Installing The Roof Outer Skin

• Pre clean the bonding surfaces (1) on the body and on the new part with cleaning agent.

  CONSUMABLE SPECIFICATION 

  Cleaning agent R2

  500 ml

  83190417324

• Clean the bonding surfaces (1) on the body and on the new part with a cleaning agent. Adhere to the air drying time of 2 min.

  Courtesy of BMW OF NORTH AMERICA, INC.

  CONSUMABLE SPECIFICATION 

  Cleaning agent R1

  100 ml, Bottle

  83192211217

• Fit the new sound insulation (expansion foam strips) in the areas (1).
• Pre-clean the bonding surfaces (1) on the body and on the new part with cleaning agent.

  CONSUMABLE SPECIFICATION 

  Cleaning agent R2

  500 ml

  83190417324

• Clean the bonding surfaces (1) on the body and on the new part with a cleaning agent. Adhere to the air drying time of 2 min!

  CONSUMABLE SPECIFICATION 

  Cleaning agent R1

  100 ml, Bottle

  83192211217

  Courtesy of BMW OF NORTH AMERICA, INC.

• Lay out following parts ready:
  • Adhesive in the adhesive gun and two further glue cartridges
  • Rear window
  • Roof trim strips
  • Preset roof clamps with the retaining straps
  • 8 locking pliers (windshield area)
  • 8 fixing pliers (rear window area)
• Complete steps 1 to 3 within 15 min as described below:
  1. Apply adhesive.
  2. Position and secure the roof outer skin.
  3. Apply adhesive to the nodes on the A-pillar and C-pillar. Remove excess adhesive.
  NOTE: TECHNICAL INFORMATION 
  Process the following steps within 15 minutes:

  1. Apply adhesive.
  2. Position and secure the roof outer skin.
  3. Apply adhesive to the nodes on the A-pillar and C-pillar.
  4. Remove excess adhesive.

  Courtesy of BMW OF NORTH AMERICA, INC.

• In the areas (1), top up flange shoulders with adhesive (bead width 5 - 8 mm) and make it smooth.
• In the areas (2), apply a 25 mm long adhesive bead with adhesive (step compensation) and make it smooth.

  ADHESIVE DESCRIPTION 

  Body adhesive K2

  2x290 ml

  83192355849

• Apply adhesive on the bonding surfaces (1).

  ADHESIVE DESCRIPTION 

  Body adhesive K2

  2x290 ml

  83192355849

• Guide the nozzle at a maximum angle of 60° on the adhesive flange.

  The adhesive bead has a cross-section of approximately 5 ± 1 mm x 10 ± 1 mm.

• Apply a short reference bead at an appropriate point for later checking.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Place the roof outer skin with helpers evenly and centrally on the vehicle.
• Fit the rear window and roof trim strips to check the correct position of roof outer skin.
• Mount roof clamps (1) and fix with a retaining strap (2).

  Courtesy of BMW OF NORTH AMERICA, INC.

• Position clamping tools only on stiffening embossings (1) in adhesive flange area of the roof outer skin. This guarantees the correct distance and hence the correct amount of adhesive between the roof outer skin and the roof frame.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Fasten the roof outer skin at 3 areas as shown with the roof clamps and retaining straps.

  Courtesy of BMW OF NORTH AMERICA, INC.

  NOTE: TECHNICAL INFORMATION 
  Adhesive hardening time K2:
  The clamping tools must remain in the vehicle for at least 1 h.
  Do not shift the vehicle during this period. Only then is it permitted to proceed with subsequent installation work.
  Check whether the reference bead has hardened after 2 hours hardening time (15 - 38°C).
  After bonding, the vehicle must remain parked for at least 12 hours at room temperature (15 - 38°C).
  The vehicle is then ready for operation.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Fasten the roof outer skin within the windshield area and the rear window area with the locking pliers (1).
• Level out leaked adhesive in the area (1) at all 4 corners of the roof outer skin (2) by spreading.

  Do not leave any sharp edges as this may compromise the tightness of the subsequent windshield and rear window bonding.

• Spread excess adhesive in roof trim strip channel. While doing so, the mounting surfaces of roof trim strip mounting elements may not be coated with adhesive.
• Remove excess adhesive. For that do not use any cleaning agent or solvent!

  Courtesy of BMW OF NORTH AMERICA, INC.

• Install ground strap (2) with the blind rivets (for ground strap) (1).
• Install all 4 ground straps.

Courtesy of BMW OF NORTH AMERICA, INC.

Sealing the roof outer skin 

• Seal the roof outer skin with sealant (1) on both side frames in a similar way to series production.

