Remove/install end tips

AR61.10-D-5709C

Remove/install end tips

14.05.2019

Model

690.6

Model

901.6, 902.6, 903.6, 904.6, 905.6

Shown: repair to left end tip

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-2000C

2

Remove lock crossmember

AR88.00-D-2302A

3

Remove radiator

Engine 611.981/983/987, 612.981

AR20.20-D-3865F

Engine 111.984

AR20.20-D-3865G

4

Remove heater unit

AR83.70-D-5302I

 The repair description is to be used in the same way for the right vehicle side

 If left end tip is being repaired
Only in vehicles with code H12, auxiliary water heater

5

Remove the reservoir for the windshield washer system, air filter box and horn

 If right end tip is being repaired

6

Remove hydraulic unit

AR42.30-D-8601C

 If left end tip is being repaired
Only in vehicles with code BB0, ABS/ABD

7

Remove shield for turbocharger

 If right end tip is being repaired

8

Remove battery and battery carrier

 If left end tip is being repaired

9

Remove mount for ABS unit

Remove/install bracket for ABS unit
Model 901.6, 902.6, 903.6, 904.6, 905.6, 690.6

AR61.10-D-0008B

 If left end tip is being repaired
Only in vehicles with code BB0, ABS/ABD

10

Remove mount for heater

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

AR61.10-D-0016B

 If left end tip is being repaired
Only in vehicles with code H12, auxiliary water heater

11

Remove holder for battery mount

AR61.10-D-0009A

 If left end tip is being repaired

12

Remove other detachable parts in repair area

13

Cover all detachable parts that remain in the repair area

14

Separate end tip (1)

AR61.10-D-5709-01A

AR64.20-D-0002A

 Bore the spot welds

 Spot weld milling cutter

*201589005100

15

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

16

Prepare end tip (1) for installation

AR61.10-D-5709-02A

17

Fit end tip (1), 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

18

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

19

Install mount for ABS unit

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

AR61.10-D-0008B

 If left end tip is being repaired
Only in vehicles with code BB0, ABS/ABD

20

Install bracket for heater H12

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

AR61.10-D-0016B

 If left end tip is being repaired
Only in vehicles with code H12, auxiliary water heater

21

Install holder for battery mount

AR61.10-D-0009A

 If left end tip is being repaired

22

Weld in the weld studs (2 and 3)

AR61.10-D-5709-04B

 If left end tip is being repaired

23

Grind off any residue welding material

24

Vacuum out hollow cavities


Metal shavings and metal grinding dust in hollow cavities
can lead to corrosion damage.

25

Clean areas repaired and priming with MB primer filler

26

Supplement standard seals with MB body sealant

AR97.10-D-4000A

 Seam seal after repair

27

Supplement standard underfloor protection with MB permanent underbody sealant

28

Paint repair area adjacent surfaces

29

Install battery and battery carrier

 If left end tip is being repaired

30

Install shield for turbocharger

 If right end tip is being repaired

31

Install hydraulic unit

AR42.30-D-8601C

 If left end tip is being repaired
Only in vehicles with code BB0, ABS/ABD

32

Install the reservoir for the windshield washer system, air filter box and horn

 If right end tip is being repaired

33

Install heater

AR83.70-D-5302I

 If left end tip is being repaired
Only in vehicles with code H12, auxiliary water heater

34

Install radiator

Engine 611.981/983/987, 612.981

AR20.20-D-3865F

Engine 111.984

AR20.20-D-3865G

35

Install lock cross member

AR88.00-D-2302A

36

Bolt on front bumper

AR88.20-D-2000C

37

Attach the 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