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Home >> Mercedes Benz >> 2007 >> C230 Automatic >> Repair and Diagnosis >> Collision >> Body Panels >> Body Panels -- Testing & Repair -- 203 Chassis - 2 Of 2 >> Testing & Repair >> Partially replace main floor - AR63.40-P-1180P

Partially replace main floor - AR63.40-P-1180P

MODEL 203.0/ 2/7, 209 

Shown on model 203.0 

Fig 1: Identifying Main Floor, Connection Carrier, Front/Rear Cross Member And Inner Longitudinal Member - Shown On Model 203.0
G04738914
REMOVING Remove     
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 undeburred vehicle parts.
Deburr replacement panels.		 AS00.00-Z-0017-01A
DANGER Risk of death  cased by vehicle slipping or toppling off of the lifting platform. Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
DANGER Risk of death  caused by high voltage used for arc welding. Risk of explosion  caused by welding in the area of highly inflammable materials. Risk of injury  caused by welding spatter and UV-light while welding. Risk of poisoning  caused by inhaling welding vapors. Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor. AS00.00-Z-0007-01A
NOTES General information on body repair   AH60.00-N-0001-01A
NOTES Measures for preventing damage to vehicles or components during electro-welding   AH00.00-N-0005-01A
NOTES Notes on paintwork repairs   AH98.00-P-9408-02A
IMPORTANT General information on MB materials   AH98.00-P-9409-03A
1.1 Remove B-pillar with side longitudinal member Model 203.0/203.2 AR63.20-P-0550P 
1.2 Side damage at center Model 203.7 AR63.10-P-0550PB
1.3 Remove outer B-pillar together with side longitudinal member Model 209.3 AR63.20-P-1370Q
1.4 Remove B-pillar complete Model 209.4 AR63.20-P-1350QA
2 Remove detachable parts in area to be repaired    
3 Cover all detachable body components that remain in the area to be repaired Tarpaulin (fireproof) *WH58.30-Z-1001-40A 
4 Separate main floor (1), inner longitudinal member (5) and center cross member   AR63.40-P-1180-06P 
    SPECIAL TOOL Spot weld milling cutter Figure
    COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot-weld loosening tool *WH58.30-Z-1006-01A 
    COMMERCIALLY AVAILABLE TOOLS Spherical cutter, dia. 12 mm *WH58.30-Z-1002-01A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Abrasive disc, dia. 115 mm, 80 m/s (max. 13.250 rpm) *WH58.30-Z-1024-04A 
    COMMERCIALLY AVAILABLE TOOLS Cutting disc, dia. 65 mm, 80 m/s (max. 23.500 rpm) *WH58.30-Z-1021-04A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint which can be spot welded *BR00.45-Z-1001-07A 
5 Prepare main floor (1), inner longitudinal member (5) and center cross member   AR63.40-P-1180-07P 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Hole punching pliers, dia. 6 mm *WH58.30-Z-1001-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
    Zinc dust paint which can be spot welded *BR00.45-Z-1001-07A 
INSTALLING Install     
6 Install main floor (1), inner longitudinal member (5) and center cross member   AR63.40-P-1180-08P 
IMPORTANT General notes on riveting   AH60.00-P-0003-01N
    COMMERCIALLY AVAILABLE TOOLS Electrode miller *WH58.30-Z-1003-01A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Abrasive disc, dia. 115 mm, 80 m/s (max. 13.250 rpm) *WH58.30-Z-1024-04A 
    COMMERCIALLY AVAILABLE TOOLS Hand riveter *WH58.30-Z-1003-29A 
    COMMERCIALLY AVAILABLE TOOLS Manual temporary fastener, dia. 6 mm, clamping area 0 to 15 mm, identification color silver *WH58.30-Z-1038-02A 
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    Inert gas welder *WE58.40-Z-1001-02A 
    Spot welder *WE58.40-Z-1002-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
    Polygrip flat/round head rivet, 6.4x14 *BR00.45-Z-1001-13A 
    Sealant *BR00.45-Z-1003-01A 
    Zinc dust paint which can be spot welded *BR00.45-Z-1001-07A 
7.1 Install B-pillar with side longitudinal member Model 203.0/203.2 AR63.20-P-0550P 
7.2 Side damage at center Model 203.7 AR63.10-P-0550PB
7.3 Installing outer B-pillar with side longitudinal member Model 209.3 AR63.20-P-1370Q
7.4 Install B-pillar complete Model 209.4 AR63.20-P-1350QA
8 Weld main floor (1) to bottom   AR63.40-P-1180-12P 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    Inert gas welder *WE58.40-Z-1001-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Tarpaulin (fireproof) *WH58.30-Z-1001-40A 
    Hollow cavity preservation gun Sata HRS no. 11072 *WE58.40-Z-1006-08A 
    Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
    Sealant *BR00.45-Z-1003-01A 
    Preservation agent *BR00.45-Z-1003-05A 
    Zinc dust paint which can be spot welded *BR00.45-Z-1001-07A 
9 Clean repair areas    
10 Prime area to be repaired with priming filler    
11 Carry out seam sealing after repairs Model 203 AR97.10-P-4000P
    Model 209 AR97.10-P-4000Q
    IMPORTANT Supplement standard seals with MB preservative.  
12 Paint repair areas and adjacent surfaces    
13 Perform cavity preservation after repair work Model 203.0 AR97.20-P-1500P
    Model 203.2 AR97.20-P-1500PA
    Model 203.7 AR97.20-P-1500PB
    Model 209 AR97.20-P-1500Q
NOTES Notes on cavity preservation   AH97.20-P-0001-01B
14 Remove tarpaulin on all detachable body components in area to be repaired    
15 Install all removed detachable body components    
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G04738915
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1002-01A Ball cutter, dia. 12 mm
WH58.30-Z-1003-01A Electrode miller
WH58.30-Z-1006-01A Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1001-02A Hole punching pliers, dia. 6 mm.
WH58.30-Z-1003-02A Clamping pliers
WH58.30-Z-1038-02A Manual temporary fastener, dia.6.4 mm - clamping range 0 -15 mm, identification color silver Firma Hausmann GmbH D-34346 Hann. Munden, Germany
WH58.30-Z-1001-03A Round wire brush, braided, dia. 70 mm
WH58.30-Z-1021-04A Cutting disk, dia. 65 mm, 80 m/s (max. 23,500 rpm)
WH58.30-Z-1024-04A Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)
WH58.30-Z-1003-29A Hand riveter
WH58.30-Z-1001-40A Tarp (fire-resistant)
WORKSHOP EQUIPMENT

WE58.40-Z-1001-02A Inert gas welder
WE58.40-Z-1002-02A Spot welder
WE58.40-Z-1001-03A Drill (electric/pneumatic)
WE58.40-Z-1002-03A Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A Body saw (electric/pneumatic)
WE58.40-Z-1005-03A Wet/dry vacuum cleaner
WE58.40-Z-1006-08A Cavity preservation gun
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1003-01A Sealant 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 Preservation agent 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 Rivet A 003 990 35 97
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