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

Model 167 

Fig 1: Welding Device (167 589 00 23 00)
G14791538Courtesy of MERCEDES-BENZ USA

IMPORTANT The following operation steps are shown on the left side of the vehicle on model 167.1. In case of damage on the right side of the vehicle, these steps must be performed analogously.

The higher-level service document as well as the safety information in the service document must be observed.

  1. Transfer positions of the available holes in the body to the top inner longitudinal member (1) with drill hole finder.
  2. Install top inner longitudinal member (1) together with the top front longitudinal member and fit and fix in place with the straighteners and the SPECIAL TOOL welding fixture.
  3. Drill rivet holes in the top inner longitudinal member (1) with a diameter of 6.7 mm (areas N).
  4. Remove top inner longitudinal member (1) and top front longitudinal member.
  5. Deburr rivet holes on top inner longitudinal member (1) and body on both sides.
  6. Remove drilling chips.
    G14791364Courtesy of MERCEDES-BENZ USA
  7. Apply 2-component adhesive to body in cross-hatched area.

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

    G14791365Courtesy of MERCEDES-BENZ USA
  8. Install top inner longitudinal member (1) and fix in place.
  9. Rivet top inner longitudinal member (1) with rivets with a diameter of 6.5 x 14.5 (area N).
  10. Top inner longitudinal member (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas O).
  11. Top inner longitudinal member (1) SHIELDED GAS SEAM WELD (area M).

    IMPORTANT Perform inert gas welding at intervals and allow to cool down in between. This reduces heat distortion.

  12. Surface grind weld seam on top inner longitudinal member (1) (areas M1 )
    G14791366Courtesy of MERCEDES-BENZ USA
    G14791367Courtesy of MERCEDES-BENZ USA
  13. Install top front longitudinal member (5), mounting support (6), and striker plate (4) and fit and fix in place with the straighteners and the SPECIAL TOOL welding fixture.
  14. Drill rivet holes in the top front longitudinal member (5), mounting support, (6) and striker plate (4) with a diameter of 6.7 mm (areas K).
  15. Drill rivet holes in the top front longitudinal member with a diameter of 6.7 mm (areas H).
  16. Remove top front longitudinal member (5), mounting support, and striker plate.
  17. Deburr rivet holes on the top front longitudinal member (5), mounting support, striker plate, and body on both sides.
  18. Remove drilling chips.
  19. Coat insides of riveted joints with zinc dust paint.
    G14791368Courtesy of MERCEDES-BENZ USA
  20. Apply 2-component adhesive to the in body and top inner longitudinal member (1) in the cross-hatched areas.

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

    G14791369Courtesy of MERCEDES-BENZ USA
    G14791370Courtesy of MERCEDES-BENZ USA
  21. Install top front longitudinal member (5), mounting support (6), and striker plate (4) and fit and fix in place with the straighteners and the SPECIAL TOOL welding fixture.
  22. Rivet top front longitudinal member (5), mounting support (6), and striker plate (4) with rivets with a diameter of 6.5 x 12.5 (areas K1 ).
  23. Top front longitudinal member (5), mounting support (6), and striker plate (4) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas J).
  24. Mounting support (6) SHIELDED GAS SEAM WELD (area S).

    IMPORTANT Perform inert gas welding at intervals and allow to cool down in between. This reduces heat distortion.

  25. Bend sheet metal lug shut (arrow).
  26. Rivet top front longitudinal member (5) with rivets with a diameter of 6.5 x 12.5 (areas H1 ).
  27. Top front longitudinal member (5) SHIELDED GAS SEAM WELD (area G).

    IMPORTANT Perform inert gas welding at intervals and allow to cool down in between. This reduces heat distortion.

    G14791371Courtesy of MERCEDES-BENZ USA
  28. Striker plate (4) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas E).
    G14791372Courtesy of MERCEDES-BENZ USA
  29. End plate (4) SHIELDED GAS SEAM WELD (area D).
  30. Fit strut (3) and fix in place.
  31. Drill rivet holes on the strut (3) with a diameter of 6.7 mm (areas C).
  32. Remove strut (3).
  33. Deburr rivet holes on the strut (3) and on the body on both sides.
  34. Remove drilling chips.
  35. Coat insides of riveted joints with zinc dust paint.
    G14791373Courtesy of MERCEDES-BENZ USA
  36. Apply 2-component adhesive to body in crosshatched areas.

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

    G14791374Courtesy of MERCEDES-BENZ USA
  37. Fit strut (3) and fix in place.
  38. Drill strut (3) with rivets with a diameter of 6.5 x 12.5 (areas C1 )
  39. Strut (3) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas C2 ).
  40. Strut (3) SHIELDED GAS SEAM WELD (area L).

    IMPORTANT Perform inert gas welding at intervals and allow to cool down in between. This reduces heat distortion.

    G14791375Courtesy of MERCEDES-BENZ USA
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