Partially replace main floor - AR63.40-P-1180Y
MODEL 219
| Removing | |||
| Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding splatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. | Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. | AS00.00-Z-0007-01A | |
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. |
AS00.00-Z-0017-01A | |
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-N-0005-01A | ||
| General information on body repair | AH60.00-N-0001-01A | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1 | Remove front fender | AR88.10-P-1000TX | |
| 2 | Remove front door | AR72.10-P-0500TX | |
| 3 | Remove rear door | AR72.12-P-0600TX | |
| 4 | Remove door sill moldings | AR68.30-P-4100TX | |
| 5 | Remove front seat | AR91.10-P-1000TX | |
| 6 | Remove rear seat cushion | AR91.12-P-1020TX | |
| 7 | Remove paneling on B-pillar | AR68.30-P-4700TX | |
| 8 | Remove seat belt | AR91.40-P-0630TX | |
| 9 | Remove floor mats | ||
| 10 | Cover all detachable parts remaining in vehicle | Tarp (fire-resistant) | |
| 11.1 | Remove A-pillar with side longitudinal member | AR63.20-P-1150Y | |
| 11.2 | Remove B-pillar with side longitudinal member | ||
| 12.1 | Remove main floor panel front section (1.1) | AR63.40-P-1180-13Y | |
| Figure | |||
| Vario Drill WS 91 spot weld removing tool Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Cutting disk, Ø 65 mm, 80 m/s (max. 23, 500 rpm) Hot air gun - 3000 W Drill Straight grinder Angle grinder Body jig saw Wet/dry vacuum cleaner |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 12.2 | Remove main floor panel rear section (1.2) | AR63.40-P-1180-14Y | |
| Figure | |||
| Ball cutter, dia. 12 mm Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Cutting disk, Ø 65 mm, 80 m/s (max. 23, 500 rpm) Drill Straight grinder Angle grinder Body jig saw Wet/dry vacuum cleaner |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 13.1 | Prepare new parts for main floor panel front section (1.1) | AR63.40-P-1180-15Y | |
| Round wire brush, braided, dia. 70 mm Drill Body jig saw |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 13.2 | Prepare new parts for main floor panel rear section (1.2) | AR63.40-P-1180-16Y | |
| Round wire brush, braided, dia. 70 mm Drill Body jig saw |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 14.1 | Install main floor panel front section (1.1) | AR63.40-P-1180-17Y | |
| General information on riveting | AH60.00-P-0003-01N | ||
| Electrode miller Clamping pliers Round wire brush, braided, dia. 70 mm Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver |
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| Taurus 3 blind rivet tool with 100 mm extension unit | Blind rivet/punch riveting method Inverter spot welder Drill Wet/dry vacuum cleaner Sealant |
*BR00.45-Z-1003-01A | |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Polygrip flat round head rivet, 6.4 X 14 | *BR00.45-Z-1001-13A | ||
| 14.2 | Install main floor panel rear section (1.2) | AR63.40-P-1180-18Y | |
| General information on riveting | AH60.00-P-0003-01N | ||
| Electrode miller Clamping pliers Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver Round wire brush, braided, dia. 70 mm |
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| Taurus 3 blind rivet tool with 100 mm extension unit | Blind rivet/punch riveting method Inverter spot welder Drill Wet/dry vacuum cleaner Sealant |
*BR00.45-Z-1003-01A | |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Polygrip flat round head rivet, 6.4 X 14 | *BR00.45-Z-1001-13A | ||
| 15.1 | Install A-pillar with side longitudinal member | AR63.20-P-1150Y | |
| 15.2 | Install B-pillar with side longitudinal member | ||
| 16 | Clean repair areas | ||
| 17 | Prime repair area using primer filler | ||
| 18 | Paint repair areas and adjacent surfaces | ||
| 19 | Carry out seam sealing after repairs | AR97.10-P-4000Y | |
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 20 | Remove tarp | ||
| 21 | Apply additional cavity preservation | AR97.20-P-1500Y | |
| Notes on cavity preservation | AH97.20-P-0001-01B | ||
| Combination pressure spray gun (corrosion protection) |
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| MB cavity wax preservation, 1 l | *BR00.45-Z-1003-05A | ||
| 22 | Install front fender | AR88.10-P-1000TX | |
| 23 | Install front door | AR72.10-P-0500TX | |
| 24 | Install rear door | AR72.12-P-0600TX | |
| 25 | Install seat belt | AR91.40-P-0630TX | |
| 26 | Install paneling at B-pillar | AR68.30-P-4700TX | |
| 27 | Install door sill moldings | AR68.30-P-4100TX | |
| 28 | Install front seat | AR91.10-P-1000TX | |
| 29 | Install rear seat cushion | AR91.12-P-1020TX | |
| 30 | Install floor mats |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | White sealing compound, 310 ml, DBL 6069.20 | A 001 989 63 20 |
| BR00.45-Z-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 20 |
| BR00.45-Z-1003-05A | Cavity sealant, solvent-free (1 l container) | A 000 986 72 70 05 |
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
| BR00.45-Z-1001-13A | Blind rivet 6.4 X 14 | A 003 990 35 97 |