Remove/install end tips

AR61.10-D-5709A

Remove/install end tips

14.05.2019

Model

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

Repair of left end profile is shown

1

End tip

2

Welding bolts

3

Welding bolts

 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 front bumper

AR88.20-D-2000B

2

Remove front-end center section

AR88.30-D-2302A

3

Remove radiator

AR20.20-D-3865A

4

Remove heater unit

AR83.70-D-5302F

 The repair description must be correspondingly performed for the right side of the vehicle

 In the case of the repair of the left end profile
Only for vehicles with heating, code H12

5

Remove windshield washer system reservoir, air filter box and horn

 In the case of the repair of the right end profile

6

Remove hydraulic unit

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

AR42.30-D-8601A

 In the case of the repair of the left end profile
Only for vehicles with ABS, code BB0

7

Remove heat shield for turbocharger

 In the case of the repair of the right end profile
Only for model 901.4, 902.4, 903.4, 904.4

8

Remove battery, battery carrier and engine control unit with bracket

 In the case of the repair of the left end profile

9

Remove bracket for horn

Model 901.0##/3##/4## ## up to 718187, 902.0##/3##/4## ## up to 718187, 903.0##/3##/4## ## up to 718187, 904.0##/3##/4## ## up to 718187

AR62.30-D-0002A

 In the case of the repair of the right end profile

10

Remove mount for ABS unit

Up to FIN 718187

AR61.10-D-0008A

As of FIN 718188

AR61.10-D-0008B

 In the case of the repair of the left end profile
Only for vehicles with ABS, code BB0

11

Remove mount for heater

Up to FIN 882883

AR61.10-D-0016A

As of FIN 882884

AR61.10-D-0016B

 In the case of the repair of the left end profile
Only for vehicles with heating, code H12

12

Remove holder for battery mount

AR61.10-D-0009A

 In the case of the repair of the left end profile

13

Remove other detachable parts in repair area

14

Cover all detachable parts that remain in repair area

15

Separate end tip (1)

AR61.10-D-5709-01A

AR64.20-D-0002A

 Cut spot welds

 Spot weld milling cutter

*201589005100

16

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

 Zinc dust paint suitable for spot welding

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

17

Prepare end tip (1) for installation

AR61.10-D-5709-02A

18

Fit, align and attach end profile (1)

 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

19

Weld in end tip (1)

AR61.10-D-5709-03A

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

20

Install mount for ABS unit

Up to FIN 718187

AR61.10-D-0008A

As of FIN 718188

AR61.10-D-0008B

 In the case of the repair of the left end profile
Only for vehicles with ABS, code BB0

21

Install bracket for horn

Model 901.0##/3##/4## ## up to 718187, 902.0##/3##/4## ## up to 718187, 903.0##/3##/4## ## up to 718187, 904.0##/3##/4## ## up to 718187

AR62.30-D-0002A

 In the case of the repair of the right end profile

22

Install bracket for heater H12

Up to FIN 882883 only where removed bracket is installed

AR61.10-D-0016A

As of FIN 882884 and generally where a new bracket is installed

AR61.10-D-0016B

 In the case of the repair of the left end profile
Only for vehicles with heating, code H12

23

Install holder for battery mount

AR61.10-D-0009A

 In the case of the repair of the left end profile

24

Weld in weld studs (2 and 3)

AR61.10-D-5709-04A

 In the case of the repair of the left end profile

25

Grind off any residue welding material

26

Vacuum out hollow cavities


Metal shavings and/or metallic grinding dust in cavities
can lead to corrosion damage.

27

Clean areas repaired and priming with MB primer filler

28

Supplement standard seals with MB body sealant

AR97.10-D-4000A

 Seam seals after repairs

29

Supplement standard underfloor protection with MB permanent underbody sealant

30

Paint repair area adjacent surfaces

31

Install engine control unit with bracket, battery carrier and battery

 In the case of the repair of the left end profile

32

Install heat shield for turbocharger

 In the case of the repair of the right end profile
Only for model 901.4, 902.4, 903.4, 904.4

33

Install hydraulic unit

Up to FIN 718187

AR42.30-D-8601A

As of FIN 718188

AR42.30-D-8601B

 In the case of the repair of the left end profile
Only for vehicles with ABS, code BB0

34

Install windshield washer system reservoir, air filter box and horn

 In the case of the repair of the right end profile

35

Install heater

Remove/install heater unit

AR83.70-D-5302F

 In the case of the repair of the left end profile
Only for vehicles with heating, code H12

36

Install radiator

Engine 601.943

AR20.20-D-3865B

Engine 602.980

AR20.20-D-3865A

Engine 111.979

AR20.20-D-3865C

37

Install front-end center section

AR88.30-D-2302A

38

Bolt on front bumper

AR88.20-D-2000B

39

Reinstall other detachable parts

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42