Completely replace outer side longitudinal member

AR63.30-P-1000RG

Completely replace outer side longitudinal member

30.04.2019

Model

190

Modification notes

21.02.2017

Gap dimension, longitudinal member panel to fender/sidewall panel

Model 190.3

BE60.00-P-1009-01EA

1

Outer side longitudinal member

 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

 Danger

Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust

Wear dust filter mask, safety glasses and protective gloves.
Use a suitable, grounded dust extraction system.

AS60.00-Z-0007-01N

Topical note

General information on body repair

AH60.00-N-0001-01A

Topical note

General information on crack diagnosis of aluminum parts

AH60.00-P-0014-01N

Topical note

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

Note on working on aluminum components and vehicles

AH60.00-P-0034-01RG



Remove

1

Prepare all workshop equipment and commercially available devices/tools required for repair

2

Remove detachable parts in areas to be repaired

3

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

4

Remove the outer side longitudinal member (1)

AR63.30-P-1050-01RG



000 588 00 84 00 Heat gun

WS54.00-P-0049B



000 588 02 39 00 Rivet press tool

WS60.00-P-0010B

 Commercially available devices/tools
Vacuum unit suitable for aluminum dusts
Round wire brush
Spot weld milling machine
Drill bit and milling cutter for ultra-high-strength steels
Hand drill
Body saw
Wet/dry vacuum cleaner

Preparation

5

Prepare new outer side longitudinal member part (1) for installation

AR63.30-P-1050-02RG

 Commercially available devices/tools
Vacuum unit suitable for aluminum dusts
Round wire brush
Hand drill
Wet/dry vacuum cleaner



Install

 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

 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

Topical note

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

AH60.00-P-0001-02A

Topical note

Notes on processing of 2-K structural foam adhesive during body repairs

AH60.00-P-0040-01A

General notes on welding

AH60.00-P-0005-01N

General information on riveting

AH60.00-P-0003-01N

General note on use of 2-component acoustic filler foam following repairs

AH60.00-P-0033-01RQ

6

Install new outer side longitudinal member part (1)

AR63.30-P-1102-03RG



000 588 02 39 00 Rivet press tool

WS60.00-P-0010B



000 588 02 84 00 Welder

WS60.00-P-0022K

 Commercially available devices/tools
Vacuum unit suitable for aluminum dusts
Round wire brush
Drill bit for ultra-high-strength steels
Hand drill
Manual temporary fastener 6.35 mm
Wet/dry vacuum cleaner

Gap dimension, longitudinal member panel to fender/sidewall panel

*BE60.00-P-1009-01EA

Parts kit for 2-component adhesive for body

*BR00.45-Z-1162-02A

Blind rivet with countersunk head 6.415.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN)

*BR00.45-Z-1044-13A

Flow-form rivet structure 5.0 mm up to 6.1 mm clamping range (S48)

*BR00.45-Z-1052-13A

Flow-form rivet structure 7.1 mm up to 8.3 mm clamping range (S68)

*BR00.45-Z-1054-13A

2K-component filler foam

*BR00.45-Z-1090-01A

 Feeler gauge

*129589032100



Clean

7

Clean welds and sheet metal flanges

 Commercially available devices/tools
Vacuum unit suitable for aluminum dusts
Round wire brush
Hand drill
Wet/dry vacuum cleaner

8

Remove fire-resistant welding blankets

9

Clean repair area

 Commercially available devices/tools
Wet/dry vacuum cleaner

Paint

 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

 Danger

Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents

Never spray corrosion protection on flames or hot, glowing objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection.

AS97.00-Z-0001-01A

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

Topical note

Notes on sprayable joint sealant

AH97.10-P-0002-01A

Topical note

Notes on cavity preservation

AH97.20-P-0001-01B

Notes on seam seal

AH97.10-P-0002-02A

General information on MB materials

AH98.00-P-9409-03A

10

Prime repair areas using a primer filler

 Use only primer filler approved by Daimler AG. Guidelines for paint technology can be found at: https://xentryportal.i.daimler.com/wps/portal

11

Perform seam sealing after repair

AR97.10-P-4000RG

 Supplement standard seals with sealant.

12

Paint repair areas and adjacent surfaces

 Use only paints approved by Daimler AG. Guidelines for paint technology can be found at: https://xentryportal.i.daimler.com/wps/portal

13

Add cavity preserving agent

AR97.20-P-1500RG



Assemble

14

Install detachable parts in area to be repaired

Gap dimensions

Number

Designation

Model 190.3

Model 190.4

BE60.00-P-1009-01EA

Gap dimension, longitudinal member panel to fender/sidewall panel

Dimension "I"

mm

0 (+0,5)

0,5 (0,5)

See

AR60.00-P-0700-01RG

AR60.00-P-0700-01RG

Repair materials

Number

Designation

Order number

BR00.45-Z-1044-13A

Blind rivet with countersunk head 6.415.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN)

A 000 991 83 32

BR00.45-Z-1052-13A

Flow-form rivet structure 5.0 mm up to 6.1 mm clamping range (S48)

A 000 991 27 33

BR00.45-Z-1054-13A

Flow-form rivet structure 7.1 mm up to 8.3 mm clamping range (S68)

A 000 991 29 33

BR00.45-Z-1090-01A

2K-component filler foam

A 000 989 35 73

BR00.45-Z-1162-02A

Parts kit for 2-component adhesive for body

A 012 989 17 71