Install Front Roof Frame - Ar65.20-P-1006-05LWO

	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 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	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A
Notice	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	General information on riveting		AH60.00-P-0003-01N

Model 238.3

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-1043-13A	Countersunk-head blind rivet Z1 6.4X14.0 (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 6.4X15.5 (clamping range 3 mm to 5 mm, draw-off strength min 15.5 kN)	A 000 991 83 32
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

The following steps are shown on the left side of the vehicle and must be accomplished analogously on the right side of the vehicle.

The following repair materials must be used:

Apply 2-component adhesive
Rivets Ø 6.5x12.5
Countersunk-head blind rivet Ø 6.4x14.0
Countersunk-head blind rivets Ø 6.4x15.5
Countersunk-head blind rivet Ø 6.4x19.0
Countersunk-head blind rivet Ø 6.4x21.0

Courtesy of MERCEDES-BENZ USA

Install, fit and fix in place gusset plate (2).
In case of damaged gusset plate (2).
Install, fit and fix in place roof frame (1).
Drill rivet holes in gusset plate (2) with Ø 6.7 mm (areas A, B and C).
In case of damaged gusset plate (2).
Countersink rivet holes (areas A and B).
In case of damaged gusset plate (2).
Drill rivet hole in roof frame (1) with Ø 6.7 mm (area D).
Remove gusset plate (2).
In case of damaged gusset plate (2).
Remove roof frame (1).
Deburr rivet holes in gusset plate (2) and body on both sides (areas A, B and C).
In case of damaged gusset plate (2).
Deburr rivet hole in roof frame (1) and gusset plate (2) on both sides (area D).
Remove drill chips.
Apply 2-component adhesive to body in cross-hatched area.
In case of damaged gusset plate.

Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

Courtesy of MERCEDES-BENZ USA
Install and fix in place gusset plate (2).
In case of damaged gusset plate (2).
Apply 2-component adhesive on gusset plate (2) in cross-hatched area.
Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA
Install and fix in place roof frame (1).
Rivet gusset plate (2) with countersunk-head blind rivet Ø 6.4x19.0 (area E).
In case of damaged gusset plate (2).

Clamping range 7.14 mm.
Rivet gusset plate (2) with countersunk-head blind rivet Ø 6.4x21.0 (area F).
In case of damaged gusset plate (2).

Clamping range 8.4 mm.
Rivet gusset plate (2) with countersunk-head blind rivets Ø 6.4x15.5 (area G).
In case of damaged gusset plate (2).

Clamping range 3.0 mm to 4.5 mm.
Rivet gusset plate (2) with rivets Ø 6.5x12.5 (areas H).
In case of damaged gusset plate (2).

Clamping range 3.2 mm to 4.6 mm.
Rivet roof frame (1) with countersunk-head blind rivet Ø 6.4x14.0 (area J).
Clamping range 2.9 mm.
Roof frame (1) (areas K).
Roof frame (1) (areas L and M).
Perform inert gas welding at intervals and allow to cool down in between. This reduces heat distortion.