Remove/install front frame cross member

AR62.30-D-0001A

Remove/install front frame cross member

14.05.2019

Model

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

1

Cross member, front



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

Guidelines for replacing front end/wheel well

AH62.00-N-0002-01A

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

Engine 601.943

AR20.20-D-3865B

Engine 602.980

AR20.20-D-3865A

Engine 111.979

AR20.20-D-3865C

4

Remove heater unit

For version with hot-water auxiliary heater, code H12

AR83.70-D-5302F

5

Remove other detachable parts in repair area

6

Cover all detachable body components that remain in the area to be repaired

7

Remove bracket for horn

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

AR62.30-D-0002A

8

Detach front frame cross member (1)

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

AR62.30-D-0001-01A

Model 904.0/3/4

AR62.30-D-0001-01C

AR64.20-D-0002A

 Cut spot welds.

 Spot weld milling cutter

*201589005100



Install

9

Prepare connecting points of front frame crossmember (1)

AR62.30-D-0001-02A

10

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

11

Prepare front frame cross member (1) for installation

AR62.30-D-0001-07A

 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

12

Weld in front frame cross member (1)

AR62.30-D-0001-08A

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

13

Grind off any residue welding material

14

Vacuum out hollow cavities

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

15

Install bracket for horn

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

AR62.30-D-0002A

16

Clean areas repaired and priming with MB primer filler

17

Supplement standard seals with MB body sealant

AR97.10-D-4000A

 Seam seals after repairs.

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

18

Supplement standard underfloor protection with MB permanent underbody sealant

19

Paint repair area adjacent surfaces

20

Add cavity preserving agent

21

Install heater

For version with hot-water auxiliary heater, code H12.

AR83.70-D-5302F

22

Install radiator

Engine 601.943

AR20.20-D-3865B

Engine 602.980

AR20.20-D-3865A

Engine 111.979

AR20.20-D-3865C

23

Install front-end center section

AR88.30-D-2302A

24

Bolt on front bumper

AR88.20-D-2000B

25

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

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20