Suspension Strut Tower Installation - Ar62.20-P-1232-04S

Model 223.0/1/9 

14.04.2021

Method modified.

Operation step 33

The following operation steps are shown on model 223.1 on the left side of the vehicle and must be similarly performed 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 view also specifies in what direction the rivets must be set.

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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 = Rivet 6.4x12
• Y₂ = Rivet 6.5x12.5
• Y₃ = Rivet 6.5x14.5
• Y₄ = Rivet 6.4 M6
• Y₅ = Rivet 6.4
• Y₆ = rivet 6.5x13.5
• Y₇ = rivet 6.4x14
• Y₈ = rivet 6.4x17
• Y₉ = rivet 6.4x20

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

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

Welding variants 

• EE = MIG seam weld
• FF = MIG plug weld

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1. Install suspension strut tower (1), fit and fix in place with straightener.
2. Install, fit and fix in place rear mounting support (2) and front mounting support (3).
3. Drill rivet holes in suspension strut tower (1), rear mounting support (2) and front mounting support (3) with Ø 6.7 mm (areas A, B).

   Embossing points on rear mounting support (2) and front mounting support (3) must be surface ground before drilling holes.

4. Countersink rivet holes (areas B).
5. Drill holes for threaded connections in rear mounting support (2) with Ø 6 mm (area C).

   For the subsequent setting of the countersunk-head rivet nuts and/or the establishment of the threaded connection, drill through longitudinal member and suspension strut tower (1).

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6. Drill rivet holes in suspension strut tower (1) with Ø 6.7 mm (areas D, E, F).

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

7. Countersink rivet hole (area F).
8. Remove suspension strut tower (1).
9. Drill rivet holes in rear mounting support (2) with Ø 6.7 mm (areas G).
10. Drill holes for threaded connections in rear mounting support (2) and front mounting support (3) with Ø 6 mm (areas H).

    For the subsequent setting of the countersunk-head rivet nuts, drill through longitudinal member.

11. Remove rear mounting support (2) and front mounting support (3).
12. Deburr rivet holes and holes for threaded connections at suspension strut tower, rear mounting support (2), front mounting support (3) and body on both sides.

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13. Remove drilling chips.
14. Drill and countersink previously drilled holes for threaded connections with Ø 8 mm (areas J) for the setting of the countersunk-head rivet nuts.

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15. Set countersunk-head rivet nuts M6x16.5 (areas K).

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16. 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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17. 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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18. Apply 2-component adhesive to rear mounting support (2) in cross-hatched areas.

    During installation of suspension strut tower, the 2-component adhesive is partially stripped off (area L). This must be compensated for by applying additional adhesive. Also apply 2-component adhesive in corresponding area to suspension strut tower.

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

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19. Apply 2-component adhesive to front mounting support (3) in cross-hatched areas.

    During installation of suspension strut tower, the 2-component adhesive is partially stripped off (area M). This must be compensated for by applying additional adhesive. Also apply 2-component adhesive in corresponding area to suspension strut tower.

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

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20. Install and fix in place rear mounting support (2) and front mounting support (3).
21. Install suspension strut tower (1) with straightening bench, fit and fix in place.
22. Screw in bolts M6x20 (5, 6).

    Tighten once all rivets have been set.

23. Attach bolt M6x20 (7) with flanged nut M6 (8).

    Tighten once all rivets have been set.

24. Rivet suspension strut tower (1) with rivets Ø 6.5x12.5 (areas Y₂ ).
25. Rivet suspension strut tower (1) with rivets Ø 6.5x14.5 (areas Y₃ ).
26. Rivet rear mounting support (2) with rivets Ø 6.4 M6 (areas Y₄ ).
27. Rivet suspension strut tower (1) with countersunk-head rivet Ø 6.4x15.5 (area Z₂ ).
28. Screw in bolt M6x20 (9).

    Tighten once all rivets have been set.

29. Rivet suspension strut tower (1), rear mounting support (2) and front mounting support (3) with rivets Ø 6.5x14.5 (areas Y₃ ).
30. Rivet suspension strut tower (1) and front mounting support (3) with rivet Ø 6.4 (area Y₅ ).
31. Rivet suspension strut tower (1) and rear mounting support (2) with countersunk-head rivet Ø 6.4x15.5 (area Z₂ ).
32. Rivet suspension strut tower (1), rear mounting support (2) and front mounting support (3) with countersunk-head rivets Ø 6.4x17 (areas Z₃ ).

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33. Produce a MIG weld seam SG (area EE) with a length of at least 20 mm on suspension strut tower (1) for ground connection.

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