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Front Roof Frame Installation - Ar65.20-P-1006-05S

Model 223.0/1/9 

G16228192Courtesy of MERCEDES-BENZ USA

Countersunk-head rivet (Z) 

  1. Z1 = Countersunk-head rivet 6.4x14.0
  2. Z2 = Countersunk-head rivet 6.4x15.5
  3. Z3 = Countersunk-head rivet 6.4x17.0
  4. Z4 = Countersunk-head rivet 6.4x19.0
  5. Z5 = Countersunk-head rivet 6.4x21.0

Blind rivet (Y) 

  1. Y1 = Rivet 6.4x12
  2. Y2 = Rivet 6.5x12.5
  3. Y3 = Rivet 6.5x14.5
  4. Y4 = Rivet 6.4M6
  5. Y5 = Rivet 6.4
  6. Y6 = rivet 6.5x13.5
  7. Y7 = rivet 6.4x14
  8. Y8 = rivet 6.4x17
  9. Y9 = rivet 6.4x20

Flow-form rivet with countersunk head (X) 

  1. X1 = Flow-form rivet with countersunk head 1.3 mm to 2.5 mm clamping range
  2. X2 = Flow-form rivet with countersunk head 2.3 mm to 3.5 mm clamping range
  3. X3 = Flow-form rivet with countersunk head 3.35 mm to 4.1 mm clamping range
  4. X4 = Flow-form rivet with countersunk head 4 mm to 5.15 mm clamping range
  5. X5 = Flow-form rivet with countersunk head 5.0 mm to 6.1 mm clamping range
  6. X6 = Flow-form rivet with countersunk head 6.0 mm to 7.2 mm clamping range
  7. X7 = Flow-form rivet with countersunk head 7.1 mm to 8.3 mm clamping range

Flow-form rivet (W) 

  1. W1 = Flow-form rivet structure with 3.5 mm clamping range
  2. W3 = Flow-form rivet structure 3.35 mm up to 4.1 mm clamping range
  3. W4 = Flow-form rivet structure 4 mm up to 5.15 mm clamping range
  4. W5 = Flow-form rivet structure 5.0 mm up to 6.1 mm clamping range
  5. W6 = Flow-form rivet structure 6.0 mm up to 7.2 mm clamping range
  6. W7 = Flow-form rivet structure 7.1 mm up to 8.3 mm clamping range

Blind rivet (V) 

  1. V1 = rivet 3.2x4.5
  2. V2 = rivet 3.2x6.5

Blind rivet (U) 

  1. U1 = rivet 3.2x9.5

Blind rivet with countersunk head (T) 

  1. T1 = blind rivet with countersunk head 3.0 mm to 5.0 mm clamping range
  2. T2 = blind rivet with countersunk head 1.5 mm to 3.0 mm clamping range

Welding variants 

  1. EE = MIG seam weld
  2. FF = MIG plug weld
G16228206Courtesy of MERCEDES-BENZ USA

IMPORTANT The next steps are shown on model 223.1. Operation steps 1 to 12 are shown on the left side of the vehicle and must be performed in the same way on the right side of the vehicle.

The superordinate service document as well as the safety information in the service document must be observed.

The graphics show the vehicle from the perspective of the technician. This perspective also specifies the direction in which the rivets must be installed.

  1. Install roof frame lower section (2), fit, and fix in place.
  2. Drill rivet holes in roof frame lower section (2) with ø 6.7 mm bit (area A).
  3. Remove roof frame lower section (2).
  4. Deburr rivet holes in roof frame lower section (2) and body on both sides.
  5. Remove drilling chips.
    G16228837Courtesy of MERCEDES-BENZ USA
  6. Apply 2-component adhesive to body in cross-hatched area.

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

    G16228838Courtesy of MERCEDES-BENZ USA
    G16228839Courtesy of MERCEDES-BENZ USA
  7. Install roof frame lower section (2) and fix in place.
  8. Rivet roof frame lower section (2) with ø 6.5x12.5 rivets (area Y2 ).
  9. Rivet roof frame lower section (2) with ø 6.5x14.5 rivets (area Y3 ).
  10. Roof frame lower section (2) SHIELDED GAS SEAM WELD (area EE).
  11. Face-grind shielding gas weld joint (area EE).
  12. Remove grinding dust.
    G16228840Courtesy of MERCEDES-BENZ USA
  13. Install roof frame upper section (1), fit, and fix in place.
  14. Drill rivet holes in roof frame upper section (1) with ø 6.7 mm bit (areas B, C, D).
  15. Countersink rivet holes (areas B, C).
  16. Remove roof frame upper section (1).
  17. Deburr rivet holes in roof frame upper section (1) and body on both sides.
  18. Remove drilling chips.
    G16228841Courtesy of MERCEDES-BENZ USA
  19. Apply 2-component adhesive to body in cross-hatched areas.

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

    G16228842Courtesy of MERCEDES-BENZ USA
  20. Install roof frame upper section (1) and fix in place.
  21. Rivet roof frame upper section (1) with ø 6.5x12.5 rivets (area Y2 ).
  22. Rivet roof frame upper section (1) with ø 6.5x14.5 rivets (area Y3 ).
  23. Rivet roof frame upper section (1) with countersunk-head rivets ø 6.3x16 (areas Z2 ).
  24. Rivet roof frame upper section (1) with countersunk-head rivets ø 6.3x17.5 (areas Z3 ).
  25. Rivet roof frame upper section (1) with countersunk-head rivets ø 6.3x19.5 (areas Z4 ).
  26. Roof frame upper section (1) SHIELDED GAS SEAM WELD (areas EE).
  27. Face-grind shielding gas weld joint (areas EE).
  28. Remove grinding dust.
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