Installing The Roof Outer Skin

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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 DESCRIPTION

Cleaning agent R1 100 ml, Bottle 83192211217
Fit 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
- Rear window
- Roof trim strips
- Preset roof clamps with the retaining straps
- 7 locking pliers (windshield area)
- 7 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 DESCRIPTION

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 DESCRIPTION

Cleaning agent R1 100 ml, Bottle 83192211217

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In the areas (1), top up and smoothen the flange outlets with adhesive K2 (bead width 5 - 8 mm).
In the areas (2), apply a 25 mm long adhesive bead with adhesive K2 (level compensation) and smoothen it.
ADHESIVE DESCRIPTION

Body adhesive K2 2x290 ml 83192355849
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) slightly with 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 clamps (1) and fix with a retaining 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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Fasten the roof outer skin at 3 areas as shown with the roof clamps and retaining straps.

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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

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.

CONSUMABLE DESCRIPTION

Sealant D1 (seam sealing)

310 ml

83422409985

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

Precondition

Temperature of roof outer skin and the clamps at least 20°C.

If applicable, preheat the roof outer skin and clamps with a blow dryer up to a maximum of 40°C.

All bonding surfaces (1) are marked with marking lines (2) on the roof outer skin.
Clean the bonding surfaces (1) with solvent cleaner R2 and a microfiber cloth.
CONSUMABLE DESCRIPTION

Cleaning agent R2 500 ml 83190417324
Prime the bonding surfaces (1) with activator 205 and immediately wipe with a microfiber cloth.

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ADHESIVE DESCRIPTION

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 marking lines (2).

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Position the clamp (1) with 2 special tools 0 493 687 (00 9 340) at a distance of 1.5 mm to the side frame (2).
Strongly press the clamp (1) with both thumbs on the entire surface for at least 5 s.
Do not tilt the clamp (1).
NOTE: Strong pressure and prolonged time increases the bond.
Repeat the procedure on all clamps.

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Apply (3) adhesive K4 in the area (2) between the clamp (1) and the roof outer skin.
Repeat the procedure on all clamps.
The roof trim strip can be mounted after at least 4 h hardening time.

ADHESIVE DESCRIPTION

Body adhesive K4

50 ml, Cartridge

83192456697

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