Installing The Roof Outer Skin

Install new sound insulations (source foam strips) in the areas (1).

Model	Number	Length (in mm)
G16	4	700
F93	4	360

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NOTE: TECHNICAL INFORMATION
Process the following steps within 15 minutes:

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

Lay out following parts ready:
- Adhesive in the adhesive gun
- Windshield
- Rear window
- Roof trim strips
- Presetting fixing tools
- 6 locking pliers (windshield area)
- 6 fixing pliers (rear window area)
Preclean the bonding surfaces (1) on the body and on the new part with cleaning agent R2.
CONSUMABLE SPECIFICATION

Cleaning agent R2 500 ml 83190417324
Clean the bonding surfaces (1) on the body and on the new part with cleaning agent R1.
Adhere to the air drying time of 2 min!

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CONSUMABLE SPECIFICATION

Cleaning agent R1 100 ml, Bottle 83192211217
Apply adhesive K2 to the bonding surfaces (1).
ADHESIVE SPECIFICATION

Body adhesive K2 2x290 ml 83192355849
Guide the nozzle at an angle of maximum 60° on the adhesive flange.
The adhesive bead has a cross-section of approximately 5 ± 1 mm x 10 ± 1 mm.

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Place roof outer skin with helpers evenly and centrally on vehicle.
Fit the rear window and roof trim strips to check correct installation position of the roof outer skin.
Position the clamping tools only on the stiffening impressions (1) in the adhesive flange area of the roof outer skin.
This ensures the correct distance and thus the correct amount of adhesive between the roof outer skin and the roof frame.

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Fix roof outer skin with the securing tools 2 469 797.

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Fasten the roof outer skin within the windshield area and the rear window area with the locking pliers (1).

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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.
Observe the hardening time of the adhesive.
Level out leaked adhesive in the area (1) at all 4 corners of the roof outer skin (2) by spreading.
No sharp edges should be left behind, otherwise the subsequent bonding of the front and rear windows could show a leakage.
Spread excess adhesive in roof trim strip channel. The mounting surfaces of the mounting elements of the roof trim strips must not be coated with adhesive.
Remove excess adhesive. For that do not use any cleaning agent or solvent!

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Check the ground straps for damage and renew the ground straps, if necessary.
Install the ground strap (2) with the blind rivets (1).
Install all 4 ground straps.

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Sealing the roof outer skin

NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.
Seal the roof outer skin with sealant (1) on both side frames in a similar way to series production.

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CONSUMABLE SPECIFICATION

Sealant D1 (seam sealing) 310 ml 83422409985

Installing the clamps for the roof trim strip (equipment version with CFRP roof)

NOTE: TECHNICAL INFORMATION
The temperature of the roof skin and the clamps must be at least 20°C. The outer roof skin and the clamps can, if necessary, be warmed up with a hair dryer to maximum 40°C.
Ensure that all the bonding surfaces (1) on the roof outer skin are marked with marker lines (2).
Clean the bonding surfaces (1) with solvent cleaner and a microfiber cloth.
CONSUMABLE SPECIFICATION

Cleaning agent R2 500 ml 83190417324

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Primer the bonding surfaces (1) and immediately wipe it dry with a microfiber cloth.
ADHESIVE SPECIFICATION

Aktivator-205 250 ml, Bottle 83190030155
Let the bonding surfaces (1) dry for 2 min.
Detach the protective film from the clamp (1).
Position the clamp (1) centrally between the marker lines (2).
Dimension (a) = 1 mm
Ensure that the clamp (1) is aligned parallel to the roof frame (3).
Dimension (b) = Dimension (b)
Press the clamp (1) firmly and completely over the entire surface with both the thumbs for at least 5 s.

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NOTE: Strong pressure and prolonged time increases the bond.
Repeat the steps for all other clamps.