Installing Outer Roof Skin

Clean bonding surfaces on vehicle and on new part with cleaning agent R1.

Fig 1: Identifying Adhesive And Sealant Areas On Roof Outer Skin

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Apply sealant D1 in areas (2).

Apply adhesive in areas (1).

Fig 2: Identifying Adhesive Areas On Roof Outer Skin

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Apply adhesive in areas (1) and (2).

Apply a somewhat larger quantity of adhesive in the node areas of the A- and C-pillars.

NOTE: Excess material is later used for spreading to side frame.

Place roof outer skin with helpers evenly and centrally on vehicle.

Fit roof strips for positioning if necessary.

Insert 4 star screws (1) hand-tight.

Fig 3: Identifying Star Screws On Roof Channel

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Fig 4: Identifying Roof Pliers And Tensioning Straps

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Secure roof outer skin with 4 roof pliers (1) and 2 tensioning straps (2).

NOTE: To generate an optimum contact pressure, mount roof pliers according to the graphics as left.

Fig 5: Identifying Proper Position Of Mounting Roof Pliers

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Fig 6: Identifying Rivet And ECM Screws Area On Roof Outer Skin

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Rivet roof outer skin with 14 punch rivets in areas (2).

Set punch rivets in corners starting at a distance of approx. 200 mm.

NOTE: After the adhesive hardens, install two EMC SCREWS in areas (2).

In so doing, bear in mind subsequent fitting of roof trim strips.

Mounting surfaces of roof trim strip clips must not be moistened with adhesive.

Adapt step (1) between roof outer skin (2) and A-pillar with emerging adhesive. Remove excess adhesive.

IMPORTANT: Do not use any cleaning agents containing solvents.

Do not leave any traces of sharp edges as this could compromise the tightness of the subsequent bond.

Fig 7: Identifying Step Between Roof Outer Skin And A-Pillar

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After the adhesive hardens, tighten 4 star screws in the roof channel.

Tightening torque, see 41 31 2AZ in 41 31 ROOF .