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Partially Install Main Floor Panel - Ar63.40-P-1180-27LW

Model 205 

Model 253 

Model 293 

MAIN FLOOR PANEL PARTIAL INSTALLATION MODIFICATION NOTES

31.08.2021 Work procedure revised The whole document

IMPORTANT The following operation steps are shown on the left side of the vehicle on model 205.0. In case of damage on the right side of the vehicle, these steps must be performed analogously.

The superordinate service document as well as the safety information in the service document must be observed.

G14187034Courtesy of MERCEDES-BENZ USA
G14187035Courtesy of MERCEDES-BENZ USA
  1. Install main floor (1), fit and fix in place.
  2. Pre-drill rivet holes from below in main floor (1) with Ø 6.5 mm bit through existing holes in body (area A).
  3. Install, fit and fix lower longitudinal member (6) in place.
  4. Drill rivet holes in main floor (1) and lower longitudinal member (6) with 0 6.7 mm bit (areas A, B, C).

    IMPORTANT Drill rivet holes through present holes in main floor (1) (area A).

    Drill rivet holes through present holes in body (areas C).

  5. Model 205

    Drill rivet holes in main floor (1) with Ø 6.7 mm bit (areas B2 ).

    G14187036Courtesy of MERCEDES-BENZ USA
  6. Mark position of rivet holes on main floor (1).

    IMPORTANT Observe dimensions (d, e, f, g, h, i, j, k, l, m).

    G14187037Courtesy of MERCEDES-BENZ USA
  7. Drill rivet holes in main floor (1) with Ø 6.7 mm bit (areas N1 , N2 ).

    IMPORTANT Drill rivet holes at positions marked previously (areas N1 ).

    G14187038Courtesy of MERCEDES-BENZ USA
  8. Drill rivet holes in lower longitudinal member (6) with Ø 6.7 mm bit (areas N3 ).
  9. Remove main floor (1) and bottom longitudinal member (6).
  10. Deburr rivet holes on main floor (1), bottom longitudinal member (6) and body on both sides.
  11. Remove drill chips.
  12. Coat insides of riveted joints with zinc dust paint.

    NOTES Do not coat insides of riveted joints, to which 2-component adhesive is to be applied, with zinc dust paint.

    Otherwise adhesion problems may occur.

    G14187039Courtesy of MERCEDES-BENZ USA
  13. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Apply 2-component adhesive at bottom (area O). Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

  14. Apply 2-component adhesive to lower longitudinal member (6) in cross-hatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G14187040Courtesy of MERCEDES-BENZ USA
    G14187041Courtesy of MERCEDES-BENZ USA
    G14187042Courtesy of MERCEDES-BENZ USA
  15. Install main floor (1) and bottom longitudinal member and fix in place.
  16. Rivet main floor (1) and lower longitudinal member with Ø 6.4x12 rivets (areas P1 , P4 ).
  17. Model 205

    Rivet main floor (1) with Ø 6.4x12 rivet (areas P3 ).

  18. Drill one panel thickness of main floor (1) with Ø 7 mm bit (area P2 ).
  19. Main floor (1) SHIELDED GAS PLUG WELD (area P2 ).
    G14187043Courtesy of MERCEDES-BENZ USA
  20. Rivet main floor (1) with Ø 6.4x12 rivet (area O1 ).
  21. Rivet main floor (1) with Ø 6.5x12.5 rivets (areas O2 ).
    G14187044Courtesy of MERCEDES-BENZ USA
  22. Rivet bottom longitudinal member (6) with Ø 6.5x12.5 rivet (areas R).
    G14187045Courtesy of MERCEDES-BENZ USA
  23. Install front front seat crossmember (3) and rear front seat crossmember (4), align and fix in place.

    IMPORTANT Observe dimensions (r, s).

  24. Model 205

    Install, fit and fix in place reinforcement (5).

    G14187046Courtesy of MERCEDES-BENZ USA
  25. Drill rivet holes in front front seat crossmember (3), in rear front seat crossmember (4) and in reinforcement (5) with Ø 6.7 mm bit (areas S1 S2 ).
  26. Model 205.0/1/2/3, 253, 293 Drill rivet holes in reinforcement (5) with Ø 6.7 mm bit (area S4 ).

    IMPORTANT Drill rivet holes from bottom through present holes in body (area S2 ).

    G14187047Courtesy of MERCEDES-BENZ USA
  27. Model 253, 293

    Drill rivet holes in front front seat crossmember (3) and in rear front seat crossmember (4) with Ø 6.7 mm bit (areas S3 ).

    G14187048Courtesy of MERCEDES-BENZ USA
  28. Drill rivet holes in front front seat crossmember (3) and in rear front seat crossmember (4) with 0 6.7 mm bit (areas T).
  29. Model 205

    Drill rivet holes in front front seat crossmember (3), in rear front seat crossmember (4) and in reinforcement (5) with Ø 6.7 mm bit (areas T1 ).

  30. Model 205.0/1/2/3

    Drill rivet holes in reinforcement (5) with Ø 6.7 mm bit (area T5 ).

  31. Remove front front seat crossmember (3) and rear front seat crossmember (4).
  32. Model 205

    Remove reinforcement (5).

  33. Deburr rivet holes on front front seat crossmember (3), rear front seat crossmember (4) and body on both sides.
  34. Model 205

    Deburr rivet holes on reinforcement (5) and body on both sides.

