.
    G14791749Courtesy of MERCEDES-BENZ USA
  32. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT In these areas, the 2-component adhesive can be partially stripped off during installation of longitudinal member connecting part. Compensate for this loss by applying multiple layers. Also apply 2-component adhesive to new part.

    Observe pretreatment of bonding surfaces and the manufacturer's specifications for the curing and processing time of 2-component adhesive.

    G14791750Courtesy of MERCEDES-BENZ USA
  33. Install and fix in place longitudinal member connecting part (3).
  34. Rivet longitudinal member connecting part (3) with rivets Ø 6.5x12.5 (areas K).
  35. Rivet longitudinal member connecting part (3) with rivets Ø 6.5x14.5 (areas L1 ).
  36. Rivet longitudinal member connecting part (3) from inside with rivets Ø 6.5x14.5 (area L2 ).
  37. Rivet longitudinal member connecting part (3) with rivets Ø 6.4 M6 (area M1 ).
  38. Longitudinal member connecting part (3) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area M2 ).

    NOTES The new resistance spot welds must be positioned at precisely the same position as the factory resistance spot welds, as these areas were previously bonded (area M2 ).

    Otherwise the required minimum strength of the weld joint is not ensured.

  39. Longitudinal member connecting part (3) SHIELDED GAS PLUG WELD (area M3 ).
    G14791751Courtesy of MERCEDES-BENZ USA
  40. Install, fit and fix in place bracket at its original position.
  41. Drill rivet holes in bracket with Ø 6.7 mm (areas N).
  42. Remove bracket.
  43. Deburr rivet holes on bracket and body on both sides.
  44. Remove drilling chips.
  45. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G14791752Courtesy of MERCEDES-BENZ USA
  46. Install and fix in place bracket.
  47. Rivet bracket with rivets Ø 6.5x12.5 (areas O).
  48. Rivet bracket with rivet Ø 6.5x14.5 (area P).
  49. Bracket SHIELDED GAS PLUG WELD (area Q).
    G14791753Courtesy of MERCEDES-BENZ USA
    G14791754Courtesy of MERCEDES-BENZ USA

    Shown with removed inner side wall 

  50. Transfer positions of existing holes in body with drill hole finder to cover plate (2) (areas R).
  51. Install, fit and fix in place cover plate (2).
  52. Drill rivet holes with Ø 6.7 mm (areas S).
  53. Remove striker plate (2).
  54. Drill rivet holes at positions transferred with drill hole finder in cover plate (2) with Ø 6.7 mm (areas R).
  55. Deburr rivet holes on cover plate (2) and body on both sides.
  56. Remove drilling chips.

    IMPORTANT Observe pretreatment of bonding surfaces.

  57. Coat insides of riveted joints on which no adhesive is applied with zinc dust paint.
    G14791755Courtesy of MERCEDES-BENZ USA

    Shown with removed inner side wall 

  58. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G14791756Courtesy of MERCEDES-BENZ USA

    Shown with removed inner side wall 

  59. Install and fix in place cover plate (2).
  60. Rivet cover plate (2) with rivets Ø 6.4x12 (areas T).
  61. Rivet cover plate (2) with rivets Ø 6.5x12.5 (areas U).
  62. Rivet cover plate (2) with rivets Ø 6.5x14.5 (areas V).
  63. Rivet cover plate (2) with rivets Ø 6.4 M6 (areas W).
  64. Cover plate (2) SHIELDED GAS SEAM WELD (area X).

    IMPORTANT Perform inert gas welding at intervals and allow to cool down in between.

    This reduces heat distortion.

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