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Main Floor Panel Partial Installation - Ar63.40-P-1180-27FR

Model 257, 290 

IMPORTANT The following operation steps are shown on the left side of the vehicle on model 257. In case of damage on the right side of the vehicle, these steps must be performed analogously.

Additional information can be found in the superordinate service document.

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

G16555327Courtesy of MERCEDES-BENZ USA
  1. Install main floor (1), fit and fix in place.
  2. Drill rivet holes with a diameter of 6.5 mm in main floor (1) from below through the existing holes in the body (area A).
  3. Install bottom longitudinal member, fit and fix in place.
  4. Drill rivet holes on main floor (1) and bottom longitudinal member with 6.7 mm bit (areas A, B1 , and C).

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

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

    G16555328Courtesy 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=14mm

    M= 30 mm

    G16555329Courtesy of MERCEDES-BENZ USA
  6. Drill rivet holes on main floor (1) with 6.7 mm bit (areas N1 , N2 ).

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

    G16555330Courtesy of MERCEDES-BENZ USA
  7. Drill rivet holes on bottom longitudinal member (6) with ø 6.7 mm bit (areas N3 ).
  8. Remove main floor (1) and bottom longitudinal member (6).
  9. Deburr rivet holes on main floor (1), bottom longitudinal member (6) and body on both sides.
  10. Remove drilling 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.

    G16555331Courtesy of MERCEDES-BENZ USA
  12. 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.

  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.

    G16555332Courtesy of MERCEDES-BENZ USA
    G16555333Courtesy 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 with ø 6.4x12 rivet (areas P1 ).
  16. Rivet main floor (1) and bottom longitudinal member with ø 6, 4x12 rivets (areas P4 ).
    G16555334Courtesy of MERCEDES-BENZ USA
  17. Rivet main floor (1) with ø 6.4x12 rivet (area Q1 ).
  18. Rivet main floor (1) with ø 6.5x12.5 rivet (areas Q2 ).
    G16555335Courtesy of MERCEDES-BENZ USA
  19. Rivet bottom longitudinal member (6) with ø 6.5x12.5 rivet (areas R).
    G16555336Courtesy of MERCEDES-BENZ USA
  20. Install front seat crossmembers (3, 4), align, and fix in place.

    IMPORTANTDimensions: 

    r = 576 mm

    s = 576 mm

    G16555337Courtesy of MERCEDES-BENZ USA
  21. Drill rivet holes with a diameter of 6.7 mm in the front seat crossmembers (3, 4) and the reinforcement (5) (areas S1 , S2 ).

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

  22. Drill rivet holes on reinforcement (5) with ø 6.7 mm bit (area S4 ).
  23. Insert reinforcement (7) and position.
  24. Drill rivet holes with a diameter of 6.7 mm in reinforcement (7) of front seat rear crossmember (4) (area S3 ).
    G16555338Courtesy of MERCEDES-BENZ USA
    G16555339Courtesy of MERCEDES-BENZ USA
  25. Drill rivet holes on front seat crossmembers (3, 4) with 6.7 mm bit (areas T).
  26. Remove front seat crossmembers (3, 4).
  27. Deburr rivet holes on the front seat crossmembers (3, 4) and body on both sides.
  28. Remove drilling chips.
  29. Coat with zinc dust paint insides of those riveted joints that will not be bonded.
    G16555340Courtesy of MERCEDES-BENZ USA
  30. Install front seat crossmembers (3, 4) and fix in place.
  31. Rivet front seat crossmember (3, 4) and reinforcement (5) with rivets with a diameter of 6.4x12 (areas U1 ).
  32. Rivet front seat crossmembers (3, 4), reinforcement (5) and lower longitudinal member with rivets with a diameter of 6.5x12.5 (areas U2 ).
  33. Rivet front seat crossmembers (3, 4) with rivets with a diameter of 6.5x12.5 (areas U4 ).
  34. Rear rear front seat crossmember (4) SHIELDED GAS SEAM WELD (area U3 ).
  35. Rivet reinforcement (7) of front seat rear crossmember (4) with rivets with a diameter of 6.4x12 (areas U6 ).
  36. Rivet reinforcement (7) of front seat rear crossmember (4) with rivets with a diameter of 6.5x12.5 (areas U8 ).
    G16555341Courtesy of MERCEDES-BENZ USA
  37. Rivet front front seat crossmember (3) with ø 6.5x12.5 rivets (area V1 ).
  38. Rivet front seat crossmembers (3, 4) with rivets with a diameter of 6.5x12.5 (areas V2 ).
  39. Rivet front seat crossmembers (3, 4) with rivets with a diameter of 6.5x12.5 (areas V3 ).
    G16555342Courtesy of MERCEDES-BENZ USA
  40. Install connecting carrier (2), fit and fix in place.
  41. Drill rivet holes with a diameter of 6.7 mm in connecting carrier (2) (areas W1 , W2 , W5 ).

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

    G16555343Courtesy of MERCEDES-BENZ USA
  42. Drill rivet holes with a diameter of 6.7 mm in connecting carrier (2) (areas W6 , W7 ).
  43. Countersink rivet holes on connecting carrier (2) (areas W7 ).
    G16555344Courtesy of MERCEDES-BENZ USA
    G16555345Courtesy of MERCEDES-BENZ USA
  44. Drill rivet holes with a diameter of 6.7 mm in lower longitudinal member (6) (areas W3 , W4 ).

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

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

  49. Apply 2-component adhesive to body in cross-hatched area.

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

    G16555346Courtesy of MERCEDES-BENZ USA
  50. Install connecting carrier (2) and fix in place.
  51. Rivet connecting carrier (2) with ø 6.4x12 rivet (areas X1 ).
  52. Rivet connecting carrier (2) with ø 6.5x12.5 rivet (areas X2 ).
  53. Rivet connecting carrier (2) with ø 6, 5x12.5 rivets (areas X3 ).
  54. Rivet connecting carrier (2) with an M6 rivet with a diameter of 6.4 (area X4 ).
  55. Rivet connecting carrier (2) with ø 6.5x14.5 rivets (area X5 ).
  56. Rivet connecting carrier (2) SHIELDED GAS SEAM WELD (area X6 ).
    G16555347Courtesy of MERCEDES-BENZ USA
  57. Rivet connecting carrier (2) with ø 6, 5x12.5 rivets (areas X7 ).
  58. Rivet connecting carrier (2) with a rivet with a diameter of 6.5x12.5 (area X8 ).
  59. Rivet connecting carrier (2) with ø 6.5x14.5 rivets (area X9 ).
  60. Rivet connecting carrier (2) with ø 6.4x15.5 countersunk-head blind rivets (areas X10 ).
  61. Rivet connecting carrier (2) with ø 7 mm one panel thickness (area Y).
  62. Connecting carrier (2) SHIELDED GAS PLUG WELD (area Y).
    G16555348Courtesy of MERCEDES-BENZ USA
    G16555349Courtesy of MERCEDES-BENZ USA
  63. Rivet bottom longitudinal member (6) with ø 6.5x12.5 rivet (areas Z).
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