Replace complete center roof paneling

AR65.10-P-1000Q

Replace complete center roof paneling

15.11.11



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 rear wall window

3

Remove detachable parts in area to be repaired

4

Cover all detachable body components that remain in the area to be repaired

Tarp (fire-resistant)

5

Separate center roof paneling

AR65.10-P-1000-02Q



*201589005100

Vario Drill WS 91 spot weld removing tool

Round wire brush, braided, dia. 70 mm

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

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

Hot air gun - 3000 W

Drill
gotis://K_58.1_04.0

Straight grinder
gotis://K_58.0_03.0

Angle grinder
gotis://K_58.1_07.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

6

Prepare center roof paneling

AR65.10-P-1000-03Q

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

7

Install and weld in center roof paneling

AR65.10-P-1000-04Q



*209589012300

Round wire brush, braided,  70 mm

Electrode miller

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

Clamping pliers

MIG MAG gas welder (steel, brazing, aluminum)
gotis://K_60-65_17.1

Inverter spot welder
gotis://K_60-65_16.0

Drill
gotis://K_58.1_04.0

Angle grinder
gotis://K_58.1_07.0

Sealant

*BR00.45-Z-1003-01A

MB preservative

*BR00.45-Z-1003-05A

8

Clean repair areas and prime using primer filler

9

Seam sealing following repair

 Supplement standard sealants with MB body sealant.

AR97.10-P-4000Q

Sealant

*BR00.45-Z-1003-01A

10

Paint repair areas and adjacent surfaces

11

Install windshield

12

Install rear wall window

13

Cavity preservation following repair work



Notes on cavity preservation

Model 209

AH97.20-P-0001-01B

14

Install all removed assembly 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