Repair instructions
    Body Structures
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      Floors
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        Rear Upper Structure
          DB-RM-01A005-02-001 - 765 LT Remove/Install Service hatch - Bulkhead
          DA-RM-01A005-02-001 - Remove/Install service hatch - Bulkhead
          DA-RM-01A005-03-001 - Remove/Install panel - Roof
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Instructions
Body Structures / Upper Structures / Rear Upper Structure / DA-RM-01A005-03-001 - Remove/Install panel - Roof
Preparation work
1.     
2.     
Care Point: Remove both sides.
3.     
Care Point: Remove both sides.
4.     
5.     
6.     
Care Point: Remove both sides.
7.     
Care Point: Remove both sides.
8.     
9.     
10.    
11.    
12.    
Care Point: Remove both sides.
13.    
14.    
Care Point: Remove both sides.
15.    
Care Point: Remove both sides.
16.    
17.    
Care Point: Remove both sides.
18.    
19.    
Care Point: Remove both sides. Follow procedure to remove covers and disconnect electrical connectors only.
20.    
Care Point: Remove both sides.
21.    
22.    
WARNING!
 
Risk of explosion and Fire hazard caused by handling solvent and adhesive.
Injury caused by fire or explosions.
No smoking!
•
No open flames!
•
Always use skin protection cream, protective gloves and safety glasses.
•
Provide for good ventilation at workplace.
•
Keep storage containers closed wherever possible or close immediately after use.
•
Always work in an enclosed aluminium or composite booth with suitable dust and fume extraction.
•
Always follow instructions on manufacturer’s data sheets for solvents and adhesives.
 
WARNING!
 
Sharp vehicle parts.
Caused by scraping or cutting.
Always wear protective gloves when working on or near sharp and burred vehicle parts.
•
Repair panels must be deburred.
 
WARNING!
 
Vapour inhalation or swallowing of adhesive material
When glue vapors are inhaled, the respiratory system could be damaged because even small amounts of the substances contained in some types of glues can attack the mucous membranes.
Swallowing glue can cause poisoning symptoms such as headaches, dizziness, cramps, stomach aches, vomiting, respiratory paralysis and unconsciousness. Moreover, irritation may occur to the respiratory paths and eyes.
Provide for good ventilation at workplace.
•
No fire, sparks, open flames or smoking.
•
Wear protective gloves and safety glasses and, if necessary, respiratory protection and protective clothing.
•
Do not fill glue into beverage cups
•
Store glue where it is not accessible for unauthorized persons.
 
WARNING!
 
Risk of explosion and injury when handling polyester and epoxy resins!
When processing polyester and epoxy resins with their hardeners, vapours result which are generally combustible.
The vapours from liquid polyester and epoxy resins with hardeners and their mixtures are a health hazard. Direct contact with skin or eyes result in irritation.
No smoking!
•
No open flames!
•
Always use skin protection cream, protective gloves and safety glasses.
•
Provide for good ventilation at workplace.
•
Do not eat or drink at workplace.
•
Keep storage containers closed wherever possible or close immediately after use.
 
WARNING!
 
Risk of injury caused by grinding dust or carbon fibers!
When performing some certain types of work on carbon fiber reinforced plastics such as cutting, sanding, grinding, etc., carbon fiber dust containing fine short fibers is produced. This dust or fibers irritate the bronchial tubes and can cause damage to the lungs. Fibers that get stuck in the lungs can cause damage to the lungs.
The sharp fibers in carbon fiber dust cause tiny injuries when they penetrate into the surface of the skin which can lead to skin irritations - particularly in the presence of dirt.
Always wear fine dust filter masks, safety glasses and protective gloves when handling carbon reinforced plastic materials.
•
Avoid stirring up dust, immediately extract all dust caused by sanding/grinding with approved vacuum cleaners when processing carbon reinforced plastic materials.
•
The extraction systems must be grounded to prevent a dust explosion.
•
Use only tools that have connections for extractor units.
•
Wipe away remaining dust residues with a moist, lint-free rag.
 
Remove panel - Roof
 
Care Point:
Make sure all Personal Protective Equipment (PPE) is worn.
Care Point:
Record the position of the panel - roof.
Care Point:
If the panel - roof is removed it must be renewed.
 
1.  
Remove seal (1).
 
2.  
Remove seal (2).
 
3.  
Fit protective covers to the body exterior.
 
4.  
Fir protective covers to the interior of the vehicle.
 
 
Care Point:
Do not overheat the upper structure.
Care Point:
Risk of component damage.
Care Point:
When the adhesive has softened cutting cord may aid the removal of the panel - roof.
 
5.  
(3) adhesive path
(4) panel roof
 
6.  
With care apply heat to area (A) and releases the adhesive.
 
7.  
With care apply heat to area (B) and releases the adhesive.
 
8.  
With care apply heat to area (C), releases the adhesive and remove the panel - roof.
 
Install panel - Roof
1.  
Remove the remaining adhesive from the upper structure (1).
 
2.  
Dry fit the new panel - roof and check alignment, record the position and remove the panel - roof.
 
 
Care Point:
Observe the manufacturers data sheet.
 
3.  
Degrease the bond path of the upper structure and the new panel - roof.3M VHB Surface Cleaner
 
 
Care Point:
Check 3M DP620 data sheet and expiry date.
Care Point:
Make sure equal delivery from the tubes.
 
4.  
Fit and trim the nozzle (N1).
 
5.  
Apply adhesive bead to the upper structure. 3M DP620
 
 
Care Point:
Two technicians required.
Care Point:
Follow manufactures recommendations for the curing time.
 
6.  
Fit the panel - roof to the upper structure and align to the recorded marks.
 
7.  
Install the remaining components in reverse order.
 
   
   
   Note