Front Longitudinal Member Partial Installation - Ar62.20-P-1255-03S

Model 223.0/1/9 

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Countersunk-head rivet (Z) 

• Z₁ = Countersunk-head rivet 6.4x14.0
• Z₂ = Countersunk-head rivet 6.4x15.5
• Z₃ = Countersunk-head rivet 6.4x17.0
• Z₄ = Countersunk-head rivet 6.4x19.0
• Z₅ = Countersunk-head rivet 6.4x21.0

Blind rivet (Y) 

• Y₁ =Blind rivet 6.4x12.0
• Y₂ = Blind rivet 6.5x12.5
• Y₃ = blind rivet 6.5x14.5
• Y₄ =Blind rivet 6.4 M6
• Y₅ = blind rivet 6.4
• Y₆ = blind rivet 6.5X13.5
• Y₇ =Blind rivet 6.4x14.0
• Y₈ =Blind rivet 6.4x17.0
• Y₉ =Blind rivet 6.4x20

Flow-form rivet with countersunk head (X) 

• X₁ = Flow-form rivet with countersunk head 1.3 mm to 2.5 mm clamping range
• X₂ = Flow-form rivet with countersunk head 2.3 mm to 3.5 mm clamping range
• X₃ = Flow-form rivet with countersunk head 3.35 mm to 4.1 mm clamping range
• X₄ = Flow-form rivet with countersunk head 4 mm to 5.15 mm clamping range
• X₅ = Flow-form rivet with countersunk head 5.0 mm to 6.1 mm clamping range
• X₆ = Flow-form rivet with countersunk head 6.0 mm to 7.2 mm clamping range
• X₇ = Flow-form rivet with countersunk head 7.1 mm to 8.3 mm clamping range

Flow-form rivet (W) 

• W₁ = Structured flow form rivet with 3.5 mm clamping range
• W₃ = Flow-form rivet structure 3.35 mm up to 4.1 mm clamping range
• W₄ = Flow-form rivet structure 4 mm up to 5.15 mm clamping range
• W₅ = Flow-form rivet structure 5.0 mm up to 6.1 mm clamping range
• W₆ = Flow-form rivet structure 6.0 mm up to 7.2 mm clamping range
• W₇ = Flow-form rivet structure 7.1 mm up to 8.3 mm clamping range

Blind rivet (V) 

• V1 = rivet 3.2x4.5
• V2 = rivet 3.2x6.5

Blind rivet (U) 

• U1 = rivet 3.2x9.5

Blind rivet with countersunk head (T) 

• T1 = Blind rivet with countersunk head with 3.0 mm to 5.0 mm clamping range
• T2 = Blind rivet with countersunk head with 1.5 mm to 3.0 mm clamping range

The next steps are shown on the left side of the vehicle for model 223.1 and must be performed in the same way on the right side of the vehicle in the event of damage.

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

The graphics show the vehicle from the mechanic's perspective. At the same time, this perspective also specifies the direction in which the rivets must be placed.

1. Transfer existing holes in body to front longitudinal member (1) using drill hole finder (areas A, D).
2. Install front longitudinal member (1), fit, and fix in place.
3. Drill rivet holes in front longitudinal member (1) with a Ø 6.7 mm bit (areas A, B, C, D).

   Drill rivet holes through existing holes in body (area B).

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4. Drill rivet holes in front longitudinal member (1) with a Ø 6.7 mm bit (areas E, F).

   Drill rivet holes through present holes in body (areas E).

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   Courtesy of MERCEDES-BENZ USA

5. Install rear longitudinal member (2), fit and fix in place.
6. Drill rivet holes in rear longitudinal member (2) with a Ø 6.7 mm bit (area F).

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7. Drill rivet holes in rear longitudinal member (2) with a Ø 6.7 mm bit (areas G, H).

   Drill rivet holes through existing holes in body (area H).

8. Remove front longitudinal member and rear longitudinal member (2).
9. Deburr rivet holes on front longitudinal member, rear longitudinal member (2), and body on both sides.
10. Remove drill chips.

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11. Apply 2-component adhesive to body in cross-hatched areas.

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

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12. Apply 2-component adhesive in cross-hatched areas on front longitudinal member (1).

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

13. Install front longitudinal member (1) and fix in place.
14. Rivet front longitudinal member (1) with Ø 6.5x12.5 rivets (areas Y₂ ).
15. Rivet front longitudinal member (1) with Ø 6.5x14.5 rivets (area Y₃ ).

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16. Rivet front longitudinal member (a1) with Ø 6.4x12.0 rivets (area Y₁ ).
17. Rivet front longitudinal member (1) with Ø 6.5x12.5 rivets (areas Y₂ ).
18. Rivet front longitudinal member (1) with Ø 6.5x14.5 rivets (areas Y₃ ).

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    Courtesy of MERCEDES-BENZ USA

19. Apply 2-component adhesive to body in cross-hatched areas.

    Apply 2-component adhesive to inside (area J). Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

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20. Install rear longitudinal member (2) and fix in place.
21. Rivet rear longitudinal member (2) with Ø 6.4x12.0 rivets (areas Y₁ ).
22. Rivet rear longitudinal member (2) with Ø 6.5x12.5 rivets (areas Y₂ ).

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23. Rivet rear longitudinal member with Ø 6.4x12.0 rivets (areas Y₁ ).
24. Rivet rear longitudinal member and front longitudinal member with Ø 6.5x12.5 rivets (areas Y₂ ).
25. Rivet rear longitudinal member and front longitudinal member (1) with Ø 6.5x14.5 rivets (areas Y₃ ).