Replace upper front longitudinal member - AR62.20-P-1286EW

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MODEL 212, 218

Fig 1: Upper Front Longitudinal Member Components

Courtesy of MERCEDES-BENZ USA

	Removing
	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 splatter 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
	Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes	Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only.	AS00.00-Z-0016-01A
	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
	Measures for preventing damage to vehicles or components when performing electric welding work		AH00.00-N-0005-01A
	General information on body repair		AH60.00-N-0001-01A
	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	General information on MB materials		AH98.00-P-9409-03A
1	Prepare all workshop equipment and commercially available tools required for repair
2	Remove all detachable parts in repair area.
3	Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket	Welding protective blanket
4.1	Separate upper front longitudinal member (1), lower front longitudinal member (2), front longitudinal member reinforcement (3) and fender bracket (4)	If upper front longitudinal member (1) is damaged severely.	AR62.20-P-1286-01EW
		Spot weld milling cutter Weld-spot milling machine Body jig saw Hot-air gun Round wire brush Wet and dry vacuum cleaner	Figure
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
4.2	Partially separate upper front longitudinal member (1)	If upper front longitudinal member (1) is damaged slightly in front area.	AR62.20-P-1287-01EW
4.2	Partially separate upper front longitudinal member (1)	Spot weld milling cutter Weld-spot milling machine Body jig saw Hot-air gun Round wire brush Wet and dry vacuum cleaner	Figure
5.1	Prepare upper front longitudinal member (1), lower front longitudinal member (2) and front longitudinal member reinforcement (3) for installation	If upper front longitudinal member (1) is damaged severely.	AR62.20-P-1286-02EW
5.1		Round wire brush Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
5.2	Partially prepare upper front longitudinal member (1) for installation	If upper front longitudinal member (1) is damaged slightly in front area. Body jig saw Round wire brush	AR62.20-P-1287-02EW
	Install
6	Install welding device		AR62.20-P-1286-05CW
		Welding device	Figure
		Adapter	Figure
7.1	Install upper front longitudinal member (1), lower front longitudinal member (2), front longitudinal member reinforcement (3) and fender bracket (4)	If upper front longitudinal member (1) is damaged severely.	AR62.20-P-1286-03EW
	General information on riveting		AH60.00-P-0003-01N
		Welding device	Figure
		Adapter Multifunction device (spot welding) Inert gas welder Hand riveting tool Vice grip pliers (standard) Manual temporary fastener Round wire brush Wet and dry vacuum cleaner	Figure
		Adhesive	*BR00.45-Z-1092-02A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Rivet	*BR00.45-Z-1001-13A
		Polygrip countersunk-head rivet, 6.4x14	*BR00.45-Z-1002-13A
7.2	Partially install upper front longitudinal member (1)	If upper front longitudinal member (1) is damaged slightly in front area.	AR62.20-P-1287-03EW
		Welding device	Figure
		Adapter Multifunction device (spot welding) Inert gas welder Vice grip pliers (standard) Round wire brush Wet and dry vacuum cleaner	Figure
		Adhesive	*BR00.45-Z-1092-02A
8	Clean weld joints and sheet metal flanges with rotary wire brush	Round wire brush
9	Clean repair area	Wet and dry vacuum cleaner
	Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.	No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
10	Prime repair area with primer filler	Passenger car primer filler 283-150 VOC	*BR00.45-Z-1031-07A
	Notes on paintwork repairs		AH98.00-P-9408-02A
11	Carry out seam sealing after repairs	Supplement standard sealants.
		Model 212	AR97.10-P-4000EW
		Model 218.3	AR97.10-P-4000EL
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
	Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.	No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
12	Paint repair area adjacent surfaces
	Notes on paintwork repairs		AH98.00-P-9408-02A
13	Apply additional cavity preservation
		Model 212.0/1 Model 212.2	AR97.20-P-1500EW
		Model 218.3	AR97.20-P-1500EL
	Notes on cavity preservation		AH97.20-P-0001-01B
		Cavity preservation gun
		Preservation agent	*BR00.45-Z-1003-05A
14	Remove welding protection blankets	On all covered parts remaining in vehicle.
15	Install all detachable body components in area to be repaired.

Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Welding Device (204 589 01 23 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Adapter (212 589 01 23 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	White sealing compound, 310 ml, DBL 6069.20	A 001 989 63 20
BR00.45-Z-1041-01A	Seam sealant, sprayable 310 ml	A 002 989 84 20
BR00.45-Z-1092-02A	Adhesive kit, body, 2-component adhesive	A 009 989 36 71
BR00.45-Z-1003-05A	Cavity preservation, solvent-free (1 l container)	A 000 986 72 70 05
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42
BR00.45-Z-1031-07A	Passenger car primer filler 283-150 VOC	-
BR00.45-Z-1001-13A	Blind rivet 6.4x14	A 003 990 35 97
BR00.45-Z-1002-13A	Polygrip countersunk-head rivet, 6.4x14	A 003 990 86 97 05