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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 Remove Main Floor Panel - Ar63.40-P-1180-24LWO

Partially Remove Main Floor Panel - Ar63.40-P-1180-24LWO

Model 238 

REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1056-07A 1K-zinc dust paint A 000 986 28 00

IMPORTANT The following steps are shown on the left side of the vehicle and must be performed analogously on the right side in the event of damage.

  1. Expose spot welds on connecting carrier (2) and cut out (areas A).
  2. Expose spot welds on connecting carrier (2) and drill with Ø 6.5 mm (areas C).
  3. Expose inert gas welds on connecting carrier (2) and cut (area B).
    G14543866Courtesy of MERCEDES-BENZ USA
  4. Expose spot welds on connecting carrier (2) and cut out (areas R).

    IMPORTANT Joint spot welds on panels that are one behind the other must be cut out through two panel thicknesses.

    G14543867Courtesy of MERCEDES-BENZ USA
    G13774077Courtesy of MERCEDES-BENZ USA
  5. Expose spot welds on bottom longitudinal member (6) and drill with Ø 6.5 mm bit (areas P).
  6. Heat connecting carrier (2) in crosshatched area.

    IMPORTANT Cross-hatched area is bonded.

  7. Remove connecting carrier (2).
    G14543869Courtesy of MERCEDES-BENZ USA
  8. Expose spot welds on front reinforcement (7) and rear reinforcement (8) and cut out (areas T).
  9. Expose inert gas welds on front reinforcement (7) and cut (areas S).
    G15467428Courtesy of MERCEDES-BENZ USA
    G15467429Courtesy of MERCEDES-BENZ USA
  10. Expose inert gas weld seam on rear front seat crossmember (4) and cut (area D).
  11. Expose spot welds on front front seat crossmember (3) rear front seat crossmember (4) and reinforcement (5) and cut out (areas E, E1 and F1 ).

    IMPORTANT Cut out spot welds from below (areas E1 and F1 ).

  12. Expose spot welds on front front seat crossmember (3), rear front seat crossmember (4) and reinforcement (5) and drill with Ø 6.5 mm (areas G and G1 ).
  13. Expose spot welds on front front seat crossmember (3) and rear front seat crossmember (4) and cut out (areas H).

    IMPORTANT Joint spot welds on panels that are one behind the other must be cut out through two panel thicknesses.

  14. Remove front front seat crossmember (3) and rear front seat crossmember (4).
    G15467430Courtesy of MERCEDES-BENZ USA
    G15467431Courtesy of MERCEDES-BENZ USA
  15. Expose spot welds on main floor (1) and cut out (areas J1 and J3 ).
  16. Expose spot welds on main floor (1) and drill with Ø 6.5 mm bit (area J2 ).
    G13774084Courtesy of MERCEDES-BENZ USA
  17. Expose spot welds on bottom longitudinal member (6) and cut out (areas K).
  18. Heat bottom longitudinal member (6) in crosshatched areas.

    IMPORTANT Cross-hatched areas are bonded with adhesive.

  19. Remove bottom longitudinal member (6).
    G15467433Courtesy of MERCEDES-BENZ USA
  20. Mark separating on main floor (1) and cut (area L).

    NOTES Do not cut too deeply.

    Otherwise the components below can be damaged and weakened.

    IMPORTANTDimensions  :

    11 = approx.. 70 mm

    12 = approx. 55 mm

  21. Heat main floor panel (1) in cross-hatched areas.

    IMPORTANT Cross-hatched areas are bonded with adhesive.

  22. Remove main floor panel (1).
    G15467434Courtesy of MERCEDES-BENZ USA
  23. Grind mating surfaces down to bare metal in crosshatched area.
  24. Remove grinding dust and drill chips.

    IMPORTANT Observe pretreatment of bonding surfaces.

    G13774089Courtesy of MERCEDES-BENZ USA
  25. Sand down mating surfaces to bare metal in cross-hatched areas.
  26. Remove grinding dust and drill chips.
  27. Apply zinc dust paint to crosshatched areas.

    NOTES Do not coat bonding surfaces with zinc dust paint (areas N).

    Otherwise adhesion problems may occur.

    IMPORTANT Observe pretreatment of bonding surfaces.

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