Replace complete front end assembly together with reinforcement

AR62.30-P-1570LF

Replace complete front end assembly together with reinforcement

09.03.2020

Model

217, 222

Modification notes

12.12.2016

"Rework front crossmember" added.

Operation step 7

Shown on model 222

1

Front center reinforcement

2

Outer reinforcement

3

Front crossmember

3.1

Bolts

5

Bumper bracket

6

Support

7

Impact absorber

7.1

Bolts

Shown on model 222

1

Front center reinforcement

1.2

Bolts

1.3

Bolts

1.1

Screw

Shown on MODEL 222 on right side of vehicle

2

Outer reinforcement

2.2

Bolts

2.4

Bolts

2.1

Screw

2.3

Bolts

Shown on model 222

3

Front crossmember

3.1

Screw

5

Bumper bracket

5.1

Screw

6

Support

6.1

Bolts

Shown on MODEL 222 on right side of vehicle

7

Impact absorber

7.1

Bolts

 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 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

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

 

Remove/install

1

Remove all detachable parts in repair area

 Installation: Install detachable parts in repair area only after applying wax.

2

Unscrew bolts (1.1) on front center reinforcement (1)

3

Unscrew bolts (1.2) from front center reinforcement (1)

 Model 217
Mark adjustment depth of bolts (1.2) before removal and when installing adjust bolts (1.2) to the marked depth.

4

Unscrew bolts (1.3) and remove front center reinforcement (1)

5

Unscrew bolts (2.1, 2.2, 2.3, 2.4) on left or right outer reinforcements (2) and remove left or right outer reinforcements (2)

6

Unscrew bolts (3.1) and remove front crossmember (3)

 Installation: Align sleeves in front crossmember (3) before inserting bolts (3.1).

 Bolt, impact absorber to cross member

*BA62.30-P-1001-01G

7

Rework front crossmember (3)

Model 222
with code Z22 (Panic alarm system)
If front crossmember (3) is replaced.

AR62.30-P-1570-03LF

8

Unscrew bolts (7.1) on left and right impact absorber (7) and remove left and right impact absorber (7)

 Installation: Position bolts (7.1) and push impact absorbers (7) with front crossmember (3) straight toward rear until impact absorbers (7) are flush with upper and lower bolts (7.1).

 Bolt, impact absorber to longitudinal member

*BA62.30-P-1002-01G

9

Unscrew bolts (5.1) and remove bumper brackets (5)

10

Unscrew bolts (6.1) and remove supports (6)

11

Install in the reverse order

12

Apply wax to connections on body

Topical note

Notes on cavity preservation

AH97.20-P-0001-01B



000 588 01 72 00 Sealing and corrosion protection gun

WS97.00-N-0002B

Cavity preservation (free of solvents), 1 liter

*BR00.45-Z-1003-05A

 Cross member and front reinforcement

Number

Designation

Model 217

Model 222

BA62.30-P-1001-01G

Bolt, impact absorber to cross member

M12

Nm

140

140

 Cross member and front reinforcement

Number

Designation

Model 217

Model 222

BA62.30-P-1002-01G

Bolt, impact absorber to longitudinal member

M12

Stage 1

Nm

100

100

Stage 2

°

100

100

Repair materials

Number

Designation

Order number

BR00.45-Z-1003-05A

Cavity preservation (free of solvents), 1 liter

A 000 986 72 70 10