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Home >> Mercedes Benz >> 2021 >> E53 AMG 2D Convertible >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Collision - Side Wall (238 Chassis) >> Side Wall Body Repair >> Partially Install Main Floor Panel - Ar63.40-P-1180-27LWO

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

Model 238 

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-1032-13A Blind rivet Y4 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN) A 003 990 81 97
BR00.45-Z-1035-13A Blind rivet Y1 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) A 000 991 76 32
BR00.45-Z-1044-13A Countersunk-head blind rivet Z2 6.4X15.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) A 000 991 83 32
BR00.45-Z-1056-07A 1K-zinc dust paint A 000 986 28 00
BR00.45-Z-1162-02A Parts kit for 2-component adhesive for body A 012 989 17 71

IMPORTANT The next steps are shown on the left side of the vehicle and must be performed in a similar manner on the right side of the vehicle in the event of damage.

G15467442Courtesy 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 bottom longitudinal member, fit and fix in place.
  4. Drill rivet holes in main floor (1) and lower longitudinal member with Ø 6.7 mm (areas A, B1 and C).

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

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

    G15467443Courtesy of MERCEDES-BENZ USA
  5. Mark position of rivet holes on main floor (1).

    IMPORTANTDimensions  :

    d = 8 mm

    e = 41 mm

    f = 70 mm

    g = 45 mm

    h = 29 mm

    i = 35 mm

    j = 27 mm

    k = 10 mm

    l = 14 mm

    m = 30 mm

    G15467444Courtesy of MERCEDES-BENZ USA
  6. Drill rivet holes in main floor (1) with Ø 6.7 mm (areas N1 and N2 ).

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

    G13774100Courtesy of MERCEDES-BENZ USA
  7. Drill rivet holes in lower longitudinal member (6) with Ø 6.7 mm bit (areas N3 ).
  8. Remove main floor (1) and lower longitudinal member (6).
  9. Deburr rivet holes on main floor (1), bottom longitudinal member (6) and body on both sides.
  10. Remove drill chips.
  11. 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.

    G15467446Courtesy of MERCEDES-BENZ USA
  12. Apply 2-component adhesive to body in cross-hatched 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.

  13. 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.

    G13774095Courtesy of MERCEDES-BENZ USA
    G15467448Courtesy of MERCEDES-BENZ USA
  14. Install main floor (1) and bottom longitudinal member and fix in place.
  15. Rivet main floor (1) and bottom longitudinal member withØ 6.4x12 rivet (areas P1 ).

    IMPORTANT Clamping range 1.90 mm

  16. Rivet main floor (1) and bottom longitudinal member withØ 6, 4x12 rivets (areas P4).

    IMPORTANT Clamping range 3.00 mm up to 3.20 mm

    G15467449Courtesy of MERCEDES-BENZ USA
  17. Rivet main floor (1) with Ø 6.4x12 rivet (area Q).

    IMPORTANT Clamping range 1.70 mm

  18. Rivet main floor (1) with Ø 6.5x12.5 rivets (areas Q2 ).

    IMPORTANT Clamping range 2.90 mm up to 2.96 mm

    G13774105Courtesy of MERCEDES-BENZ USA
  19. Rivet bottom longitudinal member (6) with Ø 6.5x12.5 rivet (areas R).

    IMPORTANT Clamping range 2.80 mm

    G15467451Courtesy of MERCEDES-BENZ USA
  20. Install front front seat crossmember (3) and rear front seat crossmember (4), align and fix in place.

    IMPORTANTDimensions  :

    r = 576 mm

    s = 576 mm

    G15467452Courtesy of MERCEDES-BENZ USA
  21. Drill rivet holes in front seat front crossmember (3) in front seat rear crossmember (4) and in reinforcement (5) with Ø 6.7 mm (areas S1 and S2 ).

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

  22. Drill rivet holes in reinforcement (5) with Ø 6.7 mm bit (area S4 ).
  23. Drill rivet holes in front reinforcement (7) and in rear reinforcement (8) with Ø 6.7 mm (areas S3 ).
    G15467453Courtesy of MERCEDES-BENZ USA
  24. Drill rivet holes in front front seat crossmember (3) and in rear front seat crossmember (4) with Ø 6.7 mm bit (areas T).
  25. Remove front front seat crossmember (3) and rear front seat crossmember (4).
  26. Deburr rivet holes on front front seat crossmember (3), rear front seat crossmember (4) and body on both sides.
  27. Remove drill chips.
  28. Coat with zinc dust paint insides of those riveted joints that will not be bonded.
    G15467454Courtesy of MERCEDES-BENZ USA
    G15467455Courtesy of MERCEDES-BENZ USA
  29. Install front front seat crossmember (3) and rear front seat crossmember (4) and fix in place.
  30. Rivet front front seat crossmember (3), rear front seat crossmember (4) and reinforcement (5) with Ø 6.4x12 rivets (areas U1 ).

    IMPORTANT Clamping range 1.95 mm up to 2.05 mm

  31. Rivet front front seat crossmember (3), rear front seat crossmember (4), reinforcement (5) and bottom longitudinal member with Ø 6.5x12.5 rivets (areas U2 ).

