Remove/Install Front Roof Frame - Ar65.20-P-1006LWR

Model 205.4 

Fig 1: Front Roof Frame Location

Courtesy of MERCEDES-BENZ USA

	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.	See AS00.00-Z-0017-01A .
	General information on body repair		See AH60.00-N-0001-01A .
	Information on preventing damage to electronic components due to electrostatic discharge		See AH54.00-P-0001-01A .
	Pretreatment of bonding surfaces		See AH60.00-P-0008-01SX .
	General information on MB materials		See AH98.00-P-9409-03A .
	Remove
1	Remove detachable parts in area to be repaired
2	Cover all detachable parts remaining on vehicle with spark protection blankets
3	Set up straightening bench with straightening bench crossmembers and straightening tool set
	000 588 01 23 00 Body straightening system		See WS60.00-P-0023K .
4	Place vehicle on straightening bench and fasten
5	Remove roof frame (1) and mounting console (2)		See AR65.20-P-1006-02LWR .
	000 588 00 84 00 Heat gun	Commercially available devices/tools  Round wire brush Spot weld milling machine Wet/dry vacuum cleaner	See WS54.00-P-0049B .
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
6	Prepare roof frame (1) and mounting console (2)	Commercially available devices/tools  Round wire brush	See AR65.20-P-1006-04LWR .
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	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.	See AS00.00-Z-0007-01A .
	Measures for preventing damage to components when performing electric welding and soldering work		See AH60.00-P-0001-02A .
	General information on riveting		See AH60.00-P-0003-01N .
7	Install roof frame (1) and mounting console (2)		See AR65.20-P-1006-05LWR .
	000 588 02 84 00 Welder		See WS60.00-P-0022K .
	000 588 01 84 00 Welder		See WS60.00-P-0021K .
	000 588 01 23 00 Body straightening system	Commercially available devices/tools  Round wire brush Manual temporary fastener Blind rivet gun (minimum pull-off force 19 kN) Wet/dry vacuum cleaner	See WS60.00-P-0023K .
		Blind rivet 6.5 X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	*BR00.45-Z-1012-13A
		Parts kit for 2-component adhesive for body	*BR00.45-Z-1162-02A
		Side portal frame
8	Release vehicle from straightening bench, lift vehicle and remove straightening bench
9	Clean welds and sheet metal flanges	Commercially available devices/tools  Round wire brush
10	Remove spark protection blankets
11	Clean repair area	Commercially available devices/tools  Wet/dry vacuum cleaner
12	Prime repair area using primer filler Notes on paintwork repairs	Use only primer filler approved by Daimler AG	See AH98.00-P-9408-02A .
13	Seal seam following repairs		See AR97.10-P-4000LW .
14	Paint repair areas and adjacent surfaces Notes on paintwork repairs	Use only paints approved by Daimler AG	See AH98.00-P-9408-02A .
15	Add cavity preserving agent		AR97.20-P-1500LW
16	Install all detachable body components in area to be repaired

Courtesy of MERCEDES-BENZ USA