Upper Front Longitudinal Member Replacement - Ar62.20-P-1286S
Model 223.0/1/9
MODIFICATION NOTES
| 06.01.2023 | Rivet data updated. | ||
| 29.03.2023 | Number of rivet holes changed. | Operation step 2 | AR62.20-P-1286-03S |
| 29.03.2023 | Number of rivets changed. | Operation step 16 | AR62.20-P-1286-03S |
| 29.03.2023 | Rivet changed. | Operation step 24 | AR62.20-P-1286-03S |
| 29.03.2023 | Flow-form rivet structure W1 changed to flow-form rivet structure W3. | Operation step 6 |
Fig 1: Upper And Lower Front Longitudinal Members And Upper Rear Longitudinal Member Component Locations (Model 223.0/1/9)
| 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 | |
| Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust | Wear dust filter mask, safety glasses, and protective gloves. Use a suitable, grounded dust extraction system. |
AS60.00-Z-0007-01N | |
| Risk of injury. Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | AS00.00-Z-0002-01A | |
| 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. | AS00.00-Z-0017-01A | |
| Notice | Information on preventing damage to electronic components due to electrostatic discharge | Deburr repair panels. | AH54.00-P-0001-01A |
| Notice | General information on body repair | AH60.00-P-0001-01S | |
| Notice | Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | |
| General information on repair of vehicles with ultra-strength steels. | AH60.00-P-0024-01N | ||
| Note on working on aluminum components and vehicles | AH60.00-P-0034-01RG | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| Remove | |||
| 1 | Remove detachable parts in area of repair point. | ||
| 2 | Cover all detachable parts remaining in vehicle with spark protection blanket. | ||
| 3 | Remove upper front longitudinal member (1), lower front longitudinal member (2), and upper rear longitudinal member (3). | Model 223.0/1/9 except code Z07 (B7 armoring on special protection version) |
AR62.20-P-1286-01S |
| 000 588 04 39 00 Rivet press tool | WS60.00-P-0440B | ||
| 000 588 03 39 00 Rivet die | WS60.00-P-0386K | ||
| 000 588 15 84 00 Heat gun | WS54.00-P-0125B | ||
| Install | |||
| The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases | Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system. | AS00.00-Z-0007-01A | |
| Notice | Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | |
| General information on riveting | AH60.00-P-0003-01S | ||
| General notes on welding | AH60.00-P-0005-01N | ||
| 4 | Prepare upper front longitudinal member (1), lower front longitudinal member (2), and upper rear longitudinal member (3). | Model 223.0/1/9 except code Z07 (B7 armoring on special protection version) |
AR62.20-P-1286-02S |
| 5 | Install positioning device. | AR62.20-P-1286-09S | |
| Fig 2 | |||
| 6 | Install upper front longitudinal member (1), lower front longitudinal member (2), and upper rear longitudinal member (3). | Model 223.0/1/9 except code Z07 (B7 armoring on special protection version) |
AR62.20-P-1286-03S |
| Install fixture for positioning longitudinal member from above | AR62.20-P-1286-09S | ||
| 000 588 04 39 00 Rivet press tool | WS60.00-P-0440B | ||
| 000 588 12 84 00 Welder | WS00.00-P-0318K | ||
| Flow-form rivet structure W6 6.0 mm up to 7.2 mm clamping range (S5) | *BR00.45-Z-1030-13A | ||
| Flow-form rivet structure W4 4 mm up to 5.15 mm clamping range (S3) | *BR00.45-Z-1028-13A | ||
| Adhesive kit, body, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A | ||
| Blind rivet Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1016-13A | ||
| Blind rivet Y4 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN) | *BR00.45-Z-1032-13A | ||
| Countersunk-head blind rivet Z3 6.4x17.0 (clamping area 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1055-13A | ||
| Countersunk-head blind rivet Z4 6.4x19.0 (clamping range 6 mm to 8 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1056-13A | ||
| Flow-form rivet structure W3 3.35 mm up to 4.1 mm clamping range (S2) | *BR00.45-Z-1027-13A | ||
| Fig 2 | |||
| 7 | Clean sheet metal flanges. | ||
| 8 | Remove spark protection blankets. | ||
| 9 | Clean repair area. | ||
| 10 | Treat repair areas with primer filler. | ||
| Notice | Notes on paintwork repairs | AH98.00-P-9408-02A | |
| General information on operation items and work procedures for painting | AH98.00-P-0003-01A | ||
See guidelines for paint technology in the workshop portal. |
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| 11 | Seal seam after repair. | AR97.10-P-4000S | |
| 12 | Paint repair areas and adjacent surfaces. | ||
| Notice | Notes on paintwork repairs | AH98.00-P-9408-02A | |
| General information on operation items and work procedures for painting | AH98.00-P-0003-01A | ||
Model 223.0/1/9 Right side of vehicle Paint coat thickness at right upper front longitudinal member (1) at stamp field (4) and reserve field (5) may not exceed 50 urn. Paint damage can otherwise occur during subsequent application of vehicle identification number. |
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Right side of vehicle Commercially available devices/tools Paint layer measuring instrument |
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Right side of vehicle To achieve paint coat thickness > 50 μm, paintwork structure in this area must be implemented as follows: Clean new part→ Roughen new part→ Clean new part→ Base coat, 1 spray pass→ Clearcoat, 1 spray pass |
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See guidelines for paint technology in the workshop portal. |
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| Silicone remover, order No. 893222600 | *BR00.45-Z-1060-04A | ||
| 13 | Supplement cavity preservation. | AR97.20-P-1500S | |
| 14 | Reinstall detachable parts in area of repair point. |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1012-13A | Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | A 004 990 16 97 |
| BR00.45-Z-1016-13A | Blind rivet Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | A 004 990 17 97 |
| BR00.45-Z-1027-13A | Flow-form rivet structure W3 3.35 mm up to 4.1 mm clamping range (S2) | A 000 991 10 33 |
| BR00.45-Z-1028-13A | Flow-form rivet structure W4 4 mm up to 5.15 mm clamping range (S3) | A 000 991 12 33 |
| BR00.45-Z-1030-13A | Flow-form rivet structure W6 6.0 mm up to 7.2 mm clamping range (S5) | A 000 991 20 33 |
| BR00.45-Z-1032-13A | Blind rivet Y4 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN) | A 003 990 81 97 |
| BR00.45-Z-1055-13A | Countersunk-head blind rivet Z3 6.4x17.0 (clamping area 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) | A 000 991 86 32 |
| BR00.45-Z-1056-13A | Countersunk-head blind rivet Z4 6.4x19.0 (clamping range 6 mm to 8 mm, draw-off strength min. 15.5 kN) | A 000 991 87 32 |
| BR00.45-Z-1060-04A | Silicone remover, order No. 893222600 | Adolf Wurth GmbH & Co. KG Reinhold-Wurth-Str. 12-17 74653 Kunzelsau-Gaisbach Germany Tel. +49 7940 15-0 Fax +49 7940 15-1000 http://www.wuerth.de |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 012 989 17 71 |