Body - Repairing Unevenness in the Roof Panel
SECTION8
Group
81
NO.
809
DATE
Aug. 1996
Repairing unevenness in the panel above roof arches
850
REFERENCE: TP 8201201, SERVICE MANUAL SECTION 8 (82 - 86, 88) INTERIOR, EXTERIOR; 850 1992-
Repairing unevenness in the roof panel
The adhesive used to bond the roof to the roof arches may cause unevenness in the roof panel which look like dents from the outside. This is caused by the adhesive pulling the roof panel down onto the roof arch as it cures.
This unevenness is most common on the roof arch above the C-pillar in the 855, but also occurs on other roof arches in both the 854 and 855.
The repair method consists of cutting off the adhesive bead pulling down the panel, allowing the panel to rise to its correct shape. The roof and roof arch are then bonded with PUR adhesive.
Method
Remove headlining.
See Service Manual Section 8 (82 - 86, 88) "Interior, exterior 850 1992- Pages 86-89.
Check that there are no other causes of unevenness in the roof panel.
The arrowed insert shows the roof arches with their adhesive beads (shaded) viewed diagonally from below in the passenger compartment.
The adhesive beads (shaded) on the roof arch may be different lengths as illustrated.
The illustrations show roof arches with adhesive beads viewed diagonally from below.
Cut off the adhesive beads between the roof arch and roof where unevenness occurs (and only there!).
Check to see if the unevenness has gone when the adhesive bead has been removed.
If not, cut off another adhesive bead next to it.
Blow clean with compressed air.
Clean the surface using Heptan H cleaner, P/N 1161436-9.
To obtain the best bond on EO paintwork apply paint primer P/N 1161386-6
If the adhesive bead is on the outside of the roof arch flange: (See also illustration below)
Apply rapid bonding adhesive, P/N 1161434-4, in the Evode adhesive joint ("E" in the illustration below).
Apply PUR adhesive (D) outside so that it bonds the cut (E) Evode adhesive joints (C), roof (A) and roof arch (B).
Apply PUR adhesive (D), P/N 1356443-0, along the length of the roof arch.
If the Evode adhesive bead is normal:
Apply PUR adhesive bead(s) at least as long as the Evode adhesive bead.
A = roof panel
B = roof arch
C = Evode adhesive bead (cut)
D = PUR adhesive bead
Reinstall headlining according to Service Manual.
WARRANTY STATEMENT: Claims may be submitted under the New Car Limited Warranty when a manufacturing defect is present using claim type: 01
Operation No. Labor description Time allowance
85510-2 Headlining Remove-Install/Replace 854 1.3 hr
85510-2 Headlining Remove-Install/Replace 855 1.7 hr
85511-2 Headlining with sun roof Remove-Install/Replace 854 1.3 hr
85511-2 Headlining with sun roof Remove-Install/Replace 855 1.8 hr
81908-3 Bonding roof arches 0.2 hr