Rear Roof Frame Installation - Ar65.20-P-1008-03S

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

Model 223.0/1/9 

Courtesy 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 6.4x12.0
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 6.4x14.0
8. Y₈ = rivet 6.4x17.0
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

Courtesy of MERCEDES-BENZ USA

The following steps are shown on the left side of the vehicle for model 223.1 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 mechanic's perspective. At the same time, this perspective also specifies the direction in which the rivets must be placed.

1. Install roof frame upper section (1) and roof frame lower section, fit, and fix in place.
2. Drill rivet holes in roof frame upper section (1) and roof frame lower section with ø 6.7 mm bit (areas A).
3. Countersink rivet holes in roof frame upper section (1) and roof frame lower section (areas A).
4. Punch rivet holes in roof frame upper section (1) and roof frame lower section with ø 6.0 mm bit using a rivet press tool (areas B).
5. Remove roof frame upper section (1) and roof frame lower section.
6. Deburr rivet holes in roof frame upper section (1) and roof frame lower section on both sides.
7. Remove drilling chips.

   Courtesy of MERCEDES-BENZ USA

   Courtesy of MERCEDES-BENZ USA

8. Model 223.0/1

   except code 413 (Panoramic sliding sunroof/glass roof)

   Insert structured foam parts (3) with 2-component adhesive for reinforcements in roof frame lower section (2).

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

9. Model 223.0/1

   except code 413 (Panoramic sliding sunroof/glass roof)

   Apply 2-component adhesive for reinforcements to structured foam parts (3) in cross-hatched areas (areas C).

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

10. Apply 2-component adhesive to roof frame lower section (2) in cross-hatched areas.

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

11. Install roof frame upper section (1) and roof frame lower section and fix in place.
12. Rivet roof frame upper section (1) and roof frame lower section with ø 6.4x17.0 countersunk-head rivets (areas Z₃ ).
13. Rivet roof frame upper section (1) and roof frame lower section with a flow-form rivets structure with a 4 mm to 5.15 mm clamping range (areas W₄ ).
14. Roof frame upper section (1) (area EE).
15. Face-grind shielding gas weld joints (area EE).
16. Remove grinding dust.

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