Partially replace front longitudinal member

AR62.20-P-1255V

Partially replace front longitudinal member

16.3.11

14.2.11

Reference point and dimensions changed for cuts

Operation step 7

AR62.20-P-1255-01V



Removing

 Danger!

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding splatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes.

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

AS00.00-Z-0007-01A

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

Danger!

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.

Deburr repair panels.

AS00.00-Z-0017-01A



Measures for preventing damage to components when performing electric welding and soldering work

AH60.00-P-0001-02A



General information on body repair

AH60.00-N-0001-01A



General information on MB materials

AH98.00-P-9409-03A



General information on riveting

AH60.00-P-0003-01N

1

Remove detachable parts in area to be repaired

2

Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket

Welding protective blanket

gotis://K_60-65_23.0

3

Equip straightening bench with module members, cross members and straightening tool set.

 Observe enclosed set-up plans.

Straightening tool set, passenger cars (Celette)

gotis://K_60-65_02.0

Straightening system, passenger cars ( Car Bench)

gotis://K_60-65_03.0

4

Place vehicle on straightening bench lift and fasten

Two-column lift 3.0 - -3.5 t electromechanical

gotis://H_00.1_01.0

Two-post lifting platform, 2.5 - 3.5 t electrohydraulic

gotis://H_00.1_01.1

5

Remove front reinforcement

Model 171

AR62.30-P-1400V

Model 172

AR62.30-P-1400W

6

Completely remove front cross member

Model 171

AR62.30-P-1300V

Model 172

AR62.30-P-1300W

7

Partially cut off front longitudinal member (1)

Round wire brush

gotis://K_58.3_06.0

AR62.20-P-1255-01V

Weld-spot milling machine

gotis://K_58.1_02.0

Body jig saw

gotis://K_58.1_01.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

8

Prepare front longitudinal member section (1)

Round wire brush

gotis://K_58.3_06.0

AR62.20-P-1255-02V

Body jig saw

gotis://K_58.1_01.0

Vice grip pliers (standard)

gotis://K_58.3_04.2

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

9

Install front longitudinal member section (1)

Straightening tool set, passenger cars (Celette)

gotis://K_60-65_02.0

AR62.20-P-1255-03V

Straightening system, passenger cars ( Car Bench)

gotis://K_60-65_03.0

Multifunction device (spot welding)

gotis://K_60-65_15.0

MIG-MAG inert gas welder

gotis://K_60-65_17.1

Pneumatic-mechanical blind rivet tool

gotis://K_58.3_10.2

Vice grip pliers (standard)

gotis://K_58.3_04.2

Round wire brush

gotis://K_58.3_06.0

Manual temporary fastener, 6.35 mm

gotis://K_58.3_10.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Blind rivet 6.512.5

*BR00.45-Z-1012-13A

10

Release vehicle from straightening bench, lift vehicle and remove straightening bench

Two-column lift 3.0 - -3.5 t electromechanical

gotis://H_00.1_01.0

Two-post lifting platform, 2.5 - 3.5 t electrohydraulic

gotis://H_00.1_01.1

11

Clean weld joints and sheet metal flanges with rotary wire brush

Round wire brush

gotis://K_58.3_06.0

12

Completely install front cross member

Model 171

AR62.30-P-1300V

Model 172

AR62.30-P-1300W

13

Install front reinforcement

Model 171

AR62.30-P-1400V

Model 172

AR62.30-P-1400W

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42

BR00.45-Z-1012-13A

Blind rivet 6.512.5

A 004 990 16 97