Replace Roof Outer Skin (CFRP Roof Equipment Specification) (M4 Coupe)
Special tools required:
- 41 3 200
- 41 3201
- 41 3 202
- 41 3 203
- 41 3 204
Read contents of BODY, GENERAL .
For stripping and rigging operations, refer to texts on KSD CD (FRU number 41 31 000).
The following components are required (see applicable BMW Parts Catalog):
- Roof outer skin (1)
Additionally required components (not pictured):
- K3 glue (1 cartridge, use only the mixing tube supplied with the product)
- ADHESIVE GUN 81 49 0 443 166 for K3 adhesive
- Window adhesive (1 cartridge)
- Clips for roof trim strip (14 pieces)
- Roof sound insulation, front and rear
- Scotchbrite Multiflex (51 91 0 402 967)
- Sika Activator 205 (83 19 0 030 155)
Installation note:
Prior to installation, roof outer skin and vehicle for at least 12 hours at room temperature (15°C to 25°C).
Store adhesive at room temperature and apply adhesive at min. 18°C.
Loosen bonded connections of the underlining in these areas (2) (identical to bonding of windscreen).
Attention!
Draw off vapor and gases!
Primed surface must not be damaged.
Do not use any metallic tools.
Starting in one corner, heat roof in area (1) in stages with a hot-air dryer until adhesive softens.
Attention!
Do not exert force to drive in wedge. If the wedge cannot be driven in, continue heating roof outer skin on adhesive flange over a large area (max. 250°C).
Carefully drive in plastic or wooden wedge at heated point. Adhesive flange must not be damaged in the process. The wedge creates tension between roof outer skin and body.
Heat next section until roof outer skin has detached from body. Reapply plastic wedge. Repeat procedure until roof outer skin is completely detached.
Take off roof outer skin.
Heat adhesive residue on connection flange with hot-air blower and remove by scraping off with plastic or wooden wedge.
Installation note:
If the primer is damaged, proceed as follows:
Pretreat damaged areas in same way as BONDING STEEL ON STEEL .
Apply adhesive K1 to the bright-finish areas with a spatula. Apply a thin and uniform coating. The roof outer skin can be bonded after a curing period of 24 hours.
Adhesive area (1) must not be painted over.
Preparation of new part:
Carry over positions of marked spacers (1) with adhesive tape to top side.
These markings are used later to position the clamps for securing the roof outer skin.
Preparation of adhesive flanges on new part:
- Preclean areas (1 to 3) with cleaning agent R2.
- Roughen areas (1 to 3) with Scotchbrite Multiflex abrasive pad.
- Preclean areas (1 to 3) with cleaning agent R2.
Maintain >30 seconds of air drying time.
After air drying, all adhesive areas must be a uniform dull grey; repeat the roughening procedure if necessary.
Preparation of adhesive flanges on car:
- Preclean areas (1 to 2) with cleaning agent R1.
Maintain >30 seconds of air drying time.
Attention!
It is absolutely essential to follow the correct order of adhesive application!
Ready the following components and tools:
- Adhesive gun 81 49 0 443 166
- K3 glue (use only the mixing tube supplied with the product)
- Window glass adhesive
- Rear window
- Roof trim strips
- Pliers set 41 3 200
- Underlining adhesive (window glass adhesive):NOTE: Adhesive areas are marked on the roof inner side by a thin line.
Apply window glass adhesive in areas (1) in a triangular shape to roof (height 11+0.5 mm) (image R4104242).
Steps 2 to 4 described below must be completed within 10 minutes!
- Adhesive: K3
Guide nozzle at an angle of max. 60° along adhesive flange.
Apply adhesive K3 in a bead shape along marking on roof (1) (bead width 6+0.5 mm).
Apply a little more adhesive in the areas (2).
Installation note:
Apply more adhesive to all four corners (1).
Excess material is later used for spreading to side frame.
- Reference bead:
Apply adhesive K3 in a bead shape in area (3).
NOTE: This operation must be carried out with a second person assisting.Uniformly position roof outer skin centrally on vehicle.
Fit windscreen and roof trim strips to check correct position of roof outer skin.
- Secure roof outer skin:
Secure roof outer skin at points marked with adhesive tape with pliers set 41 3 200.
Observe securing sequence in order to prevent distortions in the roof outer skin.
Secure roof outer skin at marked points in area of windscreen 4 times with vice-grip wrench 41 3 201.
Attention!
Risk of damage!
Secure roof outer skin only at spacers.
Remove roof trim strips.
Secure roof outer skin at marked points in front corners with pliers 41 3 202 and shaped elements 41 3 203.
Secure roof outer skin only at spacers.
Secure roof outer skin at marked points in area of B-pillar 2 times with pliers 41 3 202 and shaped elements 41 3 204.
Attention!
Risk of damage!
Secure roof outer skin only at spacers.
Remove rear window.
Secure roof outer skin at marked points in rear corners with pliers 41 3 202 and shaped elements 41 3 203.
Secure roof outer skin only at spacers.
Secure roof outer skin at marked points in area of rear window 4 times with vice-grip wrench 41 3 201.
Attention!
Risk of damage!
Secure roof outer skin only at spacers.
Adjust stage (1) between roof outer skin (2) and A-pillar or roof outer skin (2) and C-pillar with emerged adhesive. Remove excess adhesive.
Attention!
Never use cleaning agents!
Do not leave any sharp edges as this may compromise the tightness of the subsequent windscreen and rear window bonding.
Spread excess adhesive advancing into areas (1) in roof trim strip channel. Bonding surfaces of clips for roof trim strip must not be coated with adhesive.
Remove adhesive that has escaped into areas (2).
Attention!
Never use cleaning agents!
Do not move vehicle until adhesive has cured.
Check whether reference bead has hardened after 2 hours hardening time (15°C to 25°C).
The endurance strength of the structural bond is achieved after 12 hours at 20°C.
Carry out a leakage test on the complete vehicle.
Adhere to a minimum temperature of 18°C for the roof outer skin and clips.
Clean bonding surfaces using solvent cleaner R1 or R2.
Apply a thin layer of Sika Activator 205 on the bonding surfaces.
Air drying time: >2 minutes.
Follow further notes for securing components with adhesive tape; See NOTES ON COMPONENT BONDING WITH ADHESIVE TAPE (M4 COUPE) .
Label the clips (1) to the roof within the embossings.
Minimum contact pressure can be achieved by pressing firmly with thumb or ball of hand (pressing for at least 2 seconds).
Installation note:
Firmer pressure and longer time increase strength.
Trim strip must be attached only after 4 hours of hardening time.