Installing roof outer skin

Fig 1: Identifying Sealant Applying Areas On Roof Outer Skin

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

Apply sealant D1 in areas (1) analogously to Series.

Apply adhesive in areas (2).

Apply a little more adhesive to nodes of A-pillar.

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

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

Insert 4 star screws (1) hand-tight.

Fig 2: Identifying Hand-Tight Star Screw

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Rivet roof outer skin in C-pillar area with blind rivet.

Fig 3: Locating Roof Outer Skin

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In area (1) rivet roof outer skin with 7 N4 punch rivets.

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

Fig 4: Identifying Rivet Roof Outer Skin Area

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Rivet roof outer skin in areas (1) with blind rivets.

Use 8 punch rivets N4 in area (2).

Fig 5: Identifying Rivet Roof Outer Skin Areas And N4 Punch Rivet Area

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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 6: Identifying Roof Outer Skin And Adapt Step

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IMPORTANT: Spread excess adhesive in roof trim strip channel. Mounting surfaces of clips for roof trim strips must not be moistened with adhesive.

Tighten 4 star screws.

Tightening torque 41 31 1AZ .

Operation is described on the left side.

Right side identical.

Fit an EMC SCREW after adhesive has hardened in area (1).

In so doing, bear in mind subsequent fitting of roof trim strip (clips).

Fig 7: Identifying Adhesive Applying Areas On EMC Screw

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