Remove/install connection part in engine compartment

AR61.10-D-0002A

Remove/install connection part in engine compartment

14.05.2019

Model

690.6

Model

901, 902, 903 (except 903.6), 904 (except 904.6), 905

Model

903.61/66/67, 904.61/66

except code ZU7 (National version for Canada)

except code ZU8 (National version for USA)

except code ZU9 (National version for Mexico)

Model

903.62, 904.62

except code ZU9 (National version for Mexico)

1

Connection element

2

Engine compartment connection element section



Remove

 Warning

Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units.

Store airbag units with deployment side facing up; do not expose to temperatures greater than 100 °C. When working on these units, disconnect the power supply.

AS91.00-Z-0001-01D

Topical note

Notes on performing repair, body work and welding on vehicles with airbags and RTE units

AH91.00-P-0002-01M

Topical note

General information on body repair

AH60.00-N-0001-01A

1

Remove end tip

Model 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4

AR61.10-D-5709A

Model 690.6, 901.6, 902.6, 903.6, 904.6, 905.6

AR61.10-D-5709C

2

Remove detachable parts in repair area

3

Cover all detachable parts that remain in the repair area

4

Separate engine compartment connection element section (2)

AR61.10-D-0002-01A

AR64.20-D-0002A

 Bore the spot welds

 Spot weld milling cutter

*201589005100

5

Align connecting plates, grind them off and coat them with zinc dust paint

 Zinc dust paint suitable for spot welding

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

6

Prepare engine compartment connection element section (2) for installation

AR61.10-D-0002-02A

7

Fit engine compartment connection element section (2), align and clamp in place

 Danger

The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases

Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system.

AS00.00-Z-0007-01A

8

Weld in engine compartment connection element section (2)

AR61.10-D-0002-03A

Topical note

Measures for preventing damage to vehicles or components when performing electric welding work

AH00.00-N-0005-01A

General notes on welding

AH60.00-N-0005-01A

9

Grind off any residue welding material

10

Install end tip

Model 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4

AR61.10-D-5709A

Model 690.6, 901.6, 902.6, 903.6, 904.6, 905.6

AR61.10-D-5709C

11

Clean areas repaired and priming with MB primer filler

12

Supplement standard seals with MB body sealant

AR97.10-D-4000A

 Seam seal after repair

13

Supplement standard underfloor protection with MB permanent underbody sealant

14

Paint repair area adjacent surfaces

15

Add cavity preserving agent

16

Reinstall all detachable parts removed

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42