  35. Remove drill chips.
  36. Coat with zinc dust paint insides of those riveted joints that will not be bonded.
    G14187049Courtesy of MERCEDES-BENZ USA
  37. Model 253, 293

    Apply 2-component adhesive to reinforcement (5) in area of connecting flange to rear-end floor.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

  38. Install front front seat crossmember (3) and rear front seat crossmember (4) and fix in place.
  39. Model 205

    Install and fix in place reinforcement (5).

  40. Rivet front front seat crossmember (3), rear front seat crossmember (4) and reinforcement (5) with 0 6.5x12.5 rivets (area U1 , U2 ).
    1. 41.1 Model 205.0/1/2/3, 253, 293

      Rivet reinforcement (5) with Ø 6.5x12.5 rivets (area U4 ).

    2. 41.2 Model 205.4

      Drill one panel thickness of reinforcement (5) with Ø 7 mm bit (area U4 ).

  41. Model 205.4

    Reinforcement (5) (area U4 ).

  42. Model 205

    Rear rear front seat crossmember (4) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area U3 ).

    G14187050Courtesy of MERCEDES-BENZ USA
  43. Model 253, 293

    Rivet front front seat crossmember (3) and rear front seat crossmember (4) with 0 6.5x12.5 rivets (areas U1 , U5 ).

    G14187051Courtesy of MERCEDES-BENZ USA
  44. Rivet front front seat crossmember (3) and rear front seat crossmember (4) with 0 6.4x12 rivets (areas V1 , V2 ).
  45. Model 205

    Rivet reinforcement (5) with Ø 6.4x12 rivet (areas V3 ).

  46. Model 205

    Rivet reinforcement (5) with 0 6.5x12.5 rivets (area V4 ).

  47. Model 205.0/1/2/3

    Rivet reinforcement (5) with Ø 6.4x12 rivets (area V5 ).

  48. Model 205.4

    Drill one panel thickness of reinforcement (5) with Ø 7 mm bit (area V5 ).

  49. Model 205.4

    Reinforcement (5) INSPECT (area V5 ).

  50. Model 205.4

    Install, fit and fix in place reinforcement (7).

  51. Model 205.4 Reinforcement (7) SHIELDED GAS SEAM WELD (areas Z2 ).
    Fig 1: Main Floor Panel Reinforcement Component Location (Model 205.4)
    G14187052Courtesy of MERCEDES-BENZ USA
    G14187053Courtesy of MERCEDES-BENZ USA
  52. Install connecting carrier (2), fit and fix in place.
  53. Drill rivet holes in connecting carrier (2) with 0 6.7 mm bit (areas W1 , W2 ).

    IMPORTANT Drill rivet holes from below through existing holes in body (areas W2 ).

  54. Model 205.0/2/3/4, 253, 293 with code 494 (US version) Drill rivet holes in connecting carrier (2) with 0 6.7 mm bit (areas W5 ).
  55. Model 205.0/2/3/4, 253, 293 with code 494 (US version) Drill rivet holes in front reinforcement and rear reinforcement with Ø 6.7 mm bit (areas W5 ).

    IMPORTANT The front reinforcement and rear reinforcement are part of the connecting carrier (2).

    G14187054Courtesy of MERCEDES-BENZ USA
    G14187055Courtesy of MERCEDES-BENZ USA
  56. Drill rivet holes in lower longitudinal member (6) with Ø 6.7 mm bit (areas W3 , W4 ).

    IMPORTANT Drill rivet holes through present holes in lower longitudinal member (6) (area W4 ).

  57. Remove connecting carrier (2).
  58. Deburr rivet holes on connecting carrier (2) and body on both sides.
  59. Remove drill chips.
  60. Coat insides of riveted joints with zinc dust paint.

    NOTES Do not coat insides of riveted joints, to which 2-component adhesive is to be applied, with zinc dust paint. Otherwise adhesion problems may occur.

    G14187056Courtesy of MERCEDES-BENZ USA
  61. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G14187057Courtesy of MERCEDES-BENZ USA
    G14187058Courtesy of MERCEDES-BENZ USA
  62. Install connecting carrier (2) and fix in place.
  63. Rivet connecting carrier (2) with 0 6.4x12 rivet (areas X1 ).
  64. Rivet connecting carrier (2) with Ø 6.5x12.5 rivets (areas X2 ).
  65. Drill one panel thickness of connecting carrier (2) with Ø 7 mm bit (area Y).
  66. Connecting carrier (2) SHIELDED GAS PLUG WELD (area Y).
  67. Model 205.0/2/3/4, 253, 293 with code 494 (US version) Rivet connecting carrier (2) with Ø 6.4x12 rivet (area X3 ).
  68. Model 205.0/2/3/4, 253, 293 with code 494 (US version) Rivet connecting carrier (2) with Ø 6.5x12.5 rivets (areas X4 ).
    G14187059Courtesy of MERCEDES-BENZ USA
  69. Model 205.0/2/3/4, 253, 293 with code 494 (US version) Rivet connecting carrier (2) with Ø 6.5x14.5 rivets (areas X5).
  70. Model 205.0/2/3/4, 253, 293 with code 494 (US version) Rivet connecting carrier (2) SHIELDED GAS SEAM WELD (area X6 ).
    G14187060Courtesy of MERCEDES-BENZ USA
  71. Rivet bottom longitudinal member (6) with Ø 6.5x12.5 rivet (areas Z).
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