Notes for bonding sound insulation (SI), doors (Cooper Convertible)

Required special tools: 

• 51 0 300

General: 

Sound insulation is bonded to the inner door panel.

Bonded sound insulation must not be loaded (e.g. leak test) before 5 hours have elapsed.

On-the-job safety: 

When working with bonding products (adhesive, cleaning agent, etc.):

• Wear safety goggles, hand protection and, if necessary, an apron.
• Ensure the area is well ventilated.
• Change work clothes contaminated with adhesive immediately.
• Change work clothes contaminated with solvents and swelling agents immediately (keep spare work clothes on hand).
• Take skin protection measures, provide washing facilities including hot water, use silicone-free skin creams.
• Always keep an eyewash on hand, change the water regularly (once a month).
• Comply with the relevant safety regulations.

Handling adhesive area on inner door panel: 

Adhesive  Butyl bead applied to sound insulation with protective film Butyl mini-round profile ø 4 mm from the roller Butyl round profile ø 6 mm from the roller

Cleaning  CLEANING AGENT R2 Under no circumstances: paint thinning  Carry out bonding only after an air drying time ≤ 1 min. Air drying time may be omitted if the entire bonding surface is wiped with a dry cloth After cleaning, the bonding surface may not be touched with hands or contaminated again

Repair in area of sound insulation, door: 

Repair

Cut the butyl cord between the sound insulation and the inner door panel with a sharp knife After the repair is finished, position a new butyl cord 4 mm dia. directly on the original adhesive bead Heat the butyl bead with a standard hot air blower until the butyl cord frays when touched slightly. Do not damage the sound insulation in the process Press on with special tool 51 0 300. Perform this work extremely carefully because the increased amount of adhesive requires contact pressure of ≤ 20 N/cm (compared to firm thumb pressure ~ 30 N/cm) Visually check the adhesive bead and its compression (no capillaries or broken adhesive bead permitted)

in the event of damaged sound insulation or leakage

In the cases mentioned, the complete sound insulation must be replaced. After removing the sound insulation, removal all butyl remnants from the inner door panel. Apply 6 mm dia. butyl cord to new sound insulation Press on with special tool 51 0 300. Contact pressure ≤ 20 N/cm (compare to firm thumb pressure ~ 30 N/cm)

The sound insulation must be bonded watertight below the door lock: 

• Flat bonding surface required all round.
• No bonding in the event of moisture (e.g. condensation, etc.).
• Bonding area must not show any traces of adhesion-reducing residues (e.g. separating agents, greases, oils, paraffins, plastisols, cavity wax, polishing dust residues, etc.).
• Remove the protective film directly before joining (under no circumstances remove earlier, since the butyl, because of its stickiness, will very quickly pick up adhesion-reducing dirt contaminants).
• The sound insulation must be attached with positional accuracy to the inner door panel because it will no longer be possible to change the position without damaging the butyl bead.
• With repainted areas, the maximum permitted temperature of 90°C may not be exceeded in the area of the sound insulation. Otherwise, the sound insulation must be removed (and replaced, if necessary).

Expiry date of adhesive  :

24 months, see label on packaging.

Disposal of the cleaning cloth: 

Cleaning cloths and cleaning agent residues are hazardous waste (see also safety data sheet).

Disposal of adhesive: 

Hazardous waste (see also safety data sheet).