Replace Partial Main Floor - AR63.40-P-1180GZ
MODEL 164
MODEL 166
Shown on model 164.8
| Remove | |||
| 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 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 | |
| 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 components when performing electric welding and soldering work | AH60.00-P-0001-02A | ||
| General information on body repair | AH60.00-N-0001-01A | ||
| 1 | Remove all detachable parts in repair area | ||
| 2 | Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket | ||
| 3 |
Equip straightening bench with module members, cross members and straightening tool set 000 588 01 23 00 Body straightening system |
WS60.00-P-0023K | |
| 4 |
Place vehicle on straightening bench and fasten 000 588 00 80 00 Vehicle lift |
WS00.00-P-0040B | |
| 5 | Remove B-pillar complete | Model 166.8 | AR63.20-P-1350GQX |
| Model 166.0 | AR63.20-P-1350GQ | ||
| Model 164 | AR63.20-P-0550GZ | ||
| 6 | Partially separate main floor | Wet and dry vacuum cleaner Rotary wire brush Spot weld milling machine Body jig saw |
AR63.40-P-1180-20GZ |
| 7 | Prepare mating surfaces on vehicle for partial main floor | AR63.40-P-1180-19GZ | |
| Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint | *BR00.45-Z-1001-07A | ||
| 8 | Prepare main floor section for installation | AR63.40-P-1180-21GZ | |
| Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint | *BR00.45-Z-1001-07A | ||
| Install | |||
| 9 | Install partial main floor, fit and weld in | AR63.40-P-1180-22GZ | |
| General information on riveting | AH60.00-P-0003-01N | ||
| Blind rivet 6.5X14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1016-13A | ||
| Fig 1 | |||
| 10 | Install B-pillar complete | Model 166.8 | AR63.20-P-1350GQX |
| Model 166.0 | AR63.20-P-1350GQ | ||
| Model 164 | AR63.20-P-0550GZ | ||
| 11 |
Release vehicle from straightening bench, lift vehicle and remove straightening bench 000 588 00 80 00 Vehicle lift | WS00.00-P-0040B | |
| 12 | Clean weld joints and sheet metal flanges with rotary wire brush | ||
| 13 | Clean repair area | ||
| 14 | Remove welding protection blankets | ||
| 15 | Risk of explosion
caused by paint vapors igniting. Risk of poisoning
caused by inhaling paint vapors. Prime repair area using primer filler |
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 |
| 16 | Perform seam sealing after repair | Model 166 | AR97.10-P-4000GQ |
| Model 164 | AR97.10-P-4000GZ | ||
| 17 | Risk of explosion
caused by paint vapors igniting. Risk of poisoning
caused by inhaling paint vapors. Paint repair areas and adjacent surfaces |
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 |
| 18 | Add cavity preserving agent | Model 166 | AR97.20-P-1500GQ |
| Model 164 | AR97.20-P-1500GZ | ||
| 19 | Reinstall all detachable parts removed | ||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint | A 000 986 34 42 |
| BR00.45-Z-1016-13A | Blind rivet 6.5X14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | A 004 990 17 97 |