Side Roof Frame Installation And Welding In - Ar65.20-P-1200-03RG

	000 588 04 39 00 Rivet press tool		WS60.00-P-0440B
	000 588 12 84 00 Welder		WS00.00-P-0318K

Model 190.3

with code 397 (Carbon roof)

Model 190.3

with code 416 (Panoramic sunroof)

Model 190.3

with code M032 (Black Series version)

GAP DIMENSIONS

Number	Designation			Model 190.3
BE60.00-P-1011-01EA	Gap dimension, sidewall panel to E-line trim strip	Dimension "K"	mm	1 (±0, 5)
BE60.00-P-1011-01EA	Gap dimension, sidewall panel to E-line trim strip	See		AR60.00-P-0700-01RG

GAP DIMENSIONS

Number	Designation			Model 190.3
BE60.00-P-1014-01EA	Gap dimension, sidewall panel to roof trim strip	Dimension "N"	mm	2, 5 (±1)
BE60.00-P-1014-01EA	Gap dimension, sidewall panel to roof trim strip	See		AR60.00-P-0700-01RG

GAP DIMENSIONS

Number	Designation			Model 190.3
BE60.00-P-1016-01EA	Gap dimension, sidewall panel to E-line trim strip	Dimension "P"	mm	1 (±0, 5)
BE60.00-P-1016-01EA	Gap dimension, sidewall panel to E-line trim strip	See		AR60.00-P-0700-01RG

GAP DIMENSIONS

Number	Designation			Model 190.3
BE60.00-P-1019-01EA	Gap dimension, roof to roof trim strip	Dimension "S"	mm	3 (±0, 5)
BE60.00-P-1019-01EA	Gap dimension, roof to roof trim strip	See		AR60.00-P-0700-01RG

Fig 1: Feeler Gauge (129 589 03 21 00)

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REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1012-13A	Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	A 004 990 16 97
BR00.45-Z-1052-13A	Flow-form rivet structure 5.0 mm up to 6.1 mm clamping range (S48)	A 000 991 27 33
BR00.45-Z-1053-13A	Flow-form rivet structure 6.0 mm up to 7.2 mm clamping range (S58)	A 000 991 28 33
BR00.45-Z-1162-02A	Parts kit for 2-component adhesive for body	A 012 989 17 71

The following operation steps are shown on the left side of the vehicle. In case of damage, these steps must be similarly performed on the right side of the vehicle. Replace self-pierce rivets installed in vehicle by high-strength rivets according to clamping range.

Install and fit side roof frame, carbon roof or panoramic roof and roof trim strip.
Only fit carbon roof or panoramic roof, do not install and bond.
Check gaps using feeler gauge and adjust.
Fix in place side roof frame.
Remove roof trim strip and carbon roof or panoramic roof.
Drill rivet hole in side roof frame (1) with Ø 6.7 mm (area D1).
Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt these and drill together.
Prepare side roof frame (1) with rivet press tool (area C1).
Transfer present positions for rivet connections from vehicle to new part. In the case of new part to new part connections, adapt these and prepare together.
Remove side roof frame (1).
Deburr drilling holes on side roof frame (1) and on body on both sides (area D1).
Observe pretreatment of bonding surfaces.
On side roof frame (1), apply 2-component adhesive (crosshatched areas).
Observe manufacturer's specification for drying and processing time of 2-component adhesive.

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Install, fit and fixed in place side roof frame (1).
Rivet side roof frame (1) with rivet press tool and flow-form rivets or flow-form rivets (area C2).
Use flow form rivet structure 5.0 mm up to 6.1 mm clamping range (S48) or flow form rivet structure 6.0 mm up to 7.2 mm clamping range (S58).
Rivet side roof frame (1) with rivet press tool and blind rivets (area D2).
Use blind rivet 6.5x12.5 (clamping range 2 mm up to 5 mm, draw-off strength min. 19 kN).

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Tack weld side roof frame (1) with welder ( ) (areas A and B).
When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush.

Tack welds seams at start and end ( ).
Check weld seam gaps.
Check all weld seam gaps before start of welding. The weld seam gap may not be greater than 1 mm, where required use a body weld.
Weld side roof frame (1) with welder ( ) (areas A and B).
MIG weld (SG ) in intervals and allow to cool down in between. This reduces heat distortion.
Level welds on side roof frame (1).
Remove shavings using wet/dry vacuum cleaner.

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