Installing Upper Concave Washer

→ Avoid working in an area with highly inflammable or explosive materials.

→ Cover highly inflammable or explosive areas.

→ Remove highly inflammable or explosive parts.

Fig 1: Identifying Upper Concave Washer

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1. Cover the fuel tank with fire-proof covers.
   Fig 2: Covering Fuel Tank

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   Information 

   The concave washer is made of rust-proof steel and is supplied bare

   • Before installation, clean the complete concave washer to remove all grease using acetone. 
   • The bonding areas must not be sanded; cleaning with acetone is sufficient. 
2. Prepare the concave washer for installation.
   1. 2.1. Clean bonding areas with acetone.
      Fig 3: Cleaning Bonding Areas

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   2. 2.2. Tack-weld the "concave washer support" (Part No.: 970.501.910.00 → Concave washer support/wedge → Tack-welding concave washer support  ) at the marked position using two spotwelds.
      Fig 4: Tack-Welding Concave Washer Support

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3. Apply adhesive (000.043.207.66). → Adhesive 000.043.207.66 → Application depth: 5 mm 
   Fig 5: Applying Adhesive

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4. Fit concave washer.
   1. 4.1. Align the concave washer according to the markings.
      Fig 6: Marking Installation Position

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   2. 4.2. Check installation position using an electronic angle measuring device (commercially available - or use angle measuring device and spirit level if necessary) and make adjustments as required:
      1. 4.2.1. Determine zero position (angle -item A-  ) of the angle measuring device (-item C-  ) at reference point "mounting/chassis subframe mounting" (-item B-  ) and set it to "zero".
         Fig 7: Identifying Zero Position Of Angle Measuring Device

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      2. 4.2.2. Check installation position of concave washer: → Nominal value: 8.4°-1° 
         Fig 8: Checking Installation Position Angle Of Concave Washer

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         Check that installation position angle (-item A-  ) of concave washer (-item B-  ) with respect to reference point (chassis subframe mounting -item C-  ) corresponds to the nominal value 8.4 ° (- 1°) and make adjustments if necessary.

5. Secure the concave washer with a tack-weld using inert gas.
   Fig 9: Tack-Welding Concave Washer

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6. Check that the concave washer is lying flat on the longitudinal member. Re-position if necessary.
7. Apply a full weld to the concave washer at points -A, B and C-  using inert gas. → Length: 15 mm+5 mm 
   Fig 10: Welding In Concave Washer

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8. Grind down contact surfaces.
   Fig 11: Grinding Contact Surfaces

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