Removing, installing section of front side rail

AR31.30-P-0060GH

Removing, installing section of front side rail

29.1.01



Remove



The steps described below should be performed for both the right and left-hand sides.

The repair of the front side rail must only be performed in the event of damage that extends to at most the front axle support.



General information on repairs to body

All models

AH60.00-N-0001-01A

1

Remove body from frame

AR60.80-P-1200GH

2

Equip straightening bench with module cross members and straightening set

 Pay attention to the arrangement drawings enclosed with the straightening angle set. Refer to:

Celette straightening set, design

AR60.10-P-1070GH

Celette straightening set

*WE58.40-Z-1014-01A

Car-Bench straightening set

*WE58.40-Z-1017-01A

3

Mount frame on Celette straightening bench

AR60.10-P-1380GH

4

Remove detachable body components in area to be repaired

5

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

*WH58.30-Z-1001-40A

6

Remove front cross member frame (7)

 If the front cross member frame (7) is damaged, it can be removed together with the section of front side rail (4) and must not be detached from the section of side rail.

AR31.30-P-0070GH

7

Remove section of front side rail (4)

AR31.30-P-0060-01GH

*WE58.40-Z-1003-03A

*WE58.40-Z-1004-03A

8

Straighten and grind off connecting plates

9

Clean cavities using suction

 Metal filings or metallic grinding dust in cavities can lead to corrosive damage.

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A



Install

10

Prepare section of front side rail (4) for installation

AR31.30-P-0060-02GH

*WE58.40-Z-1001-03A

*WE58.40-Z-1003-03A

*WE58.40-Z-1004-03A

11

Fit section of front side rail (4), straighten and fix.

 In order to fit section of side rail, secure the front cross member frame (7) using the straightening tool and then fit the section of front side rail (4).

Danger!

The high voltage used for arc welding presents a lethal hazard. Risk of explosion from welding in areas close to highly flammable materials. Risk of injury from weld splatter and UV-light when welding. Welding gases are poisonous when inhaled.

Use insulating mats. Wear protective clothing, safety glasses, and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor.

AS00.00-Z-0007-01A



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

All models

AH00.00-N-0005-01A



The welding work described below must be carried out to DIN ISO 5817.

12

Weld in section of front side rail (4).

AR31.30-P-0060-03GH

*WE58.40-Z-1001-02A

13

Grind off weld seam at side of front side rail (4) using angular grinder and coat repaired area with zinc dust paint.

 Zinc dust paint that can be spot welded

*WE58.40-Z-1003-03A

14

Weld in front body console (9)

AR31.30-P-0080GH

15

Deburr and remove grease from stiffening brackets (5, 6).

16

Weld in stiffening brackets (5, 6)

AR31.30-P-0060-04GH

*WE58.40-Z-1001-02A

17

Install front cross member frame (7)

AR31.30-P-0070GH

18

Coat repaired area with zinc dust paint

 Zinc dust paint that can be spot welded

19

Clean areas repaired and prime with MB priming filler

20

Paint area repaired and adjacent surfaces

 See Paintwork Manual

21

Supplement hollow cavity preservation

22

Reinstall all detachable body components

23

Remove frame from Celette straightening bench

AR60.10-P-1380GH

24

Fit body to frame.

AR60.80-P-1200GH

Number

Designation

WH58.30-Z-1001-40A

Tarp (fire-resistant)

WE58.40-Z-1014-01A

Celette straightening bracket set 7163.300 (model 163)

WE58.40-Z-1017-01A

Car bench straightening bracket set 82 427, (model 163)

WE58.40-Z-1001-02A

Inert gas welder

WE58.40-Z-1001-03A

Drill (electric/pneumatic)

WE58.40-Z-1003-03A

Angle grinder (electric/pneumatic)

WE58.40-Z-1004-03A

Body saw (electric/pneumatic)

WE58.40-Z-1005-03A

Wet/dry vacuum cleaner