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Remove/install front longitudinal member - AR62.20-P-1242MCC

MODEL 451.3/4 

Illustrated on model 451.3 

Fig 1: Identifying Front Longitudinal Member Remove/Install Component
G10978677Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

30.1.09 Information on alternative repair methods are worked in (riveting or plug welding as alternative and structural bonding)    
REMOVING Removing     
DANGER Risk of death  caused by high voltage used for electric welding. Risk of explosion  caused by welding in the area of highly inflammable materials. Risk of injury  caused by welding spatter and UV light while welding. Risk of poisoning  caused by inhaling welding fumes. Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. AS00.00-Z-0007-01A
DANGER 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
NOTES Pretreatment of bonding surfaces   AH60.00-P-0008-01MCC
NOTES Measures for preventing damage to vehicles or components when performing electric welding work   AH00.00-P-0005-01FF
NOTES Notes on performing repair, body work and welding on vehicles with airbags and ETR units   AH91.00-P-0002-01SM
NOTES General information on riveting   AH60.00-P-0003-01MCC
IMPORTANT Notes on replacing body parts   AH60.00-P-0027-01FF
IMPORTANT General information on repairs to body   AH60.00-P-0001-01FF
IMPORTANT Generally conventional tools are required for body work, additional tools required are listed above. Pneumatic/hydraulic blind rivet tool
 		  
IMPORTANT The repair method using riveting described here can be replaced NOTES by plug welding if required. Adapt preparatory work accordingly.    
1 Remove detachable parts in the repair area    
2 Cover all detachable parts remaining in vehicle (area to be repaired) NOTES Use fire-resistant weld protection blanket to prevent damage from flying sparks.  
3 Partially remove side wall paneling On model 451.3 AR63.10-P-0115MCC
    On model 451.4 AR63.10-P-0115MCO
4 Remove lower A-pillar outer section On model 451.4 AR63.20-P-1102MCO
5 Remove lower A-pillar reinforcement On model 451.3 AR63.20-P-1114MCC
    On model 451.4 AR63.20-P-1114MCO
6 Partially remove side wall reinforcement   AR63.20-P-0862MCC
7 Partially remove longitudinal member reinforcement   AR63.30-P-0818MCC
8 Remove front wheel well locking lug   AR63.20-P-0013MCC
9 Remove longitudinal member locking lug   AR62.20-P-1267MCC 
10 Remove mounting console on bottom front longitudinal member   AR62.20-P-1265MCC 
11 Partially remove outer longitudinal member inner shell on entrance   AR63.30-P-1143MCC
12 Remove front longitudinal member (1)   AR62.20-P-1242-01MCC
13 Prepare connecting points for front longitudinal member (1) on body   AR62.20-P-1242-02MCC
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
14 Prepare front longitudinal member (1) for installation   AR62.20-P-1242-04MCC
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install     
15 Install front longitudinal member (1) IMPORTANT The repair method using bonding described here is not required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant. AR62.20-P-1242-03MCC
    Adhesive *BR00.45-Z-1092-02A 
    Rivet *BR00.45-Z-1001-13A 
16 Partially install longitudinal member inner shell on entrance   AR63.30-P-1143MCC
17 Install mounting console on bottom front longitudinal member   AR62.20-P-1265MCC 
18 Install longitudinal member locking lug   AR62.20-P-1267MCC 
19 Install front wheel well locking lug   AR63.20-P-0013MCC
20 Partially install longitudinal member reinforcement   AR63.30-P-0818MCC
21 Partially install side wall reinforcement   AR63.20-P-0862MCC
22 Install lower A-pillar reinforcement On model 451.3 AR63.20-P-1114MCC
    On model 451.4 AR63.20-P-1114MCO
23 Install lower outer A-pillar On model 451.4 AR63.20-P-1102MCO
24 Partially install side wall paneling On model 451.3 AR63.10-P-0115MCC
    On model 451.4 AR63.10-P-0115MCO
25 Install front diagonal strut console on longitudinal member On model 451.4 AR61.10-P-5140MCO
26 Clean welds and sheet metal flange with wire brush and clean areas to be repaired    
27 Prime area to be repaired using primer filler    
28 Supply standard seam seals with body sealant   AR97.10-P-4000MCC
    Sealant *BR00.45-Z-1003-01A 
29 Supplement standard underbody protection with permanent underbody sealant Underfloor protection *BR00.45-Z-1001-05A 
30 Paint area repaired and adjacent surfaces    
NOTES Notes on paintwork repairs   AH98.00-P-9408-02MCC
31 Apply additional cavity preservation   AR97.20-P-1500FF
    Teroson protective wax *BR00.45-Z-1008-05A 
32 Reinstall all detachable parts removed    
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1003-01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20
BR00.45-Z-1092-02A Adhesive kit, body, 2-component adhesive A 009 989 36 71
BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10
BR00.45-Z-1008-05A Teroson protective wax
Art. no.: 122.73Q		 Henkel Loctite
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
BR00.45-Z-1001-13A Blind rivet 6.4 x 14 A 003 990 35 97
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