Front Roof Frame Removal And Installation - Ar65.20-P-1006S
Model 223.0/1/9
| Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust | Wear dust filter mask, safety glasses, and protective gloves. Use a suitable, grounded dust extraction system. |
AS60.00-Z-0007-01N | |
| 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 | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | |
| Notice | General information on body repair | AH60.00-P-0001-01S | |
| Notice | Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | |
| Note on working on aluminum components and vehicles | AH60.00-P-0034-01RG | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| Remove | |||
| 1 | Remove detachable parts in area of repair point. | ||
| 2 | Cover all detachable parts remaining in vehicle with spark protection blanket. | ||
| 3 | Remove center roof paneling. | Model 223.0/1 except code 413 (Panoramic sliding sunroof/glass roof) |
AR65.10-P-1000S |
| 4 | Separate roof frame upper section (1) and roof frame lower section (2). | AR65.20-P-1006-02S | |
| 000 588 02 39 00 Rivet press tool | WS60.00-P-0010B | ||
| 5 | Remove roof frame mounting supports. | If roof frame mounting supports are damaged. | AR65.20-P-1006-10S |
| 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-0003-01S | ||
| General notes on welding | AH60.00-P-0005-01N | ||
| 6 | Prepare roof frame upper section (1) and roof frame lower section (2). | AR65.20-P-1006-04S | |
| 7 | Prepare roof frame mounting supports. | If roof frame mounting supports are damaged. | AR65.20-P-1006-11S |
| 8 | Install roof frame mounting supports. | If roof frame mounting supports are damaged. | |
| AR65.20-P-1006-12S | |||
| 000 588 02 39 00 Rivet press tool | WS60.00-P-0010B | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A | ||
| Blind rivet Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1016-13A | ||
| Blind rivet Y4 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN) | *BR00.45-Z-1032-13A | ||
| Blind rivet Y5 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN) | *BR00.45-Z-1034-13A | ||
| Countersunk-head blind rivet Z3 6.4x17.0 (clamping area 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1055-13A | ||
| 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 | ||
| Flow hole bolt M5 | *BR00.45-Z-1085-13A | ||
| Flow-form rivet with countersunk head X4 4 mm to 5.15 mm | *BR00.45-Z-1073-13A | ||
| Flow-form rivet with countersunk head X5 5.0 mm to 6.1 mm | *BR00.45-Z-1074-13A | ||
| Flow-form rivet with countersunk head X7 7.1 mm to 8.3 mm | *BR00.45-Z-1076-13A | ||
| 9 | Install and fit roof frame lower section (2). | ||
| 10 | Execute common separating cuts on roof frame lower section (2) and body. | ||
| 11 | Remove roof frame lower section (2). | ||
| 12 | Install and fit roof frame upper section (1). | ||
| 13 | Execute common separating cuts on roof frame upper section (1) and body. | ||
| 14 | Remove roof frame upper section (1). | ||
| 15 | Prepare weld puddle protection. | AR60.00-P-0070-01S | |
| 16 | Install roof frame upper section (1) and roof frame lower section (2). | AR65.20-P-1006-05S | |
| Make weld seam on vehicles with aluminum body | AR60.00-P-0070-01S | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A | ||
| Blind rivet Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1016-13A | ||
| Countersunk-head blind rivet Z2 6.4x15.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1044-13A | ||
| Countersunk-head blind rivet Z3 6.4x17.0 (clamping area 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1055-13A | ||
| 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 | ||
| 17 | Clean weld joints and sheet metal flange. | ||
| 18 | Remove spark protection blankets. | ||
| 19 | Clean repair area. | ||
| 20 | Prime repair area using primer filler | ||
| Notice | Notes on paintwork repairs | AH98.00-P-9408-02A | |
| General information on operation items and work procedures for painting | AH98.00-P-0003-01A | ||
| 21 | Seal seam after repair. | AR97.10-P-4000S | |
| 22 | Paint repair areas and adjacent surfaces. | ||
| Notice | Notes on paintwork repairs | AH98.00-P-9408-02A | |
| General information on operation items and work procedures for painting | AH98.00-P-0003-01A | ||
| 23 | Supplement cavity preservation. | AR97.20-P-1500S | |
| 24 | Install center roof paneling. | Model 223.0/1 except code 413 (Panoramic sliding sunroof/glass roof) |
AR65.10-P-1000S |
| 25 | Install all detachable parts in area of repair point. |
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-1016-13A | Blind rivet Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | A 004 990 17 97 |
| BR00.45-Z-1032-13A | Blind rivet Y4 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN) | A 003 990 81 97 |
| BR00.45-Z-1034-13A | Blind rivet Y5 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN) | A 003 990 80 97 |
| 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-1055-13A | Countersunk-head blind rivet Z3 6.4x17.0 (clamping area 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) | A 000 991 86 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-1073-13A | Flow-form rivet with countersunk head X4 4 mm to 5.15 mm | A 000 991 49 02 |
| BR00.45-Z-1074-13A | Flow-form rivet with countersunk head X5 5.0 mm to 6.1 mm | A 000 991 50 02 |
| BR00.45-Z-1076-13A | Flow-form rivet with countersunk head X7 7.1 mm to 8.3 mm | A 000 991 52 02 |
| BR00.45-Z-1085-13A | Flow hole bolt M5 | A 000 990 60 11 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |