Roof, Replacing, Vehicles With Panorama Roof: Procedure

Separating Points

CAUTION:

Risk of injury due to flying metal shavings.

Irritation and injury to skin and eyes possible.

- Wear protective eyewear.

- Wear safety gloves.

CAUTION:

Do not damage the underlying reinforcements when performing the separation cuts.

- Perform the separation cuts using the Edge Milling Unit.

- Re-welding the reinforcements is not permitted due to safety reasons.

-- Roughly cut the roof -1- at the separation cut -2- using the Edge Milling Unit maintaining a 30 mm distance parallel to the plasmatron seam.

-- Loosen the original joint on the front and rear roof crossmember using Spot Weld Breaker.

-- Heat the bonds between the roof and the roof crossmembers, using the Hot Air Gun and loosen, using a Plastic Wedge.

-- Remove the roof -1- from the body.

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NOTE:

Do not damage the roof pillar when removing the remainder of the roof.

Do not use cutting or grinding discs; use a lamellar disc instead.

-- Cut the remainder of the roof -1- using Tin Snips.

-- Grasp the remainders using pliers and break the Plasmatron seam by moving them back and forth.

-- Remove the remaining material using the One-Handed Angle Grinder.

-- Remove adhesive residue and sealing compound from the front and rear roof crossmembers using a Flat Blade Scraper.

-- Use the One-Handed Angle Grinder to sand the adhesive surfaces and welding surfaces to bare metal.

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-- Grind down the adhesive surface for the Two-Part Body Adhesive :D 180 003 M3 -1- to bare metal using the One-Handed Angle Grinder.

-- Apply corrosion protection on the adhesive surface for the One-Part Assembly Adhesive :D 190 MKD A3 -2-. Refer to ADHESIVE SURFACE PRETREATMENT WHEN REPLACING LASER-SOLDERED ROOFS .

-- Clean the adhesive surfaces using Silicone Remover :LVM 020 000 A5 .

-- Apply Primer :D 181 220 A1 to the adhesive surface for the One-Part Assembly Adhesive -2- using the Applicator :D 009 500 25 .

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Replacement Parts

Roof
One-Part Assembly Adhesive :D 190 MKD A3 , five cartridges
Two-Part Body Adhesive :D 180 003 M3 , three cartridge sets
Silicone Remover :LVM 020 000 A5
One-Part Adhesive Sealant :D 476 KD3 M2 , one cartridge
Primer :D 181 220 A1
Applicator :D 009 500 25
Felt Strips

New Part, Preparing

NOTE:

To guarantee a problem-free and long lasting roof repair, the following procedure must always be followed.

Adhesive materials must be applied very quickly.

Pay attention to the adhesive processing time (pot life).

To apply the adhesive sealant, use a Compressed air gun and an electric or compressed air driven Double Cartridge Gun.

Applying the adhesive tape parallel to the side adhesive seam on the roof prevents contamination.

-- Grind down the welding surfaces on the roof -1- to bare metal using the One-Handed Angle Grinder.

-- Grind down the adhesive surfaces for the Two-Part Body Adhesive :D 180 003 M3 at the roof -1- and the roof railing bracket -2- to bare metal using the One-Handed Angle Grinder.

NOTE:

Fit the roof to the vehicle while it is resting on its wheels or on the Alignment Bracket.

-- Place the roof -1- on the roof frame and check the roof alignment to the roof pillars (visual inspection).

-- Check the fit of the roof with the windshield and rear lid.

-- Remove the roof.

-- Clean the adhesive surfaces using Silicone Remover :LVM 020 000 A5 .

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-- Clean the adhesive surfaces using Silicone Remover :LVM 020 000 A5 .

-- Apply One-Part Assembly Adhesive :D 190 MKD A3 between the roof and roof frame reinforcement, using the Compressed Air Gun.

-- Apply adhesive beads (5 cm in length) One-Part Assembly Adhesive :D 190 MKD A3 between the roof and roof frame reinforcement, using the Compressed Air Gun.

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-- Clean the adhesive surfaces -2- for the One-Part Assembly Adhesive :D 190 MKD A3 parallel to the roof flange at the left and right side of the roof -1- using Silicone Remover :LVM 020 000 A5 .

-- Apply Primer :D 181 220 A1 to the adhesive surfaces -2- for the One-Part Assembly Adhesive :D 190 MKD A3 using the Applicator :D 009 500 25 .

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Applying

-- For the corresponding bead geometry, cut off approximately 2 mm from the nozzle -B-.

Fig 1: Cut Adhesive Tube

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-- Clean the adhesive surfaces using Silicone Remover :LVM 020 000 A5 .

-- Apply One-Part Assembly Adhesive :D 190 MKD A3 using the Compressed Air Glue Gun on the front roof crossmember and the rear roof crossmember in the area where it was bonded at the factory.

-- Apply One-Part Assembly Adhesive :D 190 MKD A3 using the Compressed Air Glue Gun on the left and right roof pillars according to the dimension -a-, -b- and -c-.

Dimension -a- = 3 mm

Dimension -b- = 10 mm

Dimension -c- = 14 mm

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-- Apply One-Part Assembly Adhesive :D 190 MKD A3 using the Compressed Air Glue Gun onto the inner side of the roof -1- parallel to the left and right roof flange according to the dimension -a- and -b-.

Dimension -a- = 14 mm

Dimension -b- = 12 mm

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-- Cut off the first section of the Static Mixer -A- to get the correct bead diameter.

Fig 2: Cut Off First Section Of Static Mixer

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-- Operate the Double Cartridge Gun without the Static Mixer, until the Two-Part Body Adhesive comes evenly out of Connecting Pieces unit chambers.

-- Install the Static Mixer on the Connecting Piece.

-- Apply the first 100 mm of Two-Part Body Adhesive onto a piece of cardboard and only then begin the application on the vehicle.

-- Apply Two-Part Body Adhesive :D 180 003 M3 using the Double Cartridge Gun in the area of the front roof crossmember and the rear roof crossmember.

-- Apply Two-Part Body Adhesive :D 180 003 M3 using the Double Cartridge Gun in the area of the roof pillars.

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-- Coat the entire roof flanges -1- and the roof railing bracket -2- with Two-Part Body Adhesive :D 180 003 M3 .

NOTE:

Fit the roof to vehicle resting on its wheels or on the Alignment Set and secure.

-- Mount the roof -1- immediately and align it.

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Roof Depth Dimension, Adjusting

-- Secure the roof -1- at the front and rear roof crossmember with Locking Pliers.

-- Tighten the Tensioning Strap -2- across the roof in the areas shown to adjust the roof height.

-- Check the dimension -a- on the roof alignment to the roof pillar.

Dimension -a- = 6.0 mm ± 0.5 mm

-- If necessary, place the Felt Strip underneath to even it out.

-- Immediately remove any leaking Two-Part Body Adhesive :D 180 003 M3 .

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Welding

-- Weld the roof -1- with a Resistance Spot Welder, straight-line spot weld seam.

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CAUTION:

Impairment of the adhesion of the adhesive is possible.

- After bonding, the vehicle must rest on a level surface at room temperature (at least 15 °C (59 °F)) for 8 to 10 hours so that the adhesive components can harden.

- During this time, the vehicle must be on a level surface.

-- Immediately remove any excess Two-Part Body Adhesive -4-.

NOTE:

The adhesive bead -3- must seal toward the inside.

-- Apply primer to the left and right roof pillars.

-- Perform a thin fine-seam sealant -2- at the seam in between the roof -1- and the roof pillar -5- using One-Part Adhesive Sealant :D 476 KD3 M2 .

-- Seam sealing, general information. Refer to SEAM SEALING .

-- After painting the roof hollow spaces apply Cavity Sealant protective material.

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