Installing The Roof Outer Skin

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

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• Lay out following parts ready:
  • Adhesive in the adhesive gun and two further glue cartridges
  • Windshield
  • Rear window
  • Roof trim strips
  • Preset roof clamps with the retaining straps
  • 6 locking pliers (windshield area)
  • 6 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.

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• 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!

  CONSUMABLE SPECIFICATION 

  Cleaning agent R1

  100 ml, Bottle

  83192211217

• Apply adhesive  .
  NOTE: This step is only applicable for equipment version with aluminum roof.
• At the left and right roof frames, top up all the flange recesses (1)  with adhesive K2 and make them smooth (level adjustment).

  Apply adhesive so that all flange sections form one level for the remaining bonding surface.

  ADHESIVE SPECIFICATION 

  Body adhesive K2

  2x290 ml

  83192355849

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• Apply a 25 mm long adhesive bead K2 on both the level jumps (1)  at the front convertible roof brace on the left and right and make them smooth. (level compensation)

  Apply adhesive so that all the increments form one level for the remaining bonding surface.

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• Apply a 25 mm long adhesive bead on both the level jumps (1)  at the rear convertible roof brace on the left and right K2 and smooth (leveling).

  Apply adhesive so that all the increments form one level for the remaining bonding surface.

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• Apply adhesive K2 to the bonding surfaces (1)  .
• 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.

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• Coat the areas (1)  with a thin coat of adhesive K2.
• In area (2)  , apply a reference bead with an approximate 200 - 300 mm length for future inspection.

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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 the correct installation position of roof outer skin.
• Mount roof pliers (1)  and fix with a tensioning strap (2)  .

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• 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.

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• Fix roof outer skin as shown in 2 areas with the roof clamp and the retaining straps (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.

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• 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!

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

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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 

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

• 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

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

  ADHESIVE SPECIFICATION 

  Aktivator -205

  250 ml, Bottle

  83190030155

  Courtesy of BMW OF NORTH AMERICA, INC.

• 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.