Shown on left front longitudinal frame member (1) |
1 | Front longitudinal frame member |
2 | Bracket with towing lug |
6 | Bracket |
D61.10-1109-06
Warning | Risk of injury during testing and repair operations related to pyrotechnical components | Do not expose pyrotechnical component parts to temperatures above 100 °C or 212 °F. Disconnect current supply when working on such component parts. | |
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. | |
Topical note | General information on body repair | ||
Topical note | Guidelines for replacing front end/wheel well | ||
Information, assessment and legal requirements when working with, handling and storing pyrotechnical components | |||
| Remove | ||
1 | Remove engine with transmission | ||
2 | Remove front axle | ||
3 | Remove battery and battery holder | When removing left front longitudinal frame member (1). | |
4 | Remove air filter housing and air intake hose | When removing right front longitudinal frame member (1). | |
5 | Remove washer fluid reservoir | When removing right front longitudinal frame member (1). | |
6 | Remove ventilation box | When removing right front longitudinal frame member (1). | |
7 | Remove hydraulic unit | When removing left front longitudinal frame member (1). | |
8 | Remove heater unit | Model 909 | |
9 | Remove cross member | ||
10 | Remove all detachable parts in repair area | ||
11 | Cover all detachable parts remaining on vehicle with spark protection blanket | ||
12 | Set up straightening bench | ||
| 000 588 01 23 00 Body straightening system | ||
Set up straightening bench with module members, multi-Z straightening set system and straightening set. | |||
13 | Lift vehicle on straightening bench | ||
14 | Separate front longitudinal frame member (1) | ||
Work instructions for cutting | |||
Spot weld milling cutter | |||
15 | Straighten connecting plates, grind down to bare metal and coat with zinc dust paint | Zinc dust paint suitable for spot welding | |
| Install | ||
16 | Prepare front longitudinal frame member (1) for installation | ||
Zinc dust paint suitable for spot welding | |||
17 | Fit front longitudinal frame member (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. | |
18 | Weld in front longitudinal frame member (1) | ||
Topical note | Measures for preventing damage to vehicles or components when performing electric welding work | ||
General notes on welding | |||
19 | Grind off any residue welding material | ||
20 | Clean cavities | | |
21 | Install cross member | ||
22 | Remove spark protection blankets | ||
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. | |
23 | Clean areas repaired and priming with MB primer filler | Use only primer filler approved by Daimler AG. | |
24 | 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. | |
25 | Paint repair area adjacent surfaces | Use only paints approved by Daimler AG. | |
26 | Add cavity preserving agent | ||
27 | Reinstall all detachable parts removed from repair area | ||
28 | Install heater | Model 909 | |
29 | Install hydraulic unit | When installing left front longitudinal frame member (1). | |
30 | Install ventilation box | When installing front longitudinal frame member (1). | |
31 | Install washer fluid reservoir | When installing right longitudinal frame member (1). | |
32 | Install air filter box and air intake hose | When installing right longitudinal frame member (1). | |
33 | Install battery and battery holder | When installing left front longitudinal frame member (1). | |
34 | Install front axle | ||
35 | Install engine with transmission |
201 589 00 51 00
Spot weld milling cutter
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