Partially replace main floor - AR63.40-P-1180CW: Notes

WARNING: This page is about a different car, the 2011 Mercedes-Benz C300, 2010 Mercedes-Benz C300, 2009 Mercedes-Benz C300, and 2008 Mercedes-Benz C300. However, it is still accessible from the selected car via links, so may be relevant.

MODEL 204

Shown on model 204.0

Fig 1: Identifying Main Floor Components

Courtesy of MERCEDES-BENZ USA

	Removing
	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
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	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
	Measures for preventing damage to vehicles or components when performing electric welding work		AH00.00-N-0005-01A
	General information on body repair		AH60.00-N-0001-01A
	Notes on paintwork repairs		AH98.00-P-9408-02A
	General information on MB materials		AH98.00-P-9409-03A
	General information on riveting		AH60.00-P-0003-01N
1	Prepare all workshop equipment and commercially available tools required for repair
2	Remove all detachable parts in area to be repaired
3	Cover all detachable parts remaining vehicle with fireproof tarpaulin
4	Equip straightening bench with module members, cross members and straightening tool set.	Observe setup plans provided.

5	Lift vehicle with two-post lifting platform
6	Set vehicle onto straightening bench
7	Fasten vehicle to straightening bench
8	Remove B-pillar complete
		Model 204.0/2	AR63.20-P-1350CW
		Model 204.3	AR63.20-P-1350CC
		Model 204.9	AR63.20-P-1350WX
9	Remove A-pillar outer section	Only remove A-pillar panels.
		Model 204.0/2	AR63.20-P-1102CW
		Model 204.3	AR63.20-P-1102CC
		Model 204.9	AR63.20-P-1102WX
10	Remove connecting carrier (1), front crossmember (2), rear crossmember (3), main floor panel (4), offset reinforcement (5), outer inner longitudinal member (6) and outer longitudinal member (7)		AR63.40-P-1180-06CW

		Spot weld milling cutter	Figure
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
11	Prepare connecting carrier (1), front crossmember (2), rear crossmember (3), main floor panel (4), offset reinforcement (5), outer inner longitudinal member (6) and outer longitudinal member (7)		AR63.40-P-1180-07CW
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
12	Install connecting carrier (1), front crossmember (2), rear crossmember (3), main floor panel (4), offset reinforcement (5), outer inner longitudinal member (6) and outer longitudinal member (7)		AR63.40-P-1180-08CW

		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 6.4X14	*BR00.45-Z-1001-13A
13	Install A-pillar outer section	Only install A-pillar panels.
		Model 204.0/2	AR63.20-P-1102CW
		Model 204.3	AR63.20-P-1102CC
		Model 204.9	AR63.20-P-1102WX
14	Install B-pillar complete
		Model 204.0/2	AR63.20-P-1350CW
		Model 204.3	AR63.20-P-1350CC
		Model 204.9	AR63.20-P-1350WX
15	Unfasten vehicle from straightening bench
16	Lift vehicle with two-post lifting platform
17	Remove straightening bench.
18	Clean weld joints and sheet metal flanges with rotary wire brush
19	Clean repair areas
	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 skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
20	Prime repair area using primer filler	Use only primer filler approved by Daimler AG.
21	Carry out seam sealing after repairs	Supplement standard sealant with sealant.	AR97.10-P-4000CW
		White sealing compound, 310 ml, DBL 6069.20	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
	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 skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
22	Paint repair areas and adjacent surfaces	Use only paints approved by Daimler AG.
	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 anticorrosion agents on flames or glowing hot 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
23	Apply additional cavity preservation		AR97.20-P-1500CW

	Notes on cavity preservation		AH97.20-P-0001-01B
		Cavity sealant, solvent-free (1 \| container)	*BR00.45-Z-1003-05A
24	Remove tarp	On all covered parts remaining in vehicle.
25	Install all removed detachable parts

Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

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-1092-02A	Adhesive kit, body, 2-component adhesive	A 009 989 36 71
BR00.45-Z-1003-05A	Cavity sealant, solvent-free (1 \| 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 6.4X14	A 003 990 35 97