Separate side roof paneling - AR65.10-P-1020-01WX

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MODEL 117.9, 156, 176, 204.9, 212.2, 242, 246

The following operation steps are shown on MODEL 204.9.

The separation points shown ensure an optimum given repair area. It is possible to vary between A and D-pillar within this area according to the scope of damage. Repair method remains the same.

1. 1.1) MODEL 156
  Mark separating points on side roof paneling (1) (areas A, B, and C).
  
  Mark separating point at Y-marking (area C).
2. 1.2) MODEL 117.9, 176, 204.9, 212.2, 242, 246
  Mark separating points on side roof paneling (1) (areas A, B, C and D).
  
  Mark separating points at Y-markings (areas C and D).

Fig 1: Side Roof Paneling Separating Points - Shown On Model 204.9

Courtesy of MERCEDES-BENZ USA

1. 2.1) MODEL 156
  Cut side roof paneling (1) at separating points (areas A, B and C).
  
  Do not make the cuts too deep. Otherwise the components below can be damaged and weakened.
2. 2.2) MODEL 117.9, 176, 204.9, 212.2, 242, 246
  Cut side roof paneling (1) at separation points (area A, B, C and D).
  
  Do not cut too deeply. Otherwise the components below can be damaged and weakened.
Expose spot welds on side roof paneling (1) and cut out (areas E, F, G and H).
MODEL 117.9, 204.9, 212.2, 242, 246
Expose spot welds on side roof paneling (1) and cut out (area I).
Heat side roof paneling (1) in crosshatched area.
Cross-hatched area is bonded.
Remove damaged side roof paneling (1).

Fig 2: Side Roof Paneling Spot Weld Areas
Courtesy of MERCEDES-BENZ USA
Grind mating surfaces down to bare metal in the cross-hatched inner C-pillar sidewall.
Sand down spot weld flanges to bare metal on both sides.
Remove shavings using wet/dry vacuum cleaner.
Coat insides of spot weld flanges with zinc dust paint.
Do not coat bonding surfaces with zinc dust paint (area F₁ ). Otherwise adhesion problems may occur.

Observe pretreatment of bonding surfaces.

Fig 3: Bonding Surfaces (Area F1)
Courtesy of MERCEDES-BENZ USA