ROOF PANEL

Operation 7210E28 · EXTERNAL PARTS

The vehicle should be in the following condition before the operation: windscreen detached, sun roof (if fitted) detached, roof panel lining detached, roof panel arch detached, fixed rear side window glass detached, tailgate detached, roof bar detached, sliding side doors detached, aerial detached, window bags detached, wiring released and moved aside.

Removing

- Work on the component highlighted having previously made sure that the equipment illustrated below is available.

1. Assembled roof panel

- Check that the components connected are not distorted by checking the bodyshell alignment measurements using suitable equipment (gauges, templates or jigs).

Carry out any bodyshell straightening operations before cutting the component.

- Trace then, using an 8 mm drill bit, make holes in the roof panel as illustrated in the diagram for subsequent fill welding.

Remove the anti-corrosion treatment in the replacement part contact areas using a rotary brush and apply electro-galvanizing paint.

- Reduce the spot welds as indicated in the diagram using a chamfering machine.

- Remove the 12 rivets in the front section of the roof panel using a drill

- Remove the 12 rivets from the side part of the roof panel, using a drill, starting from the front section and working symmetrically on both sides.

- Remove the roof panel.

Refitting

- Prepare the edges to be welded and protect them using thermoweldable primer

- Prepare the edges to be welded and protect them using thermoweldable primer

- Position the preformed reference beads (A)

- Apply structural adhesive

- Position the preformed reference beads (B).

- Apply structural adhesive.

- Apply sealing and welding compound (C) as illustrated in the diagram.

- Centre the roof panel using the rear crossmember as a reference and applying pressure at the tailgate hinges.

- Before starting the operation of rivetting, position several sections of adhesive.

- Using special rivets (Parts code 9641318080) and the special fitting equipment, begin rivetting the roof panel starting from (D) firstly towards the front section and then towards the rear section working symmetrically on both sides.

- Using special rivets (Parts code 9641318080) and special equipment, begin rivetting the roof at the front section.

- Proceed with the MIG welding in areas (E) illustrated in the diagram and finish off using a spot welder in the remaining areas and then grind the welds using a disc grinder.

- Check that the welded component is correctly positioned.

- Apply electro-galvanizing paint to the ground parts.

- Proceed with waxing the box sections.

When the operation is completed, refit the elements removed previously.