Upper Front Longitudinal Member Installation - Ar62.20-P-1286-03S

	000 588 04 39 00 Rivet press tool		WS60.00-P-0440B
	000 588 03 39 00 Rivet die		WS60.00-P-0386K

Model 223.0/1/9 

except code Z07 (B7 armoring on special protection version) 

29.03.2023	Number of rivet holes changed.	Operation step 2
29.03.2023	Number of rivets changed.	Operation step 16
29.03.2023	Rivet changed.	Operation step 24

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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) 

• Wi = Flow-form rivet structure 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

Welding variants 

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

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The following 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 perspective also specifies the direction in which the rivets must be placed.

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1. Install upper front longitudinal member (1), lower front longitudinal member (2) and upper rear longitudinal member (3), fit using positioning device and fix in place.
2. Drill rivet holes in upper front longitudinal member (1), lower front longitudinal member (2) and upper rear longitudinal member (3) with Ø 6.7 mm (areas A, C).
3. Countersink rivet holes in upper rear longitudinal member (3) (area C).
4. Punch rivet holes in upper rear longitudinal member (3) with Ø 6.0 mm using rivet press tool (area B).

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5. Drill rivet holes in upper front longitudinal member (1) and lower front longitudinal member (2) with Ø 6.7 mm (areas D, F).
6. Countersink rivet holes in lower front longitudinal member (2) (area D).
7. Punch rivet holes in upper front longitudinal member (1) and lower front longitudinal member (2) with Ø 6.0 mm using rivet press tool (areas E).
8. Remove upper front longitudinal member (1), lower front longitudinal member (2), upper rear longitudinal member (3) and positioning device.
9. Deburr rivet holes in upper front longitudinal member (1), lower front longitudinal member (2), upper rear longitudinal member (3) and in the body on both sides.
10. Remove drilling 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 to body in cross-hatched areas.

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

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

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

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14. Install upper front longitudinal member (1), lower front longitudinal member (2) and upper rear longitudinal member (3) using positioning device and fix in place.
15. Rivet upper front longitudinal member (1) and lower front longitudinal member (2) with rivets Ø 6.5x14.5 (areas Y₃ ).
16. Rivet upper front longitudinal member (1) and upper rear longitudinal member (3) with rivets Ø 6.5x12.5 (areas Y₂ ).
17. Rivet upper front longitudinal member (1) and upper rear longitudinal member (3) with Ø 6.4 M6 rivets (areas Y₄ ).
18. Rivet upper rear longitudinal member (3) with countersunk-head rivet Ø 6.4x17.0 (area Z₃ ).
19. Rivet upper rear longitudinal member (3) with flow-form rivet structure 4 mm to 5.15 mm clamping range (areas W₄ ).
20. Rivet upper rear longitudinal member (3) with flow-form rivet structure 6.0 mm to 7.2 mm clamping range (areas W₆ ).

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21. Rivet upper front longitudinal member (1) and lower front longitudinal member (2) with Ø 6.4 M6 rivets (areas Y₄ ).
22. Rivet upper front longitudinal member (1) with Ø 6.5x14.5 rivets (areas Y₃ ).
23. Rivet lower front longitudinal member (2) with countersunk-head rivet Ø 6.4x19.0 (area Z₄ ).
24. Rivet upper front longitudinal member (1) and lower front longitudinal member (2) with flow-form rivet structure 3.35 mm up to 4.1 mm clamping range (areas W₃ ).
25. Create MIG weld seam (area EE) on upper front longitudinal member (1).

    Only on right hand side of vehicle.

    Theft-relevant component.

26. Remove positioning device.

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