Repair Procedure

THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.

1. Remove the sun visors.

2. Remove the sun visor center supports.

3. If equipped, remove the coat hooks.

4. If equipped, remove the root rail modules (air duct/grab handle).

5. Remove the A-pillar trim covers.

6. Remove the B-pillar trim covers.

7. Remove the C-pillar trim covers.

8. If equipped, remove the over head console/reading lamps

9. Remove the dome lamp.

10. Recline the front seats.

11. Remove the push in fasteners attaching the headlining to the roof bows and let the headlining drop down and rest on the seats.








12. Use a 19 mm (3/4 in.) hole saw to make an access hole in the roof rail inner. Do not cut through the comers of the section or pierce the inner panels with the hole saw mandrel Figures 1 and 2.





13. Working through the access hole made in step 2, angle drill upward and drill a 6.3 mm (1/4 in.) hole through the first inner panel. Be careful, do not drill into the second inner panel, Figures 2 and 3.

NOTE:
PRIOR TO ATTACHING THE MIXING TIP TO THE ADHESIVE CARTRIDGE, DISPENSE A SMALL AMOUNT OF BOTH COMPONENTS TO INSURE AN EVEN FLOW. INSTALL THE MIXING TIP AND DISPENSE A SMALL AMOUNT OF ADHESIVE TO INSURE EQUAL PARTS OF MATERIAL ARE BEING MIXED. THE MIXED ADHESIVE ALLOWS 5 TO 7 MINUTES WORKING TIME BEFORE IT BEGINS TO CURE. DO NOT PREPARE THE ADHESIVE UNTIL YOU ARE READY TO DISPENSE IT.

14. Insert the end of the mixing tip into the 1/4 in. hole made in step 3 and dispense the remaining contents of the adhesive cartridge.

15. Using the 1/4 in. hole as an access hole, drill a 3 mm (1/8 in.) hole in the second inner panel. Be especially careful or use a depth stop set to 41 mm (5/32 in.) to avoid drilling into or dinging the A-pillar outer cover, Figures 2 and 3.





16. Install a 4.8 mm (3/16 in. or no. 10) diameter by 16 mm (5/8 in.) long sheet metal screw, into the existing 1/8 in. hole to pull the panels toward each other. A longer screw may pierce the exterior panel or one with a longer tapered point may not grip), Figure 4.

17. Place 3M Silencer Strip over the 3/4 in. access hole made in step 2.

18. Vacuum up all metal chips created during the drilling and sawing steps.

NOTE:
THE VEHICLE SHOULD NOT BE DRIVEN UNTIL THE ADHESIVE CURES 4 HOURS AT GREATER THAN 16° C (60° F) OR 30 MINUTES AT 60° C (140° F). FUSOR RECOMMENDS THE USE OF TEMPERATURE MONITORING STRIPS #705 WHEN USING HEATED CURE PROCEDURE.

19. Install the headlining by performing steps 1 through 11 in reverse order.