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Headlamp Support With CROSSMEMBER And Upper Frame CROSSMEMBER Removal And Installation - Ar62.30-P-2200FR

Model 257, 290 

MODIFICATION NOTES

03.05.2022 Document references added Operation step 28  

Shown on model 257 with code 233 (DISTRONIC PLUS) 

G16555074Courtesy of MERCEDES-BENZ USA
G16555075Courtesy of MERCEDES-BENZ USA

Shown on model 257 on right side of vehicle 

Shown on model 257 with code 239 (DISTRONIC PRO) 

G16555076Courtesy of MERCEDES-BENZ USA
G16555077Courtesy of MERCEDES-BENZ USA

Shown on model 290 with code 233 (DISTRONIC PLUS) 

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 crossmember (1).    
3 Remove expansion rivet (15) on left and right of crossmember (1). Model 257  
4 Unscrew bolts (14) on left and right at impact absorbers (7). IMPORTANT Model 290
3 screws (14) are installed.		  
5 Unscrew bolts (13) on left and right at impact absorbers (5).    
6.1 Remove the crossmembers (1, 3) with the brackets (4, 25), the impact absorbers (5, 7), the cross strut (2), the struts (6, 9, 28), and the lock striker (8). Model 257
except code 233 (Adaptive cruise control Plus (DISTRONIC PLUS))
except code 239 (Adaptive cruise control Pro (DISTRONIC PRO))
Model 290
except code 233 (Adaptive cruise control Plus (DISTRONIC PLUS))
IMPORTANT Aid of helper required.		  
6.2 Remove the crossmembers (1, 3) with the brackets (4, 10, 25), the impact absorbers (5, 7), the cross strut (2), the struts (6, 9, 28), and the lock striker (8). Model 257, 290
with code 233 (Adaptive cruise control Plus (DISTRONIC PLUS))
Model 257
with code 239 (Adaptive cruise control Pro (DISTRONIC PRO))
IMPORTANT Aid of helper required.		  
INSTALLING Install     
Notice  Notes on threaded connections fastened using a tightening angle-based tightening process   AH00.00-P-0020-01A
7 Install impact absorbers (7) on left and right and screw in bolts (14) until in contact. IMPORTANT Model 290
3 screws (14) are installed.
IMPORTANT Do not yet tighten bolts (14).		  
8 Install impact absorbers (5) on left and right and screw in bolts (13) until in contact. IMPORTANT Do not yet tighten bolts (13).  
9 Install the crossmember (3).    
10 Install crossmember (1) and screw in bolts (11, 12, 19) on left and right until in contact. IMPORTANT Do not yet tighten bolts (11, 12, 19).  
11 Install expansion rivet (15) on left and right of crossmember (1). Model 257  
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. IMPORTANT Model 290
3 screws (14) are installed.
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 (19) on left and right. TORQUE SPECIFICATION Bolt, cross member to soundproofing *BA62.30-P-1001-01H 
16 Tighten bolts (11, 12) on left and right. TORQUE SPECIFICATION Screw, front module carrier/cross strut to body/angle bracket for front module carrier *BA62.30-P-1007-01H 
17 Tighten screws (27) on left and right. TORQUE SPECIFICATION Bolt, front module carrier to cross member *BA62.30-P-1010-01H 
18 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 
19 Install struts (28) on left and right and tighten screws (29). Model 290
TORQUE SPECIFICATION Bolt, strut to cross member		 *BA62.30-P-1003-01H 
20 Install struts (9) on left and right and tighten bolts (17). TORQUE SPECIFICATION Bolt, strut to cross member *BA62.30-P-1003-01H 
21 Install cross strut (2) and tighten screw (20) on left and right.    
22 Tighten screw (30). Model 290  
23 Install lock striker (8) and tighten bolts (18). TORQUE SPECIFICATION Bolt, lock striker to cross member/front module carrier *BA62.30-P-1008-01H 
24 Install brackets (4) on left and right and tighten bolts (21). TORQUE SPECIFICATION Bolt, headlamp support to cross member *BA62.30-P-1002-01H 
25 Install brackets (25) on left and right and fasten with rivets (26).
General information on riveting		 IMPORTANT Model 290
4 rivets (26) are installed.		 AH60.00-P-0003-01N
    Blind rivet 6.4x14 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN) *BR00.45-Z-1001-13A 
26 Install bracket (10) and tighten screws (22). Model 257, 290
with code 233 (Adaptive cruise control Plus (DISTRONIC PLUS))
Model 257
with code 239 (Adaptive cruise control Pro (DISTRONIC PRO))		  
27 Adjust height of hood in relation to left and right fender.   AR88.40-P-3020FR
28 Apply wax at connections to body. Model 257 AR97.20-P-1500FR
    Model 290 AR97.20-P-1500FRX
29 Reinstall detachable parts in area of repair point.    
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 257 Model 290
BA62.30-P-1001-01H Bolt, cross member to soundproofing M10 Stage 1 Left side Nm 28 28
Right side Nm 35 35
Stage 2   ∠° 135 135
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 257 Model 290
BA62.30-P-1002-01H Bolt, headlamp support to cross member M6 Nm 10 10
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 257 Model 290
BA62.30-P-1003-01H Bolt, strut to cross member M8 Nm 20 20
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 257 Model 290
BA62.30-P-1004-01H Bolt, strut to soundproofing M8 Nm 20 20
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 257 Model 290
BA62.30-P-1005-01H Bolt, insulation to longitudinal member M12 Stage 1 Nm 90 90
Stage 2 ∠° 90 90
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 257 Model 290
BA62.30-P-1006-01H Bolt, soundproofing to front axle carrier M8 Nm 20 23
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 257 Model 290
BA62.30-P-1007-01H Screw, front module carrier/cross strut to body/angle bracket for front module carrier Nm 11 11
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 257 Model 290
BA62.30-P-1008-01H Bolt, lock striker to cross member/front-module carrier Nm 10 10
CROSS MEMBER AND FRONT REINFORCEMENT

Number Designation Model 257 Model 290
BA62.30-P-1010-01H Bolt, front module carrier to cross member M6 Nm 8 8
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1001-13A Blind rivet 6.4x14 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN) A 003 990 35 97
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