Remove/Install Front Roof Frame - Ar65.20-P-1006LWO
Model 238.3
| Risk of injury . Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | AS00.00-Z-0002-01A | |
| 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 | |
| Notice | General information on body repair | AH60.00-P-0001-01KOA | |
| Notice | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | |
| Notice | Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | |
| Remove | |||
| 1 | Remove detachable parts in area to be repaired | ||
| 2 | Cover all detachable parts remaining on vehicle with spark protection blankets | ||
| 3.1 | Remove center roof paneling | Model 238.3 except code 413 (Panoramic sliding sunroof/glass roof) | AR65.10-P-1000LWO |
| 3.2 | Remove roof paneling rear section | Model 238.3 with code 413 (Panoramic sliding sunroof/glass roof) | AR65.10-P-5760LWO |
| 4 | Remove roof frame (1) and gusset plates (2) | AR65.20-P-1006-02LWO | |
| 1K-zinc dust paint | *BR00.45-Z-1056-07A | ||
| 5 | Prepare roof frame (1) and gusset plates (2) | AR65.20-P-1006-04LWO | |
| 1K-zinc dust paint | *BR00.45-Z-1056-07A | ||
| 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 | |
| Notice | Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | |
| General information on riveting | AH60.00-P-0003-01N | ||
| 6 | Install roof frame (1) and gusset plates (2) | AR65.20-P-1006-05LWO | |
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Blind rivet Y2 6.5 x 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A | ||
| Countersunk-head blind rivet Z1 6.4 x 14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1043-13A | ||
| Countersunk-head blind rivet Z2 6.4 x 15.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1044-13A | ||
| Countersunk-head blind rivet Z4 6.4x19.0 (clamping range 6 mm to 8 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1056-13A | ||
| Countersunk-head blind rivet Z5 6.4x21.0 (clamping range 7.5 mm to 10 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1057-13A | ||
| 7 | Clean welds and sheet metal flanges | ||
| 8 | Clean repair area | ||
| 9.1 | Install center roof paneling | Model 238.3 except code 413 (Panoramic sliding sunroof/glass roof) | AR65.10-P-1000LWO |
| 9.2 | Install roof paneling rear section | Model 238.3 with code 413 (Panoramic sliding sunroof/glass roof) | AR65.10-P-5760LWO |
| 10 | Remove spark protection blankets | ||
| 11 | Install all detachable body components in area to be repaired |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1012-13A | Blind rivet Y2 6.5 x 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | A 004 990 16 97 |
| BR00.45-Z-1043-13A | Countersunk-head blind rivet Z1 6.4 x 14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) | A 000 991 82 32 |
| BR00.45-Z-1044-13A | Countersunk-head blind rivet Z2 6.4 x 15.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) | A 000 991 83 32 |
| BR00.45-Z-1056-07A | 1K-zinc dust paint | A 000 986 28 00 |
| BR00.45-Z-1056-13A | Countersunk-head blind rivet Z4 6.4x19.0 (clamping range 6 mm to 8 mm, draw-off strength min. 15.5 kN) | A 000 991 87 32 |
| BR00.45-Z-1057-13A | Countersunk-head blind rivet Z5 6.4x21.0 (clamping range 7.5 mm to 10 mm, draw-off strength min. 15.5 kN) | A 000 991 88 32 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |