Suspension Strut Tower Replacement - Ar62.20-P-1232S
Model 223.0/1/9
MODIFICATION NOTES
| 18.08.2021 | Operation steps added. | Operation steps 3, 11 | |
| 14.04.2021 | Method modified. | Operation step 33 | AR62.20-P-1232-04S |
| 14.04.2021 | Method modified. | Step 9 |
Fig 1: Front Suspension Strut Tower, Front And Rear Mounting Console Component Locations (Model 223.0/1/9)
| 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 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 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. Deburr repair panels. |
AS00.00-Z-0017-01A | |
| Notice | Information on preventing damage to electronic components due to electrostatic discharge | 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 | |
| Notice | General information on crack diagnosis of aluminum parts | AH60.00-P-0014-01N | |
| 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 blankets. | ||
| 3 | Remove upper front longitudinal member. | AR62.20-P-1286S | |
| 4 | Set up straightening bench with straightening bench support members and straightening set. | ||
| 000 588 50 23 00 Body straightening system | WS60.00-P-0439K | ||
| 5 | Place vehicle on straightening bench and fasten. | ||
| 6 | Remove suspension strut tower (1) with rear mounting support (2) and front mounting support (3) | AR62.20-P-1232-01S | |
| 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 | ||
| 7 | Prepare suspension strut tower (1), rear mounting support (2) and front mounting support (3). | AR62.20-P-1232-03S | |
| 8 | Install suspension strut tower (1), rear mounting support (2) and front mounting support (3). | AR62.20-P-1232-04S | |
| 000 588 04 39 00 Rivet press tool | WS60.00-P-0440B | ||
| 000 588 12 84 00 Welder | WS00.00-P-0318K | ||
| 000 588 50 23 00 Body straightening system | WS60.00-P-0439K | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| 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 | ||
| Blind rivet Y5 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN) | *BR00.45-Z-1034-13A | ||
| Countersunk-head blind rivet Z2 6.4x15.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1044-13A | ||
| 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 | ||
| Flanged nut M6 | *BR00.45-Z-1069-13A | ||
| Rivet nut with countersunk head M6x16.5 (clamping range 3.0 mm to 5.0 mm) | *BR00.45-Z-1079-13A | ||
| Screw M6x20-10.9 | *BR00.45-Z-1080-13A | ||
| 9 | Release vehicle from straightening bench, lift and remove straightening bench. | ||
| 10 | Clean weld joint and repair flanges. | ||
| 11 | Install upper front longitudinal member. | AR62.20-P-1286S | |
| 12 | Remove spark protection blankets. | ||
| 13 | 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-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-1034-13A | Blind rivet Y5 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN) | A 003 990 80 97 |
| BR00.45-Z-1044-13A | Countersunk-head blind rivet Z2 6.4x15.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) | A 000 991 83 32 |
| 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-1069-13A | Flanged nut M6 | A 002 990 67 50 |
| BR00.45-Z-1079-13A | Rivet nut with countersunk head M6x16.5 (clamping range 3.0 mm to 5.0 mm) | N 000000 004354 |
| BR00.45-Z-1080-13A | Screw M6x20-10.9 | N 000000 003765 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |