Remove/install front roof frame

AR65.20-P-1006QA

Remove/install front roof frame

11.11.11



Removing

Danger!

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

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding splatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes.

Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system.

AS00.00-Z-0007-01A



General information on body repair

All models

AH60.00-N-0001-01A



Measures for preventing damage to vehicles or components when performing electric welding work

All models

AH00.00-N-0005-01A



Notes on paintwork repairs

All models

AH98.00-P-9408-02A



General information on MB materials

All models

AH98.00-P-9409-03A

1

Remove windshield

2

Remove detachable parts in area to be repaired

3

Cover all detachable body components remaining in vehicle (area to be repaired)

Tarp (fire-resistant)

4

Equip straightening bench with modular or crossmembers and straightening tools

Observe set-up plans enclosed!

Straightening systems for passenger cars (Car Bench)

gotis://K_60-65_03.0

Passenger car straightening system (Celette)

gotis://K_60-65_02.0

5

Set vehicle onto straightening bench using two-post lift and fasten

Two-post lifting platform, 2.5 - 3.5 t electrohydraulic

gotis://H_00.1_01

6

Mount portal frame at front with inspection and welding device

Observe set-up plans enclosed!

 Portal frame

*129589032300

 Multi-Z element MZ 260

*140589262300

 When mounting the front portal frame, an additional set of Multi-Z elements MZ 260 must be used.

 Inspection and welding device

*203589002300

 Inspection and welding devices

*209589002300

 Welding devices

*209589052300

7

Separate front roof frame

AR65.20-P-1006-02QA

 Spot weld milling cutter

*201589005100

Ball cutter, dia. 12 mm

Vario Drill WS 91 spot weld removing tool

Round wire brush, braided, dia. 70 mm

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

Cutting disk, 65 mm dia., 80 m/s (max. 23,500 rpm)

drill

gotis://K_58.1_04.0

Straight grinder

gotis://K_58.0_03.0

Angle grinder

gotis://K_58.1_07.0

Body jig saw

gotis://K_58.1_01.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

8

Prepare front roof frame for installation

AR65.20-P-1006-04QA

Round wire brush, braided, dia. 70 mm

drill

gotis://K_58.1_04.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

9

Install front roof frame

AR65.20-P-1006-05QA

 Portal frame

*129589032300

 Inspection and welding device

*203589002300

 Inspection and welding devices

*209589002300

 Welding devices

*209589052300

 Multi-Z element MZ 260

*140589262300

 When mounting the front portal frame, an additional set of Multi-Z elements MZ 260 must be used.

Round wire brush, braided, dia. 70 mm

Electrode miller

Clamping pliers

Inert gas welder

gotis://K_60-65_17.0

Inverter spot welder

gotis://K_60-65_16.0

drill

gotis://K_58.1_04.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Sealant

*BR00.45-Z-1003-01A

10

Release vehicle from straightening bench and lift with two-column lift, remove straightening bench

Two-post lifting platform, 2.5 - 3.5 t electrohydraulic

gotis://H_00.1_01

11

Clean weld joints and metal flanges with wire brush

12

Clean repair areas and prime using primer filler

13

Seam sealing following repair

 Supplement standard sealants with MB body sealant.

Sealant

*BR00.45-Z-1003-01A

14

Paint repair areas and adjacent surfaces

15

Cavity preservation following repair work



Notes on cavity preservation

Model 209

AH97.20-P-0001-01B

16

Install windshield

17

Install all removed detachable parts

Number

Designation

Order number

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1003-05A

Cavity sealant, solvent-free (1 l container)

A 000 986 72 70 05

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42