    IMPORTANT Clamping range 3.10 mm up to 3.50 mm

  32. Rivet front front seat crossmember (3) and rear front seat crossmember (4) with Ø 6.5x12.5 (areas U4 ).

    IMPORTANT Clamping range 4.00 mm up to 4.10 mm

  33. Rear rear front seat crossmember (4) SHIELDED GAS SEAM WELD (area U3 ).
  34. Rivet front reinforcement (7) and rear reinforcement (8) with rivets Ø 6.4x12 (areas U6 ).

    IMPORTANT Clamping range 2.30 mm

  35. Rivet front reinforcement (7) with rivets Ø 6.5x14.5 (area U7 ).

    IMPORTANT Clamping range 5.25 mm

  36. Rivet rear reinforcement (8) with rivets Ø 6.5x12.5 (areas U8 ).

    IMPORTANT Clamping range 3.80 mm up to 4.16 mm

  37. Front reinforcement (7) SHIELDED GAS SEAM WELD (areas U5 ).
    G15467456Courtesy of MERCEDES-BENZ USA
  38. Rivet front seat front crossmember (3) with rivets Ø 6.5x12.5 (area V1 ).

    IMPORTANT Clamping range 3.50 mm

  39. Rivet front front seat crossmember (3) and rear front seat crossmember (4) with Ø 6.5x12.5 rivet (areas V2 ).

    IMPORTANT Clamping range 4.20 mm up to 4.30 mm

  40. Rivet front front seat crossmember (3) and rear front seat crossmember (4) with Ø 6, 5x12.5 rivets (areas V3).

    IMPORTANT Clamping range 5.25 mm up to 5.35 mm

    G14543898Courtesy of MERCEDES-BENZ USA
  41. Install connecting carrier (2), fit and fix in place.
  42. Drill rivet holes in connecting carrier (2) with Ø 6.7 mm (area W1, W2 and W5 ).

    IMPORTANT Drill rivet holes from bottom through present holes in body (area W2 ).

    G14543899Courtesy of MERCEDES-BENZ USA
  43. Drill rivet holes in connecting carrier (2) with Ø 6.7 mm (areas W6 and W7 ).
  44. Countersink rivet holes on connecting carrier (2) (areas W7 ).
    G14543900Courtesy of MERCEDES-BENZ USA
    G13774116Courtesy of MERCEDES-BENZ USA
  45. Drill rivet holes in lower longitudinal member (6) with Ø 6.7 mm (areas W3 and W4 ).

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

  46. Remove connecting carrier.
  47. Deburr rivet holes on connecting carrier and body on both sides.
  48. Remove drill chips.
  49. 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.

  50. Apply 2-component adhesive to body in cross-hatched areas.

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

    G13774117Courtesy of MERCEDES-BENZ USA
  51. Install connecting carrier (2) and fix in place.
  52. Rivet connecting carrier (2) with Ø 6.4x12 rivet (areas X1 ).

    IMPORTANT Clamping range 1.70 mm up to 2.20 mm

  53. Rivet connecting carrier (2) with Ø 6.5x12.5 rivets (areas X2 ).

    IMPORTANT Clamping range 3.70 mm up to 4.58 mm

  54. Rivet connecting carrier (2) with rivets Ø 6.5x12.5 (areas X3 ).

    IMPORTANT Clamping range 2.60 mm up to 3.20 mm

  55. Rivet connecting carrier (2) with rivets Ø 6.4 M6 (area X4 ).

    IMPORTANT Clamping range 7.16 mm up to 7.64 mm

  56. Rivet connecting carrier (2) with Ø 6.5x14.5 rivets (area X5 ).

    IMPORTANT Clamping range 5.02 mm up to 6.09 mm

  57. Rivet connecting carrier (2) SHIELDED GAS SEAM WELD (area X6 ).
    G14543903Courtesy of MERCEDES-BENZ USA
  58. Rivet connecting carrier (2) with rivets Ø 6.5x12.5 (areas X7 ).

    IMPORTANT Clamping range 3.97 mm up to 4.47 mm

  59. Rivet connecting carrier (2) with rivets Ø 6.5x12.5 (area X8 ).

    IMPORTANT Clamping range 3.20 mm

  60. Rivet connecting carrier (2) with rivets Ø 6.5x14.5 (area X9 ).

    IMPORTANT Clamping range 5.75 mm

  61. Rivet connecting carrier (2) with countersunk-head blind rivets Ø 6.4x15.5 (areas X10 ).

    IMPORTANT Clamping range 3.97 mm

  62. Drill one panel thickness of connecting carrier (2) with Ø 7 mm bit (area Y).
  63. Connecting carrier (2) SHIELDED GAS PLUG WELD (area Y).
    G14543904Courtesy of MERCEDES-BENZ USA
    G13774120Courtesy of MERCEDES-BENZ USA
  64. Rivet bottom longitudinal member (6) with Ø 6.5x12.5 rivet (areas Z).

    IMPORTANT Clamping range 2.95 mm up to 3.21 mm

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