Install Rear Roof Frame - Ar65.20-P-1008-03LWO
| 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
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1035-13A | Blind rivet Y1 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min 15.5 kN) | A 000 991 76 32 |
| 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-1056-07A | 1K-zinc dust paint | A 000 986 28 00 |
| 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
- Zinc dust paint
- Rivets Ø 6.4x12
- Countersunk-head blind rivets Ø 6.4x14.0
- 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 67 mm (areas A and B).
In case of damaged gusset plate (2).
- Countersink rivet holes (area A).
In case of damaged gusset plate (2).
- Remove gusset plate (2).
In case of damaged gusset plate (2).
- Deburr rivet holes in gusset plate (2) and body on both sides.
In case of damaged gusset plate (2).
- Remove drill chips.
In case of damaged gusset plate (2).
- Coat insides of riveted joints with zinc dust paint.
In case of damaged gusset plate (2).
- Remove roof frame (1).
- 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.
- Install and fix in place roof frame (1).
- Rivet gusset plate (2) with countersunk-head blind rivets Ø 6.4x14.0 (area C).
In case of damaged gusset plate (2).
- Rivet gusset plate (2) with rivets Ø 6.4x12 (areas D).
In case of damaged gusset plate (2).
- Gusset plate (2)
(areas E).
In case of damaged gusset plate (2).
- Roof frame (1)