Prepare Rear Longitudinal Member For Installation - Ar64.20-P-1200-23LF

Model 217.3 

Model 222 

except code Z07 (B7 armoring on special protection version) 

The following steps are shown on the left side of the vehicle and must be accomplished analogously on the right side in the event of damage.

Courtesy of MERCEDES-BENZ USA

Shown on MODEL 222 with CODE Z07 (Top protection) 

1. Grind mating surfaces on rear longitudinal member (1) down to bare metal in crosshatched areas.

   Sand down spot weld flanges to bare metal on both sides.

2. Remove grinding dust.
3. Coat insides of spot weld flanges with zinc dust paint.

   Do not coat bonding surfaces with zinc dust paint (areas A).

   Otherwise adhesion problems may occur.

   Observe pretreatment of bonding surfaces.

   Courtesy of MERCEDES-BENZ USA

   Shown on MODEL 222 with CODE Z07 (Top protection) 

4. Grind mating surfaces on rear longitudinal member (1) down to bare metal in crosshatched areas.

   Sand down spot weld flanges to bare metal on both sides.

5. Remove grinding dust.
6. Coat insides of spot weld flanges with zinc dust paint.

   Do not coat bonding surfaces with zinc dust paint (areas B).

   Otherwise adhesion problems may occur.

   Observe pretreatment of bonding surfaces.

   Courtesy of MERCEDES-BENZ USA

   Shown on MODEL 222 with CODE Z07 (Top protection) 

7. Mark separating point an center closing panel (10) and cut (area C).

   Transfer separation point from vehicle.

8. Grind mating surfaces on center closing panel (10) down to bare metal in crosshatched areas.

   Sand down spot weld flanges to bare metal on both sides.

9. Remove grinding dust.
10. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (area D).

    Otherwise adhesion problems may occur.

    Observe preliminary treatment of bonding surface.

11. Mark separating point on front crossmember (4) and cut (area E).

    Transfer separation point from vehicle.

12. Grind mating surfaces on front crossmember (4) down to bare metal in crosshatched areas.
13. Remove grinding dust.

    Observe pretreatment of bonding surfaces (areas F).

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

14. Mark separating point on floor (3) and cut (area G).

    Transfer separating point from vehicle and observe overlap of approx. 20 mm.

15. Grind mating surfaces on floor (3) down to bare metal in crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

16. Remove grinding dust.
17. Coat insides of spot weld flanges with zinc dust paint.
18. Grind mating surfaces on floor (3) down to bare metal in crosshatched areas.
19. Remove grinding dust.

    Observe pretreatment of bonding surfaces.

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

20. Grind mating surfaces on rear crossmember (2) down to bare metal in crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

21. Remove grinding dust.

    Observe pretreatment of bonding surfaces.

22. Model 222

    except code Z07 (B7 armoring on special protection version)

    Grind mating surfaces on longitudinal member inner panel (7) down to bare metal in crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

23. Model 222

    except code Z07 (B7 armoring on special protection version)

    Remove grinding dust.

24. Model 222

    except code Z07 (B7 armoring on special protection version)

    Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas H).

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

25. Mark separating point on reinforcement (6) and cut (area I).

    Transfer separation point from vehicle.

26. Grind mating surfaces on reinforcement (6) down to bare metal in the crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

27. Remove grinding dust.
28. Coat insides of spot weld flanges with zinc dust paint.
29. Model 222

    except code Z07 (B7 armoring on special protection version)

    Fabricate duplicator (20) from remaining piece of reinforcement (6).

    Dimensions: 

    b = approx. 120 mm

30. Model 217.3

    Separate duplicator (20) in center (area N).

31. Model 217.3

    Grind insides of duplicator half down to bare metal.

32. Model 217.3

    Remove grinding dust.

    Observe pretreatment of bonding surfaces.

    Courtesy of MERCEDES-BENZ USA

    Shown on model 217.3 

    Courtesy of MERCEDES-BENZ USA

    Shown on model 217.3 

33. Model 217.3

    Scribe separating point on longitudinal member inner panel with offset reinforcement (13) (area o₁ ).

    Dimensions:

    a = approx. 500 mm

34. Model 217.3

    Expose spot welds on offset reinforcement (14) and cut out (areas P₁ )

35. Model 217.3

    Remove offset reinforcement (14).

36. Model 217.3

    Expose spot welds on front section of longitudinal member inner panel (16) and cut out (area Q₁ ).

37. Model 217.3

    Remove front longitudinal member inner panel (16).

38. Model 217.3

    Drill longitudinal member inner panel (2) with Ø 7 mm bit (area Q₂ ).

39. Model 217.3

    Grind mating surfaces on l longitudinal member inner panel (15) down to bare metal in crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

    Courtesy of MERCEDES-BENZ USA

40. Model 217.3

    Remove grinding dust.

41. Model 217.3

    Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (area R₁ and R ₂ ).

    Otherwise adhesion problems may occur.

    Bonding surfaces are at rear.

    Shown on model 217.3 

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

42. Model 222

    except code Z07 (B7 armoring on special protection version)

    Mark separating point on longitudinal member outer shell (5) and cut (area J).

    Transfer separation point from vehicle.

43. Model 222

    except code Z07 (B7 armoring on special protection version)

    Grind mating surface on longitudinal member outer shell (5) down to bare metal in crosshatched area.

44. Model 222

    except code Z07 (B7 armoring on special protection version)

    Grind mating surfaces on longitudinal member outer shell (5) down to bare metal in crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

45. Model 222

    except code Z07 (B7 armoring on special protection version) Remove grinding dust.

46. Model 222

    except code Z07 (B7 armoring on special protection version)

    Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas K).

    Otherwise adhesion problems may occur.

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

47. Grind mating surfaces on rear bottom longitudinal member (11) down to bare metal in crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

48. Remove grinding dust.
49. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas L).

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    Courtesy of MERCEDES-BENZ USA

50. Grind mating surfaces on rear rear-end floor (12) down to bare metal in crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

51. Remove grinding dust.
52. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (area M).

    Otherwise adhesion problems may occur.

    Observe preliminary treatment of bonding surface.

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection)