Replace complete center roof paneling

AR65.10-P-1000YA

Replace complete center roof paneling

15.11.11



Remove

 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

 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



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

Model 124, 126, 129, 140, 163, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 240, 414, 463, 639

AH98.00-P-9408-02A



General information on MB materials

Model 124, 126, 129, 140, 163, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 240, 414, 463, 639

AH98.00-P-9409-03A

1

Remove tilting/sliding roof frame

AR77.20-P-3000TX

2

Remove windshield

AR67.10-P-1000Y

3

Remove rear wall window

AR67.20-P-2000Y

4

Cover all detachable parts remaining in vehicle

Tarp (fire-resistant)

5

Separate center roof paneling (1)

AR65.10-P-1000-02YA

 Spot weld milling cutter

*201589005100

Ball cutter, dia. 12 mm

Vario Drill WS 91 spot weld removing tool

Round wire brush, braided, dia. 70 mm

Cutting disk, Ø 65 mm, 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

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 (1)

AR65.10-P-1000-03YA

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 center roof paneling (1) and weld in

AR65.10-P-1000-04YA

 Spacer blocks

*219589022300

Electrode miller

Clamping pliers

Round wire brush, braided, dia. 70 mm

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

8

Clean weld joints and sheet metal flange with round wire brush

Round wire brush, braided, dia. 70 mm

Drill
gotis://K_58.1_04.0

9

Clean repair area

10

Prime repair area with primer filler

11

Carry out seam sealing after repairs


Supplement standard sealing with MB body sealant.

AR97.10-P-4000Y

Sealant

*BR00.45-Z-1003-01A

12

Paint repair areas and adjacent surfaces

13

Apply additional cavity preservation

AR97.20-P-1500Y



Notes on cavity preservation

Model 124, 126, 129, 140, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 240, 463, 639, 671, 690.6, 901, 902, 903, 904, 905

Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7

AH97.20-P-0001-01B

Combination pressure spray gun (corrosion protection)
gotis://K_91-97_01.0

MB cavity wax preservation, 1 l

*BR00.45-Z-1003-05A

14

Remove tarp

 On all covered parts remaining in vehicle.

15

Install windshield

AR67.10-P-1000Y

16

Install rear wall window

AR67.20-P-2000Y

17

Install tilting/sliding roof frame

AR77.20-P-3000TX

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