Removing and installing roof paneling

AR65.10-D-5702A

Removing and installing roof paneling

10.6.98



Removing



General notes on body repair

All models

AH60.00-N-0001-01A

1

Disconnect ground cable of battery

2

Remove headliner

3

Remove paneling on outside of A-pillar

AR88.80-D-8500A

4

Remove partition lining

5

Remove windshield

AR67.10-D-1000B

6

Remove clearance lights (6, 11)

7

Remove cover for drip rail

8

Remove detachable body components near repair work

9

Cover all attached parts remaining in area to be repaired

Tarpaulin (fire-proof)

*WH58.30-Z-1001-40A

10

Remove roof paneling (2)

AR65.10-D-5702-01A

Spot weld cutter

*201589005100

 Spot weld loosening tool Vario Drill
WS 91

*WH58.30-Z-1006-01A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Bore welding spots

AR64.20-D-0002A

11

Prepare connecting plates on vehicle for installation of roof paneling (2)

Align connecting plates, grind down and coat with zinc dust paint

 Zinc dust paint, suitable for spot welding

12

Prepare roof paneling (2) for installation

AR65.10-D-5702-02A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Straight grinder (electric/pneumatic)

*WE58.40-Z-1002-03A

Angular grinder (electric/pneumatic)

*WE58.40-Z-1003-03A

Zinc dust paint which can be spot welded

13

Fit roof paneling (2), align and secure with clamping pliers



Inspecting

14

Check windscreen aperture

AR67.10-D-0004B



Installing

Danger!

The high voltage used for arc welding presents a lethal hazard. Danger of explosion from welding near highly combustible materials. Danger of injuries from welding splash and UV light during welding. Danger of poisoning through inhaling welding vapors

Use insulating mats. Wear protective clothing, safety glasses and facemask. Remove highly combustible materials from the danger zone. Use evacuation system.

AS00.00-Z-0007-01A

15

Weld in roof paneling (2)

AR65.10-D-5702-03A

Inert gas welding unit

*WE58.40-Z-1001-02A

Spot welder

*WE58.40-Z-1002-02A



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

All models

AH00.00-N-0005-01A



General notes on welding

Models 638, 667, 668, 670, 901, 902, 903, 904

AH60.00-N-0005-01A

16

Grind off protruding welding material

Straight grinder (electric/pneumatic)

*WE58.40-Z-1002-03A

Angular grinder (electric/pneumatic)

*WE58.40-Z-1003-03A

17

Vacuum cavities

 Metal chips and/or metallic grinding dust in cavities can cause corrosion.

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

18

Clean areas repaired and prime with MB primer/filler

19

Supplement standard seals with MB body sealant

MB body sealant for sealing seams (suitable for painting)

20

Paint area repaired and adjacent surfaces

21

Supplement hollow cavity preservation

22

Install cover for drip rail

23

Install clearance lights (6, 11)

24

Install windshield

AR67.10-D-1000B

25

Install partition lining

26

Install paneling on outside of A-pillar

AR88.80-D-8500A

27

Install headliner

28

Install detachable body components removed

29

Reconnect ground lead to battery

Number

Designation

WH58.30-Z-1006-01A

Vario Drill WS 91 spot weld removing tool

WH58.30-Z-1004-20A

Hot-air gun

WH58.30-Z-1001-40A

Tarp (fire-resistant)

WE58.40-Z-1001-02A

Inert gas welder

WE58.40-Z-1002-02A

Spot welder

WE58.40-Z-1001-03A

Drill (electric/pneumatic)

WE58.40-Z-1002-03A

Straight grinder (electric/pneumatic)

WE58.40-Z-1003-03A

Angle grinder (electric/pneumatic)

WE58.40-Z-1004-03A

Body saw (electric/pneumatic)

WE58.40-Z-1005-03A

Wet/dry vacuum cleaner