Outer Longitudinal Member Shell On Entrance Removal - Ar63.30-P-1102-01FR

Model 257, 290 

The following operation steps are shown on the left side of the vehicle on model 257. In case of damage on the right side of the vehicle, these steps must be performed analogously.

Additional information can be found in the superordinate service document.

The safety information in the superordinate service document must be observed.

Courtesy of MERCEDES-BENZ USA

1. Mark separating points on longitudinal member outer shell (1) and separate according to damage (area A), (areas A, B), (areas A, C), (areas B, C), or (area C).

   Do not make the cuts too deep.

   Otherwise the components below can be damaged and weakened.

   Mark separating point along Y-marking (areas B, C).

   Dimensions: 

   a = approx. 27 mm

2. Expose spot welds on longitudinal member outer shell (1) and cut out (areas D, D₁ , E).

   Joint spot welds on panels that are one behind the other must be cut out through two panel thicknesses.

3. Heat section (2) in crosshatched area.

   Crosshatched area is bonded.

4. Remove section (2).

   Courtesy of MERCEDES-BENZ USA

   Courtesy of MERCEDES-BENZ USA

5. Expose spot welds on longitudinal member outer shell (1) and cut out (areas F and F₁ ).

   Joint spot welds on panels that are one behind the other must be cut out through two panel thicknesses.

6. Expose spot welds on longitudinal member outer shell (1) and cut out (areas G, G₁ ).

   Courtesy of MERCEDES-BENZ USA

   Courtesy of MERCEDES-BENZ USA

7. Expose spot welds and cut out from inside through opening in A-pillar (area H).

   Courtesy of MERCEDES-BENZ USA

8. Expose spot welds on inside longitudinal member outer shell and drill through with 6.5 mm bit (area J).

   Courtesy of MERCEDES-BENZ USA

9. Heat longitudinal member outer shell in crosshatched areas.

   Cross-hatched areas are bonded with adhesive.

10. Remove longitudinal member outer shell.

    Courtesy of MERCEDES-BENZ USA

11. Sand down mating surfaces to bare metal in cross-hatched areas.

    Sand down spot weld flanges to bare metal on both sides.

12. Remove grinding dust and drill chips.
13. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas K).

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

14. Grind mating surfaces down to bare metal in crosshatched area from inside.

    Do not coat bonding surface with zinc dust paint.

    Otherwise adhesion problems may occur.

    Observe preliminary treatment of bonding surface.

    Courtesy of MERCEDES-BENZ USA