Install main floor, inner longitudinal member and middle crossmember - AR63.40-P-1180-08EW

MODEL 212, 218 

Fig 1: Installing Connecting Carrier, Front Crossmember, Rear Crossmember And Main Floor

Courtesy of MERCEDES-BENZ USA

The following steps are shown on model 212.0.

1. Install connecting carrier (4), front crossmember (5), rear crossmember (6) and main floor (8), fit and fix in place.

   Align front crossmember (5) and rear crossmember (6) at bolt points and fix in place.

Fig 2: Inner Side Longitudinal Member, Connecting Carrier, Front Crossmember, Rear Crossmember And Main Floor Rivet Hole Areas
Courtesy of MERCEDES-BENZ USA
2. Install inner side longitudinal member (3), fix and fix in place.
3. Drill Ø 6.7 mm rivet holes on inner side longitudinal member (3), connecting carrier (4), front crossmember (5), rear crossmember (6) and main floor (8) (areas A, B, C, D, E, F and G).
4. Remove connecting carrier (4), front crossmember (5) and rear crossmember (6).
5. Deburr rivet holes on connecting carrier (4), front crossmember (5) and rear crossmember (6) on both sides.
Fig 3: Inner Side Longitudinal Member And Main Floor Rivet Hole Areas
Courtesy of MERCEDES-BENZ USA
6. Drill Ø 6.7 mm rivet holes on inner side longitudinal member (3) and main floor (8) (areas H, I, J and K).
7. Remove inner side longitudinal member (3) and main floor (8)
8. Deburr rivet holes on inner side longitudinal member (3) and main floor (8) on both sides.
9. Apply 2-component adhesive on body in crosshatched areas.

   Observe pretreatment of bonding surfaces. Refer to the manufacturer's information for the curing and working times of 2- component adhesive.

Fig 4: Applying 2-Component Adhesive In Crosshatched Areas
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10. Install inner side longitudinal member (3) and main floor (8), fit and fix in place.
11. Rivet inner side longitudinal member (3) and main floor (8) with Ø 6.4 X 14 Polygrip flat/round head rivets (areas H, I, J and K).
12. Apply 2-component adhesive in crosshatched areas on body and main floor (8).

    Observe pretreatment of bonding surfaces. Refer to the manufacturer's information for the curing and working times of 2-component adhesive.

Fig 5: Connecting Carrier, Front Crossmember, Rear Crossmember And Main Floor Rivet Hole Areas
Courtesy of MERCEDES-BENZ USA
13. Install connecting carrier (4), front crossmember (5) and rear crossmember (6), fit and fix in place.
14. Rivet connecting carrier (4), front crossmember (5), rear crossmember (6) and main floor (8) with Ø 6.4 X 14 Polygrip flat/round head rivets (areas A, B, C, D, E, F and G).
Fig 6: Inner Side Longitudinal Member And Offset Reinforcement Welding Areas
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15. Inner side longitudinal member (3) and main floor (8) (areas L, M, N and O).
16. Inner side longitudinal member (3) and offset reinforcement (2) _{SG ««««} (areas P, Q, R and S).

    Perform inert gas welding, allow to cool down in between to minimize heat distortion (areas P, Q, R and S).

17. Offset reinforcement (2) _{SG ⓧ} (area T).
18. Grind weld seam on contact surface down flat to outer side longitudinal member (arrow).
19. Install tank holder (7), fit and fix in place.
20. Drill Ø 6.7 mm rivet holes on tank holder (7) (area U).
21. Remove tank holder (7).
22. Deburr rivet holes on tank holder (7) on both sides.
23. Install tank holder (7), fit and fix in place.
24. Rivet tank holder (7) with Ø 6.4 X 14 Polygrip flat/round head rivets (area U).
Fig 7: Outer Side Longitudinal Member Rivet Hole Areas
Courtesy of MERCEDES-BENZ USA
25. Install outer side longitudinal member (1), fit and fix in place.
26. Drill Ø 6.7 mm rivet holes on outer side longitudinal member (1) (areas V and W).
27. Remove outer side longitudinal member (1).
28. Deburr rivet holes on both sides
29. Apply 2-component adhesive in cross-hatched areas to inside of body.

    Observe pretreatment of bonding surfaces. Refer to the manufacturer's information for the curing and working times of 2-component adhesive.

30. Install outer side longitudinal member (1), fit and fix in place.
31. Rivet outer side longitudinal member (1) with Ø 6.4 X 14 Polygrip flat/round head rivets (areas V and W).
Fig 8: Outer Side Longitudinal Member Welding Areas
Courtesy of MERCEDES-BENZ USA
32. Outer side longitudinal member (1) (areas X, Y and Z).
33. Outer side longitudinal member _{SG ««««} (1) (area AA).

    Weld inert gas welds in intervals, allow to cool down in between to minimize heat distortion (area AA).

34. Outer side longitudinal member (1) _{SG ⓧ} (area AB).
35. Clean weld joints.
36. Remove shavings and drill chips.