Replace Partial Main Floor - Ar63.40-P-1180GZ

Model 164 

Model 166 

Shown on model 164.8 

Courtesy of MERCEDES-BENZ USA

	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.	AS00.00-Z-0017-01A .
		Deburr repair panels.
Topical note	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A .
Topical note	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 .
		Observe set-up plans provided.
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		AR63.40-P-1180-20GZ .
		Commercially available devices/tools  Wet and dry vacuum cleaner Rotary wire brush Spot weld milling machine Body jig saw
7	Prepare mating surfaces on vehicle for partial main floor		AR63.40-P-1180-19GZ .
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A .
8	Prepare main floor section for installation		AR63.40-P-1180-21GZ .
		Zinc dust paint suitable for spot welding	*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 .
		Inspection and welding device
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	On all covered parts remaining in vehicle.
	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 .
15	Prime repair area using primer filler	Use only primer filler approved by Daimler AG.
16	Perform seam sealing after repair	Model 166	AR97.10-P-4000GQ .
		Model 164	AR97.10-P-4000GZ .
		Supplement standard seam seal.
	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 .
17	Paint repair areas and adjacent surfaces	Use only paints approved by Daimler AG.
18	Add cavity preserving agent	Model 166	AR97.20-P-1500GQ .
		Model 164	AR97.20-P-1500GZ
19	Reinstall all detachable parts removed

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	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