Remove/install end tips

AR61.10-D-5709NA

Remove/install end tips

14.05.2019

Model

903.61/62/66/67, 904.61/62/66

with code ZU9 (National version for Mexico)

Model

903.61/66/67, 904.61/66

with code ZU7 (National version for Canada)

Model

903.61/66/67, 904.61/66

with code ZU8 (National version for USA)

Shown: Repair of 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-2000NA

2

Remove lamp unit

AR82.10-D-4730NA

3

Remove front grille

AR88.00-D-2115NA

4

Remove front end cross member

AR88.00-D-2302NA

5

Remove radiator

AR20.20-D-3865NA

6

Remove heater unit

AR83.70-D-5302NA

 The repair description must also be used accordingly for the right side of the vehicle

 During repair of the left end tip
Only for vehicles with code H12, hot-water auxiliary heater.

7

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

 During repair of the right end tip

8

Remove hydraulic unit

AR42.30-D-8601D

 During repair of the left end tip.

9

Remove shield for the turbocharger

 During repair of the right end tip.

10

Remove battery and battery carrier

 During repair of the left end tip.

11

Remove mount for ABS unit

AR61.10-D-0008NA

 During repair of the left end tip.

12

Remove mount for heater

AR61.10-D-0016NA

 During repair of the left end tip
Only for vehicles with code H12, hot-water auxiliary heater.

13

Remove holder for battery mount

AR61.10-D-0009A

 During repair of the left end tip.

14

Remove other detachable parts in the repair area

15

Cover all detachable parts remaining in the repair area

16

Separate end tip (1)

AR61.10-D-5709-01A

AR64.20-D-0002A

 Bore spot welds.

 Spot weld milling cutter

*201589005100

17

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

18

Prepare end tip (1) for installation

AR61.10-D-5709-02A

19

Fit end tip (1), align, and clamp

 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

20

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

21

Install mount for ABS unit

AR61.10-D-0008NA

 During repair of the left end tip.

22

Install heater bracket H12

AR61.10-D-0016NA

 During repair of the left end tip
Only for vehicles with code H12, hot-water auxiliary heater.

23

Install holder for battery mount

AR61.10-D-0009A

 During repair of the left end tip.

24

Weld in weld studs (2 and 3)

AR61.10-D-5709-04B

 During repair of the left end tip.

25

Grind off any residue welding material

26

Vacuum out hollow cavities


Metal shavings or metallic grinding dust in the hollow 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

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

29

Supplement standard underfloor protection with MB permanent underbody sealant

30

Paint repair area adjacent surfaces

31

Install battery and battery carrier

 During repair of the left end tip.

32

Install shield for turbocharger

 During repair of the right end tip.

33

Install hydraulic unit

AR42.30-D-8601D

 During repair of the left end tip

34

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

 During repair of the right end tip.

35

Install heater

AR83.70-D-5302NA

 During repair of the left end tip
Only for vehicles with code H12, hot-water auxiliary heater.

36

Install radiator

AR20.20-D-3865NA

37

Install lock cross member

AR88.00-D-2302NA

38

Install grille

AR88.00-D-2115NA

39

Install lamp unit

AR82.10-D-4730NA

40

Bolt on front bumper

AR88.20-D-2000NA

41

Attach other detachable parts again

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