Replace upper front longitudinal member · ar6220s1286e · Mercedes-Benz WIS

AR62.20-S-1286E

Replace upper front longitudinal member

06.02.2020

Model

447, 448

Modification notes

24.01.2020

Validity of special tools expanded.

Operation steps 5, 6, 7.

1	Upper front longitudinal member

S62.20-5183-06

 Danger	Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)	Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.Typ 447 mit Motor 780	AS00.00-Z-0035-01A
 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
 Danger	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
 Warning	Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes	Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only.	AS00.00-Z-0016-01A
 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. Deburr repair panels.	AS00.00-Z-0017-01A
Topical note	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Topical note	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
Topical note	Notes on battery		AH54.10-P-0001-01A
Topical note	General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment	Typ 447 mit Motor 780	AH00.00-Z-0300-01A
Topical note	Notes on body repairs to the front end		AH62.00-N-0001-01A
Topical note	Special instructions for lifting and supporting vehicle		AH00.60-N-0100-01A
Topical note	General information on body repair		AH60.00-N-0001-01A
Topical note	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A
	General information on riveting		AH60.00-P-0003-01N
	General information on MB materials		AH98.00-P-9409-03A
	Remove
1	Remove all detachable parts in area of repair point.
2	Cover all detachable parts that remain in the vehicle with fire-resistant welding protection blankets.	 Commercially available devices/tools Welding protection blanket
3	Remove the upper front longitudinal member(1).		AR62.20-S-1286-01E
	000 588 00 84 00 Heat gun		WS54.00-P-0049B
		 Commercially available devices/tools Spot weld milling machine Rotary wire brush Wet and dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
4	Prepare the upper front longitudinal member(1).		AR62.20-S-1286-02E
		 Commercially available devices/tools Rotary wire brush Wet and dry vacuum cleaner
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
5	Install corresponding welding fixture.	Model 447 with engine 622, 780	AR62.20-S-1286-05EFA
		Model 447 with engine 274, 651, 654 Model 448 with engine 274	AR62.20-S-1286-05EFE
		 Bolt, suspension strut to body	*BA32.25-N-1004-04C
		 Model 447 with engine 274, 651, 654 Model 448 with engine 274 Welding device	*447589022300
		 Model 447 with engine 622, 780 Welding device	*447589032300
6	Install and weld in upper front longitudinal member (1) using welding fixture.		AR62.20-S-1286-03E
	000 588 01 84 00 Welder		WS60.00-P-0021K
		 Commercially available devices/tools Clamping pliers (Standard) Hand drill Blind riveting tool (set force > 19 kN) Rotary wire brush Wet and dry vacuum cleaner
		Adhesive kit, body, 2-component adhesive	*BR00.45-Z-1092-02A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)	*BR00.45-Z-1001-13A
		 Model 447 with engine 274, 651, 654 Model 448 with engine 274 Welding device	*447589022300
		 Model 447 with engine 622, 780 Welding device	*447589032300
	Remove
7	Remove corresponding welding fixture.	 Model 447 with engine 274, 651, 654 Model 448 with engine 274 Welding device	*447589022300
		 Model 447 with engine 622, 780 Welding device	*447589032300
	Install
8	Clean weld joints and sheet metal flanges with rotary wire brush.	 Commercially available devices/tools Rotary wire brush
9	Remove welding protection blankets.	 Commercially available devices/tools Welding protection blanket
 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.	AS98.00-Z-0002-01A
10	Prime repair area with a primer filler.
Topical note	Notes on paintwork repairs		AH98.00-P-9408-02A
		 Use only primer filler approved by Daimler AG: https://xentry.daimler.com
11	Seal seam after repair.		AR97.10-S-4000E
		 Supplement standard seals with sealant.
 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.	AS98.00-Z-0002-01A
12	Paint repair area and adjacent surfaces.
Topical note	Notes on paintwork repairs		AH98.00-P-9408-02A
		 Use only paints approved by Daimler AG, see: https://xentry.daimler.com
13	Supplement cavity preservation.		AR97.20-S-1500E
14	Install all detachable parts in area of repair point.

 Suspension struts

Number	Designation			Model 447, 448
BA32.25-N-1004-04C	Bolt, suspension strut to body	Stage 1	Nm	40
		Stage 2	°	90

447 589 02 23 00

Welding device

447 589 03 23 00

Welding device

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-1001-13A	Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)	A 003 990 35 97
BR00.45-Z-1092-02A	Adhesive kit, body, 2-component adhesive	A 012 989 17 71

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