Main Floor Panel Complete Replacement - Ar63.40-P-1160RG

Model 190 

Fig 1: Main Floor Panel And Adjacent Panels Component Locations (Model 190)

Courtesy of MERCEDES-BENZ USA

Shown on model 190.4 

	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
	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
Notice	General information on body repair		AH60.00-P-0001-01S
Notice	General information on crack diagnosis of aluminum parts		AH60.00-P-0014-01N
	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 the repair.
2	Remove detachable parts in area of repair points.
3	Cover all detachable parts that remain in the vehicle with fire-resistant welding protection blankets.
4	Remove end plate (2) and main floor (1).		AR63.40-P-1180-09RG
	000 588 15 84 00 Heat gun	Commercially available devices/tools  Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner	WS54.00-P-0125B
5	Remove inner longitudinal member weld-on plate (3).	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	AR63.30-P-1500-01RG
6	Remove rear and front rear crossmember reinforcement (4a and 5a) and rear and front crossmembers under front seat (4 and 5).	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	AR63.40-P-1190-01RG
7	Remove center main floor reinforcement (6).		AR63.40-P-1110-01RG
	000 588 15 84 00 Heat gun	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	WS54.00-P-0125B
8	Remove outer main floor reinforcement (7).	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	AR63.40-P-1100-01RG
	Preparation
Notice	Notes on processing of 2-K structural foam adhesive during body repairs		AH60.00-P-0040-01A
Notice	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
9	Prepare all mating surfaces at vehicle for main floor (1).	Commercially available devices/tools  Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner	AR63.40-P-1180-19RG
10	Prepare outer main floor reinforcement (7).	Commercially available devices/tools  Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner	AR63.40-P-1100-02RG
11	Prepare center main floor reinforcement (6).	Commercially available devices/tools  Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner	AR63.40-P-1110-02RG
12	Prepare rear and front crossmember reinforcement (4a and 5a) and rear and front crossmembers under front seat (4 and 5).	Commercially available devices/tools  Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner	AR63.40-P-1190-02RG
13	Prepare inner longitudinal member weld-on plate (3).	Commercially available devices/tools  Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner	AR63.30-P-1500-02RG
14	Prepare end plate (2) and main floor (1).	Commercially available devices/tools  Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner	AR63.40-P-1180-10RG
	Install
	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
	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
Notice	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A
	General notes on welding		AH60.00-P-0005-01N
	General information on riveting		AH60.00-P-0003-01N
15	Install outer main floor reinforcement (7).		AR63.40-P-1100-04RG
	000 588 12 84 00 Welder	Commercially available devices/tools  Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner	WS00.00-P-0318K
16	Install center main floor reinforcement (6).		AR63.40-P-1110-04RG
	000 588 04 39 00 Rivet press tool		WS60.00-P-0440B
	000 588 12 84 00 Welder	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	WS00.00-P-0318K
		Parts kit for 2-component adhesive for body	*BR00.45-Z-1162-02A
		Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	*BR00.45-Z-1012-13A
17	Install rear and front crossmembers under front seat (4 and 5) and rear and front crossmember reinforcement (4a and 5a).		AR63.40-P-1190-03RG
	000 588 12 84 00 Welder	Commercially available devices/tools  Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner	WS00.00-P-0318K
18	Install inner longitudinal member weld-on plate (3).		AR63.30-P-1500-03RG
	000 588 12 84 00 Welder	Commercially available devices/tools  Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner	WS00.00-P-0318K
19	Install main floor (1) and end plate (2).		AR63.40-P-1180-11RG
	000 588 04 39 00 Rivet press tool	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	WS60.00-P-0440B
		Parts kit for 2-component adhesive for body	*BR00.45-Z-1162-02A
		Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	*BR00.45-Z-1012-13A
		Blind rivet Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)	*BR00.45-Z-1016-13A
	Clean
20	Clean weld joints and sheet metal flange.	Commercially available devices/tools  Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner
21	Remove fire-resistant welding protection blankets.
22	Clean repair area.	Commercially available devices/tools  Wet/dry vacuum cleaner
	Paint
	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
	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
Notice	Notes on cavity preservation		AH97.20-P-0001-01B
Notice	Notes on sprayable joint sealant		AH97.10-P-0002-01A
Notice	Notes on paintwork repairs		AH98.00-P-9408-02A
	General information on operation items and work procedures for painting		AH98.00-P-0003-01A
	General note on use of 2-component acoustic filler foam following repairs		AH60.00-P-0033-01RQ
	Notes on seam seal		AH97.10-P-0002-02A
	General information on MB materials		AH98.00-P-9409-03A
23	Treat repair areas with primer filler.	Use only primer filler approved by Daimler AG. Guidelines for paint technology can be found at: https://xentry.daimler.com.
24	Seal seam after repair.	Supplement standard seals with sealant.	AR97.10-P-4000RG
25	Paint repair areas and adjacent surfaces.	Use only paints approved by Daimler AG. Guidelines for paint technology can be found at: https://xentry.daimler.com.
26	Supplement cavity preservation.		AR97.20-P-1500RG
	Assemble
27	Install detachable parts in the area of the repair point.

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1012-13A	Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	A 004 990 16 97
BR00.45-Z-1016-13A	Blind rivet Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)	A 004 990 17 97
BR00.45-Z-1162-02A	Parts kit for 2-component adhesive for body	A 012 989 17 71