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

MODEL 220 

Shown on model 220.0/1 

Fig 1: Identifying Main Floor Panel, Reinforcement And Front Crossmember

Courtesy of MERCEDES-BENZ USA

	Removing
	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.
	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.
	Measures for preventing damage to vehicles or components when performing electric welding work	All models
	General information on body repair	All models
	Notes on paintwork repairs	Model 124, 126, 129, 140, 163, 168, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463, 639
	General information on MB materials	Model 124, 126, 129, 140, 163, 168, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463, 639
1	Remove engine hood
2	Remove front fender
3	Remove front door
4.1	Remove center door	Model 220.875/878	AR72.14-P-0010MP
5	Remove rear door
6	Remove left and right front seats	Model 220.875/878
		Model 220.0/1 up to 31.8.02
		Model 220.0/1 as of 1.9.02 with code 803 model year 2003
7	Remove rear seat backrest	Model 220 875/878 with electrically adjustable rear bench seat, code 223b Model 220.875/878 except electrically adjustable rear bench seat, code 223b, except electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c Model 220 875/878 with electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c
		Model 220 0/1 with electrically adjustable rear bench seat, code 223b
		Model 220.0/1 except electrically adjustable rear bench seat, code 223b, except electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c
		Model 220 0/1 with electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c
		Model 220.875/878 with Vis-a-vis seats	AR91.12-P-1620MP
8	Remove floor mats
9	Cover vehicle passenger compartment
10	Remove detachable parts in area to be repaired
11	Cover all detachable parts remaining in vehicle	Tarp (fire-resistant)
12.1	Fit shims for straightening bench	The shim plates are required as of vehicle no. 165 to compensate the height difference between the welded spacer plates on the rear-axle mount in relation to the other lift support points. On vehicles up to vehicle no. 164 the plates are only inserted and can be removed when installing the straightening bench.
	Shim for MZ elements	Model 220.8	WF58.50-P-3330-05A
13	Equip Celette or Car-Bench straightening bench with modular members or cross members and straightening set	Observe setup plans provided. With model 220.8, the module members at the B1-S-column must be offset backwards by a meter. Fit shims with relevant MZ elements on straightening bench.
	Shim for MZ elements	Model 220.8 Passenger car straightening system (Celette) Straightening systems for passenger cars (Car a Bench)	WF58.50-P-3330-05A
14	Place vehicle on straightening bench using two-column lift	Two-post lifting platform 3.0-3.5 t, electromechanical
15	Fasten vehicle to straightening bench
16	Remove outer side wall	Except 220.8	AR63.10-P-0520M
		Model 220.8	AR63.10-P-0805MP
17	Remove inner A-pillar	Except model 220.8	AR63.20-P-1100M
		Model 220.8	AR63.20-P-1106MP
18	Remove inner B-pillar		AR63.20-P-1380-01M
19.1	Remove inner B1-pillar	Model 220.8	AR63.20-P-1361MP
20	Separate main floor (1), inner longitudinal member and center cross member		AR63.40-P-1180-06M
		Spot weld milling cutter Vario Drill WS 91 spot weld removing tool 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, Ø 65 mm, 80 m/s (max. 23, 500 rpm) Drill Straight grinder Angle grinder Body jig saw Tarp (fire-resistant)	Figure
21	Prepare main floor (1), inner longitudinal member and center cross member		AR63.40-P-1180-07M
		Round wire brush, braided, dia. 70 mm Hole punching pliers, dia. 7 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Cutting disk, Ø 65 mm, 80 m/s (max. 23, 500 rpm) Drill Straight grinder Angle grinder
	Install
22	Install main floor (1), inner longitudinal member and center cross member		AR63.40-P-1180-08M
		Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Clamping pliers Electrode miller MIG MAG gas welder (steel, brazing, aluminum) Inverter spot welder Drill Straight grinder Angle grinder Wet/dry vacuum cleaner Two-post lifting platform 3.0-3.5 t, electromechanical Tarp (fire-resistant)
23	Prepare inner B-pillar for installation		AR63.20-P-1350-02M
24	Prepare inner B-pillar with longitudinal member reinforcement between side wall		AR63.20-P-1380-02M
25	Weld in inner section and console		AR63.20-P-1100-04M
26	Install inner A-pillar	Except model 220.8
		Model 220.8	AR63.20-P-1106MP
27	Install inner B-pillar		AR63.20-P-1380-02M
28.1	Install inner B1-S-pillar	Model 220.8	AR63.20-P-1361MP
29	Install outer sidewall	Except 220.8
		Model 220.8	AR63.10-P-0805MP
30	Unfasten vehicle from straightening bench
31	Lift vehicle with two-post lift	Two-post lifting platform 3.0-3.5 t, electromechanical
32	Remove straightening bench.
33	Clean weld joints and sheet metal flange with round wire brush	Round wire brush, braided, dia. 70 mm
34	Clean repair areas
35	Prime repair area using primer filler
36	Carry out seam sealing after repairs	Supplement standard sealants with MB body sealant.
		Sealant	*BR00.45-Z-1003-01A
37	Paint repair areas and adjacent surfaces
38	Apply additional cavity preservation
	Notes on cavity preservation	Model 124, 126, 129, 140, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 463, 639, 671, 690.6, 901, 902, 903, 904, 905 Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7 Combination pressure spray gun (corrosion protection)
		MB cavity wax preservation, 1 l	*BR00.45-Z-1003-05A
39	Remove tarp from all covered parts that remained in the vehicle.	Tarp (fire-resistant)
40	Remove left and right front seats	Model 220.875/878
		Model 220.0/1 up to 31.8.02
		Model 220.0/1 as of 1.9.02 with code 803 model year 2003
41	Install rear seat backrest	Model 220 875/878 with electrically adjustable rear bench seat, code 223b Model 220.875/878 except electrically adjustable rear bench seat, code 223b, except electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c Model 220 875/878 with electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c
		Model 220 0/1 with electrically adjustable rear bench seat, code 223b
		Model 220.0/1 except electrically adjustable rear bench seat, code 223b, except electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c
		Model 220.0/1 with electrically adjustable individual rear seats, with seat ventilation, seat heater and memory package, code 224c
		Model 220.875/878 with Vis-a-vis seats	AR91.12-P-1620MP
42	Install floor mats
43	Install engine hood
44	Install front fender
45	Install front door
46.1	Install center door	Model 220.875/878	AR72.14-P-0010MP
47	Install rear door
48	Install all removed detachable parts

Special tools 

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

Courtesy of MERCEDES-BENZ USA