Roof and Associated Components: Service and Repair
Replacing Roof
Tools
Technical values
Preliminary work
Preliminary work for body repairs (without straightening bench)
INFORMATION: If it can be ensured there has been no deformation of the vehicle structure, the following repair can be carried out without the need of a straightening bench. In this case, the vehicle must not be raised when welding the component; it must stand on its wheels on an even surface.
1. Remove accessories in the repair area.
1.1 Remove accessories in the repair area according to the extent of damage to the vehicle.
2. Set up straightening bench with straightening set.
2.1 Cover all accessories remaining on the vehicle and the adjacent areas with fire-proof protective covers.
3. Reshape connection area of the sheetmetal parts to be replaced.
4. Expose joint areas.
4.1 Remove underbody protection, paint, etc. from the joint areas of the body.
Safety instructions and information on quality
CAUTION:
Non-observance of safety instructions for body repairs
- Risk of damage to the vehicle
- Danger of injury
- Read the relevant safety instructions as well as general information and quality instructions.
- Tools and metalworking tools.
Tools and materials
Tools and materials for body repairs
Straightening set 92A Cayenne, WE 1121 Body Straightening System, Car Bench WE 1122
Resistance spot welder.
Metal inert gas (MIG) welder.
Pneumatic spotweld remover Pneumatic Spotweld Remover, Vario Drill WS 90 WE 1139
Pneumatic body saw Body saw V.A.G 1523A WE 1347
Oscillating body saw (special electric cutter) Special Electric Cutter Fine WE 1137
Rotary brush;
Leister Electron hot-air blower Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119
Cartridge gun Cartridge gun V.A.G. 1628 WE 1141
Spotweld drill Spotweld drill.
Twist drill Twist drill Nr.201
Star gauges for body gap dimensions Star gauges for body gap dimensions Nr.127-1
Support adhesive; material 000 043 204 82.
Structural adhesive.
Removing roof
1. Drill out spotwelds using spotweld drill
2. Stick on adhesive tape -1- along the edge of the roof on both sides at dimension -X-. -> Distance: 2 mm+2 mm
Adhesive tape serves as cut line.
INFORMATION: Only make cuts in the top plate. Make sure not to damage the plate underneath when doing this.
3. Make cut on both sides.
4. Heat up connection areas using the hot-air gun.
5. Remove roof (three people required).
INFORMATION: During separation make sure that the components beneath are not damaged.
6. Remove remaining pieces of the roof.
6.1 Cut off laser soldered joints on side panels.
6.2 Remove the remaining pieces.
Preparing roof for installation
1. Grind both sides of connecting flanges of roof in the marked areas until bare.
2. Preparing bonding areas (structural adhesive).
3. Preparing bonding areas (support adhesive).
INFORMATION: Do not apply zinc powder paint to the bonding areas.
4. Coat all spot-weld flange areas with zinc powder paint.
Preparing connection areas of body for installing roof
1. Clean welding and sealing areas.
1.1 Clean the body connecting flanges of underbody protection, adhesive residue and paint in the marked areas.
1.2 Grind the connecting flanges until bare on both sides.
2. Preparing bonding areas (structural adhesive).
3. Preparing bonding areas (support adhesive).
INFORMATION: Do not apply zinc powder paint to the bonding areas.
4. Coat all spot-weld flange areas with zinc powder paint.
5. Touch up any paint damage in areas that will later no longer be accessible.
Installing roof
1. Apply structural adhesive and support adhesive.
1.1 Evenly apply structural adhesive to the marked areas.
Working with body structural adhesive
1.2 Apply support adhesive to the marked areas. Apply additional adhesive beads as shown.
Support adhesive;
2. Place roof on rear roof frame with three people -Pfeil A- swivel in towards the front -Pfeile B-.
INFORMATION: Have this work carried out by an assistant whilst at the same time starting with the welding work.
3. Clean surface of roof in area of side panels.
3.1 Remove most of the excess adhesive material with a plastic spatula or cloth.
3.2 Finish cleaning visible surfaces with a cloth soaked in cleaning solution.
4. Weld in front roof.
4.1 Resistance spot-weld roof.
4.2 Apply additional welded seams to roof in area of A-pillar using inert gas.
5. Weld in rear roof.
5.1 Resistance spot-weld roof.
5.2 Apply additional welded seams to roof in area of D-pillar using inert gas.
Drilling holes for roof rail
INFORMATION: As a result of different designs (roof), it is not possible to provide a roof with hole pattern for repair work. In this case, the holes must be drilled subsequently.
1. Position roof rail holder -1- on the body, align and screw down with fastening screws -2-
Holder serves as drilling template.
2. Mark holes centered through the holes on the holder -Pfeile- and carefully drill through from the inside to the outside using a Dia 6 mm drill bit.
While drilling the holes, remove the drilling chips using a vacuum cleaner.
3. Check hole spacings by fitting roof rail and correct if necessary.
4. Remove roof rail holder.
5. Drill out holes to the dimension -A-. -> Diameter: 20 mm
6. Apply corrosion protection.
Subsequent work
Subsequent work for body repairs (without straightening bench)
1. Clean joint areas and sheetmetal flanges with a wire brush.
2. Prime joint areas and sheetmetal flanges with 2K primer.
3. Restore standard seal with body sealant
Also seal the repair area carefully.
4. Paint repair area and adjacent surfaces, if necessary.
5. Restore standard undersealing with underbody sealant
6. Apply standard cavity preservation
7. Install removed accessories in the repair area.