Front Roof Frame Mounting Support Installation- Ar65.20-P-1006-12S

	000 588 04 39 00 Rivet press tool		WS60.00-P-0440B
	000 588 03 39 00 Rivet die		WS60.00-P-0386K

Model 223.0/1 

Model 223.9 

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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

The following steps are shown on model 223.1 on the left side of the vehicle and must be similarly performed on the right side of the vehicle in the event of damage.

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

The graphics show the vehicle from the mechanic's perspective. At the same time, this perspective also specifies the direction in which the rivets must be placed.

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1. Transfer existing holes in the body to mounting support (1) with drill hole finder (areas C).
2. Install mounting support (1), fit and fix in place.
3. Drill rivet holes in the mounting support (1) with ø 6.7 mm (areas A, B, C, D).

   Drill rivet holes through the existing holes in the body (areas C, D).

4. Countersink rivet holes (areas B, D).
5. Remove mounting support (1).
6. Drill hole for flow-drill screw in mounting support (1) with ø 5 mm (area F).
7. Drill holes for flow-drill screws in mounting support (1) with ø 5 mm (area E).

   Where the inner side roof frame is not exposed.

8. Drill rivet holes in mounting support (1) and deburr on body on both sides.
9. Deburr hole for flow-drill screw in mounting support (1) on both sides (area F).
10. Deburr holes for flow-drill screws in mounting support (1) on both sides (area E).

    Where the inner side roof frame is not exposed.

11. Remove drilling chips.
12. Punch rivet holes in mounting support with ø 6.0 mm with rivet press tool (area G).

    Where the inner side roof frame is exposed.

    Shown on exposed inner side roof frame 

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13. Apply 2-component adhesive to body in cross-hatched areas.

    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

14. Install mounting support (1) and fix in place.
15. Rivet mounting support (1) with ø 6.5x12.5 rivets (areas Y₂ ).
16. Rivet mounting support (1) with ø 6.5x14.5 rivets (areas Y₃ ).
17. Rivet mounting support (1) with ø 6.4x15.7 rivet (area Y₄ ).
18. Rivet mounting support (1) with ø 6.4x17.7 rivet (area Y₅ ).
19. Rivet mounting support (1) with countersunk-head rivets ø 6.3x17.5 (area Z₃ ).
20. Rivet mounting support (1) with countersunk-head rivets ø 6.3x19.5 (areas Z₄ ).
21. Rivet mounting support (1) with countersunk-head rivets ø 6x21.5 (area Z₅ ).
22. Screw in and tighten M5 flow-drill screw (2).
23. Screw in and tighten M5 flow-drill screws (3).

    Where the inner side roof frame is not exposed.

24. Rivet mounting support with flow-form rivet with countersunk head 4.0 mm to 5.15 mm clamping range (area X₄ ).

    Where the inner side roof frame is exposed.

25. Rivet mounting support with flow-form rivets with countersunk head 5.0 mm to 6.1 mm clamping range (areas X₅ ).

    Where the inner side roof frame is exposed.

26. Rivet mounting support with flow-form rivets with countersunk head 7.1 mm to 8.3 mm clamping range (areas X₇ ).

    Where the inner side roof frame is exposed.

    Shown on exposed inner side roof frame 

    Courtesy of MERCEDES-BENZ USA