Cut off main floor, inner longitudinal member and middle crossmember - AR63.40-P-1180-06EW

WARNING: This page does not describe the selected car, but rather 33 other vehicles, including the 2016 Mercedes-Benz E63 S AMG, 2016 Mercedes-Benz E400, 2016 Mercedes-Benz E350, 2016 Mercedes-Benz E300, and 2016 Mercedes-Benz E250. However, it is still accessible from the selected car via links, so may be relevant.

MODEL 212, 218

The following steps are shown on model 212.0.

Fig 1: Outer Side Longitudinal Member Section Spot Weld Areas

Courtesy of MERCEDES-BENZ USA

Expose spot welds on outer side longitudinal member section (1) (A, A₁ , B, C, D, E and F).
Drill out Ø 6.7 mm spot welds on outer side longitudinal member section (1) (areas A and A₁ ).
Cut off spot welds on outer side longitudinal member section (1) (areas B, C, D, E and F).
Heat outer side longitudinal member section (1) in cross-hatched area.
Cross-hatched area is bonded.
Remove section from outer side longitudinal member (1)

Fig 2: Offset Reinforcement And Inner Side Longitudinal Member Separating Points

Courtesy of MERCEDES-BENZ USA

Scribe separating points on offset reinforcement (2) and inner side longitudinal member (3) (areas G, H and H₁ ).
Cut offset reinforcement (2) and inner side longitudinal member (3) at separating points (areas G, H and H₁ ).
Do not damage components below.
Remove offset reinforcement section (2.1).
Expose spot welds on offset reinforcement (2) and inner side longitudinal member (3) (areas I and J).
Cut off spot welds on offset reinforcement (2) and inner side longitudinal member (3) (areas I and J).
Cut off spot weld in area J on inside.

Fig 3: Connecting Carrier, Front Crossmember, Rear Crossmember And Tank Holder Spot Weld Areas

Courtesy of MERCEDES-BENZ USA

Expose spot welds on connecting carrier (4), front crossmember (5), rear crossmember (6) and tank holder (7) (areas K, L, M and N).
Cut off spot welds on connecting carrier (4), front crossmember (5), rear crossmember (6) and tank holder (7) (areas K, L, M and N).
Remove front crossmember (5), rear crossmember (6) and tank holder (7).

Fig 4: Connecting Carrier Crosshatched Areas

Courtesy of MERCEDES-BENZ USA

Heat connecting area (4) in crosshatched areas.
Cross-hatched areas are bonded.
Remove connecting carrier (4).

Fig 5: Main Floor Separating Point

Courtesy of MERCEDES-BENZ USA

Scribe separating point on main floor (8) along bead (area U).
Cut main floor (8) at separating point (area U).
Do not damage longitudinal member below.
Expose spot welds an inner side longitudinal member (3) and main floor (8) (areas O, P, Q, R, S and T).
Cut off spot welds an inner side longitudinal member (3) and main floor (8) (areas O, P, Q, R, S and T).
Heat inner side longitudinal member (3) and main floor (8) in cross-hatched areas.
Cross-hatched areas are bonded.
Remove damaged floor (8) with inner side longitudinal member (3).

Fig 6: Grinding Mating Surfaces In Cross-Hatched Areas

Courtesy of MERCEDES-BENZ USA

Grind mating surfaces on body down to bare metal in cross-hatched areas.
Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces (areas V, W, X and Y).
Remove shavings and drill chips.
Coat insides of spot weld flanges with zinc dust paint.
Do not apply zinc dust paint to bonding surfaces (areas V, W, X and Z). Adhesion problems can occur.