Cut off upper front longitudinal member - AR62.20-P-1286-01EW

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MODEL 212, 218

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42

Fig 2: Lower Front Longitudinal Member Spot Weld Areas

Courtesy of MERCEDES-BENZ USA

Expose spot welds on lower front longitudinal member (2) and front longitudinal member reinforcement (3) (areas A, B, C, D, E, F and G).
Cut out spot welds on lower front longitudinal member (2) and front longitudinal member reinforcement (3) (areas A, B, C, D, E and F).
Drill with Ø 6 mm spot welds on front longitudinal member reinforcement (3) (area G).
Heat lower front longitudinal member (2) and front longitudinal member reinforcement (3) in crosshatched areas.
Cross-hatched areas are bonded.
Remove damaged lower front longitudinal member (2) and front longitudinal member reinforcement (3).

Fig 3: Upper Front Longitudinal Member And Fender Bracket Spot Weld Areas
Courtesy of MERCEDES-BENZ USA
Expose spot welds on upper front longitudinal member (1) and fender bracket (4) (areas H, J, K, L and M).
Cut out spot welds on fender bracket (4) (area M).
Remove fender bracket (4).
Cut out spot welds on upper front longitudinal member (1) (areas J, K and L).
Drill with Ø 6 mm spot welds on upper front longitudinal member (1) (area H).
Coarsely cut upper front longitudinal member (1) at separating point (area I).
Heat upper front longitudinal member (1) in crosshatched areas.
Cross-hatched areas are bonded.
Remove damaged front upper longitudinal member (1).

Fig 4: Upper Front Longitudinal Member Spot Weld Areas
Courtesy of MERCEDES-BENZ USA
Cut out spot welds on remaining section of upper front longitudinal member (1.1) (area N).
Remove upper front longitudinal member remaining element (1.1).
Grind mating surfaces on body down to bare metal in cross-hatched areas.
Grind spot weld flanges down to bare metal on both sides.
Remove shavings and drill chips.
Coat insides of spot weld flanges with zinc dust paint.
Do not coat bonding surfaces with zinc dust paint to prevent adhesion problems (areas O, P, Q, and R).

Observe pretreatment of bonding surfaces.