Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSMERCEDES BENZ2006E500 BASEREPAIR AND DIAGNOSISCOLLISIONGENERAL COLLISION INFORMATIONSIDE WALLTESTING & REPAIRPARTIALLY REPLACE MAIN FLOOR - AR63.40-P-1180TNOTES

2006 Mercedes Benz E500 Base

Partially replace main floor - AR63.40-P-1180T: Notes

2006 Mercedes Benz E500 BaseSECTION Notes

Model 211.0 /2

Shown on model 211.0

Fig 1: Identifying Main Floor, Bracket And Connection Carrier

	Remove
	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 untrimmed vehicle parts. Deburr metal repairs.	AS00.00-Z-0017-01A
	Risk of death. Death may result if vehicle slips or topples from the lifting platform.	Align vehicle between columns of lifting platform and position the four support plates below support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of death caused by high voltage used for arc welding. Risk of explosion caused by welding in the area of high combustible materials. Risk of injury caused by welding spatter and UV-light while welding. Risk of poisoning caused by inhaling welding vapors.	Use insulating mats. Wear protective clothing, safety glasses, and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor.	AS00.00-Z-0007-01A
	General information on repairs to body	All models	AH60.00-N-0001-01A
	Measures for preventing damage to vehicles or components when performing arc welding work	All models	AH00.00-N-0005-01A
	Notes on paintwork repairs	All models	AH98.00-P-9408-02A
1.1	Remove left front fender	When replacing main floor front section.	AR88.10-P-1000T
2	Remove left front door		AR72.10-P-0500T
3	Remove left rear door		AR72.12-P-0600T
4	Remove left front seat		AR91.10-P-1000T
5	Remove foot mats
6	Remove or detach electric lines and vacuum lines in area to be repaired
7	Remove detachable body components in area to be repaired
8	Cover all detachable body components remaining in vehicle (area to be repaired)	Tarpaulin (fireproof)	*WH58.30-Z-1001-40A
9.1	Remove A-pillar with side longitudinal member	When replacing main floor front section.	AR63.20-P-1150T
9.2	Remove B-pillar with side longitudinal member	When replacing main floor rear section.	AR63.20-P-0550T
10.1	Remove main floor front section		AR63.40-P-1180-13T
		Welding spot milling cutter	Figure
		Ball-type miller cutter, dia. 12 mm	*WH58.30-Z-1002-01A
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Vario Drill WS 91 spot-weld loosening tool	*WH58.30-Z-1006-01A
		Grinding disc, dia. 115 mm, 80 m/s (max. 13.250 rpm)	*WH58.30-Z-1024-04A
		Cutting disc, dia. 65 mm, 80 m/s (max. 23,500 rpm)	*WH58.30-Z-1021-04A
		Hot air blower - 3000 W	*WH58.30-Z-1004-20A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Straight grinder (electric/pneumatic)	*WE58.40-Z-1002-03A
		Angular grinder (electric/pneumatic)	*WE58.40-Z-1003-03A
		Body saw (electric/pneumatic)	*WE58.40-Z-1004-03A
		Wet/dry vacuum cleaner	*WE58.40-Z-1005-03A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
10.2	Remove main floor rear section		AR63.40-P-1180-14T
		Welding spot milling cutter	Figure
		Ball-type miller cutter, dia. 12 mm	*WH58.30-Z-1002-01A
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Vario Drill WS 91 spot-weld loosening tool	*WH58.30-Z-1006-01A
		Grinding disc, dia. 115 mm, 80 m/s (max. 13.250 rpm)	*WH58.30-Z-1024-04A
		Cutting disc, dia. 65 mm, 80 m/s (max. 23,500 rpm)	*WH58.30-Z-1021-04A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Straight grinder (electric/pneumatic)	*WE58.40-Z-1002-03A
		Angular grinder (electric/pneumatic)	*WE58.40-Z-1003-03A
		Body saw (electric/pneumatic)	*WE58.40-Z-1004-03A
		Wet/dry vacuum cleaner	*WE58.40-Z-1005-03A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
11.1	Prepare new parts for main floor front section		AR63.40-P-1180-15T
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Body saw (electric/pneumatic)	*WE58.40-Z-1004-03A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
11.2	Prepare new parts for main floor rear section		AR63.40-P-1180-16T
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Body saw (electric/pneumatic)	*WE58.40-Z-1004-03A
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
12.1	Install main floor front section		AR63.40-P-1180-17T
	General notes on riveting		AH60.00-P-0003-01N
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Electrode miller	*WH58.30-Z-1003-01A
		Clamping pliers	*WH58.30-Z-1003-02A
		Blind rivet tool PowerBird	*WE58.40-Z-1003-14A
		Hand riveter	*WH58.30-Z-1003-29A
		Screw-on clamping gripper, dia. 6.4 mm Clamping range 0-15 mm, identification color silver	*WH58.30-Z-1038-02A
		Inert gas welder	*WE58.40-Z-1001-02A
		Spot welder	*WE58.40-Z-1002-02A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Wet/dry vacuum cleaner	*WE58.40-Z-1005-03A
		6.4 x 14 Polygrip flat/round head rivet	*BR00.45-Z-1001-13A
		MB body sealant for sealing seams (suitable for painting/310ml cartridge)	*BR00.45-Z-1003-01A
		MB preservative	*BR00.45-Z-1003-05A
12.2	Install main floor rear section		AR63.40-P-1180-18T
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Electrode miller	*WH58.30-Z-1003-01A
		Clamping pliers	*WH58.30-Z-1003-02A
		Blind rivet tool PowerBird	*WE58.40-Z-1003-14A
		Hand riveter	*WH58.30-Z-1003-29A
		Screw-on clamping gripper, dia. 6.4 mm	*WH58.30-Z-1038-02A
		Inert gas welder	*WE58.40-Z-1001-02A
		Spot welder	*WE58.40-Z-1002-02A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Wet/dry vacuum cleaner	*WE58.40-Z-1005-03A
		MB body sealant for sealing seams (suitable for painting/310ml cartridge)	*BR00.45-Z-1003-01A
		MB preservative	*BR00.45-Z-1003-05A
13.1	Install A-pillar with side longitudinal member	When replacing main floor front section.	AR63.20-P-1150T
13.2	Install B-pillar with side longitudinal member	When replacing main floor rear section.	AR63.20-P-0550T
14	Clean areas to be repaired and prime with primer/filler	Notes on paintwork repairs
15	Seam sealing following repair	Supplement standard seals with MB body sealant.	AR97.10-P-4000T
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
16	Partially paint main floor and adjacent surfaces
17	Hollow cavity preservation following repair work
	Notes on hollow cavity preservation	Model 211	AH97.20-P-0001-01B
18	Install electric lines and vacuum lines in area to be repaired
19.1	Install left front fender	When replacing main floor front section.	AR88.10-P-1000T
20	Install left front door		AR72.10-P-0500T
21	Install left rear door		AR72.12-P-0600T
22	Install left front seat		AR91.10-P-1000T
23	Install foot mats
24	Install all removed detachable body components

