Shown on left side of vehicle |
1 | End tip |
2 | Welding bolts |
3 | Welding bolts |
D61.10-1472-06
Caution | Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. | |
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. | |
Topical note | Notes on performing repair, body work and welding on vehicles with airbags and RTE units | ||
Topical note | General information on body repair | ||
| Remove | ||
1 | Remove front bumper | ||
2 | Remove front end cross member | ||
3 | Remove radiator | ||
4 | Remove heater unit | Model 909 | |
5 | Remove windshield washer system reservoir | When repairing right end tip (1). | |
6 | Remove air filter housing | When repairing right end tip (1). | |
7 | Remove signal horn | When repairing left end tip (1). | |
8 | Remove hydraulic unit | When repairing left end tip (1). | |
9 | Remove heat shield at turbocharger | When repairing right end tip (1). | |
10 | Remove battery and battery carrier | When repairing left end tip (1). | |
11 | Remove mount for ABS unit | When repairing left end tip (1). | |
12 | Remove mount for heater | Model 909 | |
13 | Remove holder for battery mount | When repairing left end tip (1). | |
14 | Remove all detachable parts in repair area | ||
15 | Cover all detachable parts remaining on vehicle with spark protection blanket | ||
16 | Separate end tip (1) | ||
Work instructions for cutting | |||
Spot weld milling cutter | |||
17 | Straighten connecting plates, grind down to bare metal and coat with zinc dust paint | Zinc dust paint suitable for spot welding | |
| Install | ||
18 | Prepare end tip (1) for installation | ||
Zinc dust paint suitable for spot welding | |||
19 | Fit end tip (1), align and fix 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. | |
20 | Weld in end tip (1) | ||
Topical note | Measures for preventing damage to vehicles or components when performing electric welding work | ||
General notes on welding | |||
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. | |
21 | Weld in welding bolts (2, 3) | When repairing left end tip (1). | |
Topical note | Measures for preventing damage to vehicles or components when performing electric welding work | ||
General notes on welding | |||
Zinc dust paint suitable for spot welding | |||
22 | Grind off any residue welding material | ||
23 | Remove spark protection blankets | ||
24 | Clean cavities | | |
Danger | Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | |
25 | Clean areas repaired and priming with MB primer filler | Use only primer filler approved by Daimler AG: | |
26 | Supplement standard seals with MB body sealant | ||
White sealing compound, 310 ml, DBL 6069.20 | |||
Danger | Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | |
27 | Paint repair area adjacent surfaces | Use only paints approved by Daimler AG: | |
28 | Reinstall all detachable parts removed from repair area | ||
29 | Install holder for battery mount | When repairing left end tip (1). | |
30 | Install heater bracket | Model 909 | |
31 | Install mount for ABS unit | When repairing left end tip (1). | |
32 | Install battery and battery carrier | When repairing left end tip (1). | |
33 | Install heat shield at turbocharger | When repairing right end tip (1). | |
34 | Install hydraulic unit | When repairing left end tip (1). | |
35 | Install windshield washer system reservoir | When repairing right end tip (1). | |
36 | Install air filter housing | When repairing right end tip (1). | |
37 | Install horn | When repairing left end tip (1). | |
38 | Install heater | Model 909 | |
39 | Install radiator | ||
40 | Install lock cross member | ||
41 | Bolt on front bumper |
201 589 00 51 00
Spot weld milling cutter
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