Windshield CROSSMEMBER Installation - Ar62.25-P-1120-04S

Model 223.0/1/9 

Number	Designation			Model 223
BA63.10-P-1001-01A	Screw, lower A-pillar to bodyshell	M8	Nm	32
		M10	Nm	45

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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) 

• W₁ = Structured flow form rivet 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

The next steps are shown on model 223.1.

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 crossmember (1) and upper mounting supports (2), fit, and fix in place.
2. Drill rivet holes in crossmember (1) with Ø 6.7 mm (areas A, B).
3. Countersink rivet holes (area B).

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   The following operation steps 4 to 15 are shown on the left side of the vehicle and must be performed in the same way on the right side of the vehicle.

4. Install lower mounting support (3), fit, and fix in place.
5. Drill rivet holes in crossmember (1), in upper mounting support (2), and in lower mounting support (3) with a Ø 6.7 mm bit (areas C, D, E, F).

   Drill rivet holes through existing holes in replacement part (areas C).

6. Countersink rivet hole (area F).
7. Remove crossmember (1), upper mounting support (2), and lower mounting support (3).
8. Deburr rivet holes in crossmember (1), in upper mounting support (2), in lower mounting support (3), and in body on both sides.
9. Remove drill chips.
10. Fix upper mounting support (2) in place on crossmember (1).
11. Drill hole for threaded connection with a Ø 6.5 mm bit (areas G).
12. Remove upper mounting support (2).
13. Deburr hole for threaded connection at crossmember (1) and at upper mounting support (2) on both sides.
14. Remove drill chips.

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15. Apply 2-component adhesive to body in cross-hatched area.

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

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16. Apply 2-component adhesive to crossmember (1) 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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17. Install crossmember (1), upper mounting supports (2), and lower mounting supports and fix in place.
18. Rivet crossmember (1) with rivets Ø 6.5x12.5 (areas Y₂ ).
19. Rivet crossmember (1) with rivets Ø 6.5x14.5 (areas Y₃ ).
20. Rivet crossmember (1) with Ø 6.4x17 0 countersunk-head rivets (area Z₃ ).

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    The following operation steps 21 to 26 are shown on the left side of the vehicle and must be performed in the same way on the right side of the vehicle.

21. Rivet upper mounting support (2) with a Ø 6.5x12.5 rivet (area Y₂ ).
22. Rivet upper mounting support (2) and lower mounting support (3) with Ø 6.5x14.5 rivets (areas Y₃ ).
23. Rivet crossmember (1) with a Ø 6.4x17 0 countersunk-head rivet (area Z₃ ).
24. Attach screw M6x20 (4) with flanged nut M6 and tighten.
25. Screw in bolts (5, 6).
26. Create MAG weld seam (area EE) on lower mounting support (3).