Replace crossmember reinforcement below rear seat

AR63.10-P-0696QA

Replace crossmember reinforcement below rear seat

18.11.11



Removing

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

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 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



General information on body repair

All models

AH60.00-N-0001-01A



Measures for preventing damage to vehicles or components when performing electric welding work

All models

AH00.00-N-0005-01A



Notes on paintwork repairs

All models

AH98.00-P-9408-02A



General information on MB materials

All models

AH98.00-P-9409-03A

1

Remove electric lines and vacuum lines in repair area

2

Remove detachable parts in area to be repaired

3

Cover all detachable body components remaining in vehicle (area to be repaired)

Tarp (fire-resistant)

4

Equip straightening bench with modular or crossmembers and straightening tools

Observe set-up plans enclosed!

Passenger car straightening system (Celette)

gotis://K_60-65_02.0

Accessories for straightening system (Celette)

gotis://K_60-65_04.1

Straightening systems for passenger cars (Car Bench)

gotis://K_60-65_03.0

Accessories for straightening system (Car Bench)

gotis://K_60-65_04.2

5

Set vehicle onto straightening bench using two-post lift and fasten

Two-post lifting platform 3.0-3.5 t, electromechanical
gotis://H_00.1_01.0

6

Set up side portal frame with check and welding devices

Observe set-up plans enclosed!

 Side portal frame

*210589172300

 Multi-Z element MZ 260

*140589262300

 Inspection and welding device

*203589002300

 Inspection and welding devices

*209589002300

7

Remove B-pillar complete

8

Remove B-pillar reinforcement

AR63.10-P-0696-04QA

 Spot weld milling cutter

*201589005100

Ball cutter, dia. 12 mm

Round wire brush, braided, dia. 70 mm

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

Cutting disk, 65 mm dia., 80 m/s (max. 23,500 rpm)

Drill
gotis://K_58.1_04.0

Straight grinder
gotis://K_58.0_03.0

Angle grinder
gotis://K_58.1_07.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

9

Remove reinforcement on tunnel

AR63.40-P-1185-01QA

Ball cutter, dia. 12 mm

Round wire brush, braided, dia. 70 mm

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

Cutting disk, 65 mm dia., 80 m/s (max. 23,500 rpm)

Drill
gotis://K_58.1_04.0

Straight grinder
gotis://K_58.0_03.0

Angle grinder
gotis://K_58.1_07.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

10

Remove crossmember reinforcement below rear seat

AR63.10-P-0696-01QA

 Spot weld milling cutter

*201589005100

Ball cutter, dia. 12 mm

Round wire brush, braided, dia. 70 mm

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

Cutting disk, 65 mm dia., 80 m/s (max. 23,500 rpm)

Drill
gotis://K_58.1_04.0

Straight grinder
gotis://K_58.0_03.0

Angle grinder
gotis://K_58.1_07.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

11

Prepare crossmember reinforcement below rear seat

AR63.10-P-0696-02QA

Round wire brush, braided, dia. 70 mm

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

Drill
gotis://K_58.1_04.0

Angle grinder
gotis://K_58.1_07.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

12

Prepare reinforcement on tunnel for installation

AR63.40-P-1185-02QA

Round wire brush, braided, dia. 70 mm

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

Drill
gotis://K_58.1_04.0

Angle grinder
gotis://K_58.1_07.0



Install

13

Install crossmember reinforcement below rear seat

AR63.10-P-0696-03QA



General information on riveting

AH60.00-P-0003-01N

 Side portal frame

*210589172300

 Inspection and welding device

*209589002300

 Inspection and welding device

*203589002300

Round wire brush, braided, dia. 70 mm

Electrode miller

Blind rivet/punch riveting method
gotis://K_68-80_06.0

Hand riveter

Clamping pliers

Polygrip flat round head rivet, 6.414

*BR00.45-Z-1001-13A

Manual temporary fastener, dia. 6.4 mm - clamping range 0 - 15 mm, identification color silver

MIG MAG gas welder (steel, brazing, aluminum)
gotis://K_60-65_17.1

Drill
gotis://K_58.1_04.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

14

Install reinforcement on tunnel

AR63.40-P-1185-03QA

MIG MAG gas welder (steel, brazing, aluminum)
gotis://K_60-65_17.1

Drill
gotis://K_58.1_04.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

15

Install B-pillar reinforcement

AR63.10-P-0696-05QA



General information on riveting

AH60.00-P-0003-01N

Blind rivet/punch riveting method
gotis://K_68-80_06.0

Hand riveter

Clamping pliers

Polygrip flat round head rivet, 6.414

*BR00.45-Z-1001-13A

Manual temporary fastener, dia. 6.4 mm - clamping range 0 - 15 mm, identification color silver

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

16

Install B-pillar complete

17

Release vehicle from straightening bench and lift with two-column lift, remove straightening bench

Two-post lifting platform 3.0-3.5 t, electromechanical
gotis://H_00.1_01.0

18

Clean weld joints and metal flanges with wire brush

19

Clean repair areas and prime using primer filler

20

Seam sealing following repair

Supplement standard sealant using MB preservative.

Sealant

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

21

Paint repair areas and adjacent surfaces

22

Cavity preservation following repair work



Notes on cavity preservation

Model 209

AH97.20-P-0001-01B

23

Install electric lines and vacuum lines in repair area

24

Install all removed detachable parts

Number

Designation

Order number

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1041-01A

Seam sealant, sprayable 310 ml

A 002 989 84 20

BR00.45-Z-1003-05A

Cavity sealant, solvent-free (1 l container)

A 000 986 72 70 05

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

A 003 990 35 97