Fig 2: Identifying Welding Spot Milling Cutter (201 589 00 51 00)

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1002-01A	Ball cutter, dia. 12 mm
WH58.30-Z-1003-01A	Electrode miller
WH58.30-Z-1006-01A	Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1003-02A	Clamping pliers
WH58.30-Z-1038-02A	Manual temporary fastener, dia.6.4 mm - clamping range 0 -15 mm, identification color silver Firm Hausmann GmbH D-34346 Hann. Munden, Germany
WH58.30-Z-1001-03A	Round wire brush, braided, dia. 70 mm
WH58.30-Z-1021-04A	Cutting disk, dia. 65 mm, 80 m/s (max. 23,500 rpm)
WH58.30-Z-1024-04A	Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)
WH58.30-Z-1004-20A	Hot-air gun
WH58.30-Z-1003-29A	Hand riveter
WH58.30-Z-1001-40A	Tap (fire-resistant)

WORKSHOP EQUIPMENT

WE58.40-Z-1001-02A	Inert gas welder
WE58.40-Z-1002-02A	Spot welder
WE58.40-Z-1001-03A	Drill (electric/pneumatic)
WE58.40-Z-1002-03A	Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A	Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A	Body saw (electric/pneumatic)
WE58.40-Z-1005-03A	Wet/dry vacuum cleaner
WE58.40-Z-1003-14A	Blind rivet tool

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	Sealant	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	Preservation agent	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	Rivet	A 003 990 35 97

RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.