CONSUMABLE SPECIFICATION 

Courtesy of BMW OF NORTH AMERICA, INC.

Follow-up work 

• Refer to ACTIVATE HIGH-VOLTAGE SYSTEM .
• Refer to INSTALL FLAP IN RIGHT LUGGAGE COMPARTMENT TRIM PANEL .

• Clean areas (1)  with a cleaning agent.

  Adhere to the air drying time of 2 min!

  CONSUMABLE SPECIFICATION 

  Cleaning agent R1

  100 ml, Bottle

  83192211217

• Fit the new sound insulation (expansion foam strips) in the areas (1)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

• Pre-clean bonding surfaces (1)  on the body and on the new part with the cleaning agent.

  CONSUMABLE SPECIFICATION 

  Cleaning agent R2

  500 ml

  83190417324

• Clean bonding surfaces (1)  on the body and on the new part with the cleaning agent.

  Adhere to the air drying time of 2 min!

  Courtesy of BMW OF NORTH AMERICA, INC.

  CONSUMABLE SPECIFICATION 

  Cleaning agent R1

  100 ml, Bottle

  83192211217

• Lay out following parts ready:
  • Adhesive in the adhesive gun and two further glue cartridges
  • Rear window
  • Roof trim strips
  • Preset roof clamps with the retaining straps
  • 8 locking pliers (windshield area)
  • 8 fixing pliers (rear window area)
  NOTE: TECHNICAL INFORMATION 
  Process the following steps within 15 minutes:

  1. Apply adhesive.
  2. Position and secure the roof outer skin.
  3. Apply adhesive to the nodes on the A-pillar and C-pillar.
  4. Remove excess adhesive.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Top up the flange recesses in areas (1)  with adhesive (bead width 5 - 8 mm) and smooth it.

  ADHESIVE DESCRIPTION 

  Body adhesive K2

  2x290 ml

  83192355849

• Apply a 25 mm-long adhesive bead in areas (2)  (leveling) and smooth it.
• Apply adhesive on the bonding surfaces (1)  .

  ADHESIVE DESCRIPTION 

  Body adhesive K2

  2x290 ml

  83192355849

• Guide the nozzle at a maximum angle of 60° on the adhesive flange.

  The adhesive bead has a cross-section of approximately 5 ± 1 mm x 10 ± 1 mm

• Apply a short reference bead at an appropriate point for later checking.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Place roof outer skin evenly and centrally on the vehicle with the assistance of support persons.
• Fit rear window and roof trim strips to check correct position of roof outer skin.
• Mount roof clamps (1)  and fix them with cargo straps (2)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

• Position clamping tools only on stiffening embossings (1)  in adhesive flange area of the roof outer skin. This guarantees the correct distance and hence the correct amount of adhesive between the roof outer skin and the roof frame.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Fix the roof outer skin in 3 areas with roof clamps and retaining straps as shown.

  Courtesy of BMW OF NORTH AMERICA, INC.

  NOTE: TECHNICAL INFORMATION 
  Adhesive hardening time K2:
  The clamping tools must remain in the vehicle for at least 1 h.
  Do not shift the vehicle during this period. Only then is it permitted to proceed with subsequent installation work.
  Check whether the reference bead has hardened after 2 hours hardening time (15 - 38°C).
  After bonding, the vehicle must remain parked for at least 12 hours at room temperature (15 - 38°C).
  The vehicle is then ready for operation.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Fasten the roof outer skin within the windshield area and the rear window area with the locking pliers (1)  .
• Level out leaked adhesive in the area (1)  at all 4 corners of the roof outer skin (2)  by spreading.

  Do not leave any sharp edges as this may compromise the tightness of the subsequent windshield and rear window bonding.

• Spread excess adhesive in roof trim strip channel. While doing so, the mounting surfaces of roof trim strip mounting elements may not be coated with adhesive.
• Remove excess adhesive. For that do not use any cleaning agent or solvent!

  Courtesy of BMW OF NORTH AMERICA, INC.

• Install ground strap (2)  with special blind rivets (1)  .
• Install all 4 ground straps.

Courtesy of BMW OF NORTH AMERICA, INC.

Sealing the roof outer skin 

• Seal the roof outer skin with sealant (1)  on both side frames in a similar way to series production.

Courtesy of BMW OF NORTH AMERICA, INC.

CONSUMABLE SPECIFICATION 

Follow-up work 

• Refer to ACTIVATE HIGH-VOLTAGE SYSTEM .
• Refer to INSTALL FLAP IN RIGHT LUGGAGE COMPARTMENT TRIM PANEL .