Prepare main floor, inner longitudinal member and middle crossmember - AR63.40-P-1180-07EW

MODEL 212, 218 

Fig 1: Outer Side Longitudinal Member Separating Point

Courtesy of MERCEDES-BENZ USA

1. Scribe separating point on outer side longitudinal member (1) (area A).

   Transfer separation point from vehicle.

2. Cut outer side longitudinal member (1) at separation point (area A).
3. Remove remaining piece from outer side longitudinal member (1).
4. Grind mating surfaces on outer side longitudinal member (1) down to bare metal in crosshatched areas.

   Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces (area B).

5. Coat insides of spot weld flanges with zinc dust paint.

   Do not coat bonding surfaces with zinc dust paint (area B). Adhesion problems can occur.

Fig 2: Offset Reinforcement And Inner Side Longitudinal Member Separation Points
Courtesy of MERCEDES-BENZ USA
6. Scribe separation points on offset reinforcement (2) and inner side longitudinal member (3) (areas C, D and E).

   Take separation points from vehicle

7. Cut offset reinforcement (2) and inner side longitudinal member (3) at separating points (areas C, D and E).
8. Expose spot welds on offset reinforcement (2) and inner side longitudinal member (3) (areas F, G, H and I).
9. Drill Ø 6.7 mm spot welds in offset reinforcement (2) and inner side longitudinal member (3) (areas F and G).
10. Cut off spot welds on offset reinforcement (2) and inner side longitudinal member (3) (areas H and I).
11. Remove remaining sections from offset reinforcement (2) and inner side longitudinal member (3).
Fig 3: Grinding Mating Surfaces In Cross-Hatched Areas (1 Of 2)
Courtesy of MERCEDES-BENZ USA
12. Grind mating surfaces on offset reinforcement (2) and inner side longitudinal member (3)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 J and K).

13. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (area J and K). Adhesion problems can occur.

Fig 4: Grinding Mating Surfaces In Cross-Hatched Areas (2 Of 2)
Courtesy of MERCEDES-BENZ USA
14. Grind mating surfaces down to bare metal on connecting carrier (4), front crossmember (5) and rear crossmember (6) in crosshatched areas.

    Do not coat bonding surfaces with zinc dust paint (area L, M, and N). Adhesion problems can occur.

    Observe pretreatment of bonding surfaces (areas L, M and N).

Fig 5: Main Floor Separating Point
Courtesy of MERCEDES-BENZ USA
15. Scribe separating point on main floor (8) (area O).
16. Cut main floor (8) at separating point (area O).
17. Remove remaining section from main floor (8).
18. Grind mating surfaces on main floor (8) 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 P, Q, R, S and T).

19. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas P, Q, R, S and T). Adhesion problems can occur.

20. Expose spot welds on tank holder (7) (area U).
21. Cut off spot welds on tank holder (7) (area U).

    Cut out spot welds on inside of rear seat crossmember (9).

22. Remove tank holder (7) from rear seat crossmember (9).