Side Roof Frame Removal And Installation - Ar65.20-P-1200RG

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) 

Fig 1: Side Roof Frame Component Location (Model 190.3) (w/Code 397, 416, M032)

Courtesy of MERCEDES-BENZ USA

	Risk of explosion  from aluminum grinding dust, risk of injury to respiratory system from inhaling dust	Wear dust filter mask, safety glasses, and protective gloves. Use a suitable, grounded dust extraction system.	AS60.00-Z-0007-01N
	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
Notice	General information on body repair		AH60.00-P-0001-01S
Notice	General information on crack diagnosis of aluminum parts		AH60.00-P-0014-01N
Notice	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	Note on working on aluminum components and vehicles		AH60.00-P-0034-01RG
	Remove
1	Prepare all workshop equipment and commercially available devices/tools required for the repair.
2	Remove detachable parts in area of repair points.
3	Cover all detachable parts that remain in the vehicle with fire-resistant welding protection blankets.
4.1	Remove carbon roof.	Model 190.3 with code 397 (Carbon roof) Model 190.3 with code M032 (Black Series version)	AR65.10-P-1000RG
4.2	Remove panoramic roof.	Model 190.3 with code 416 (Panoramic sunroof)	AR77.21-P-0750RG
5	Remove side roof frame (1).		AR65.20-P-1200-01RG
	000 588 15 84 00 Heat gun		WS54.00-P-0125B
	000 588 04 39 00 Rivet press tool	Commercially available devices/tools  Vacuum unit suitable for aluminum dusts Round wire brush Spot weld milling machine Drill bit and milling cutter for ultra-high-strength steels Hand drill Body saw Wet/dry vacuum cleaner	WS60.00-P-0440B
	Preparation
6	Prepare side roof frame new part (1) for installation.	Commercially available devices/tools  Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner	AR65.20-P-1200-02RG
	Install
	The high voltage used for electric welding presents a lethal hazard. Risk of explosion  from welding in areas close to highly inflammable materials. Risk of injury  from weld splatter and UV-light when welding. Risk of poisoning  from inhaling welding gases	Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system.	AS00.00-Z-0007-01A
	Risk of poisoning  caused by inhaling vapors or swallowing adhesive. Risk of injury  caused by adhesive coming into contact with skin and eyes	Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only.	AS00.00-Z-0016-01A
Notice	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A
	General notes on welding		AH60.00-P-0005-01N
	General information on riveting		AH60.00-P-0003-01N
7	Install side roof frame new part (1).		AR65.20-P-1200-03RG
	000 588 12 84 00 Welder		WS00.00-P-0318K
	000 588 04 39 00 Rivet press tool	Commercially available devices/tools  Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Manual temporary fastener 6.35 mm Wet/dry vacuum cleaner	WS60.00-P-0440B
		Gap dimension, sidewall panel to E-line trim strip	*BE60.00-P-1011-01EA
		Gap dimension, sidewall panel to roof trim strip	*BE60.00-P-1014-01EA
		Gap dimension, sidewall panel to E-line trim strip	*BE60.00-P-1016-01EA
		Gap dimension, roof to roof trim strip	*BE60.00-P-1019-01EA
		Parts kit for 2-component adhesive for body	*BR00.45-Z-1162-02A
		Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	*BR00.45-Z-1012-13A
		Flow-form rivet structure 5.0 mm up to 6.1 mm clamping range (S48)	*BR00.45-Z-1052-13A
		Flow-form rivet structure 6.0 mm up to 7.2 mm clamping range (S58)	*BR00.45-Z-1053-13A
		Feeler gauge	Fig 2
8.1	Install the panoramic roof.	Model 190.3 with code 416 (Panoramic sunroof)	AR77.21-P-0750RG
8.2	Install carbon roof.	Model 190.3 with code 397 (Carbon roof) Model 190.3 with code M032 (Black Series version)	AR65.10-P-1000RG
	Clean
9	Clean weld joints and sheet metal flange.	Commercially available devices/tools  Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner
10	Remove fire-resistant welding protection blankets.
11	Clean repair area.	Commercially available devices/tools  Wet/dry vacuum cleaner
	Paint
	Risk of explosion  caused by paint vapors igniting. Risk of poisoning  caused by inhaling paint vapors.	No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
	Risk of explosion and poisoning  caused by solvent vapors and gasses. Risk of injury  to skin and eyes when working with anticorrosion agents	Never spray corrosion protection on flames or hot, glowing objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection.	AS97.00-Z-0001-01A
Notice	Notes on cavity preservation		AH97.20-P-0001-01B
Notice	Notes on sprayable joint sealant		AH97.10-P-0002-01A
	Notice Notes on paintwork repairs		AH98.00-P-9408-02A
	General information on operation items and work procedures for painting		AH98.00-P-0003-01A
	Notes on seam seal		AH97.10-P-0002-02A
	General information on MB materials		AH98.00-P-9409-03A
12	Prime repair areas with a primer filler.	Use only primer fillers approved by manufacturer. See guidelines for paint technology in the workshop portal.
13	Seal seam after repair.	Supplement standard seals with sealant.	AR97.10-P-4000RG
14	Paint repair areas and adjacent surfaces.	Only use paints approved by the manufacturer. See guidelines for paint technology in the workshop portal.
15	Supplement cavity preservation.		AR97.20-P-1500RG
	Assemble
16	Install detachable parts in the area of the repair point.

Fig 2: Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA