Installing Roof Outer Skin

Remove adhesive residues (1) to 0.5 mm.

Primed surface must not be damaged.

Smaller damage to 5 mm or scratch marks can be ignored.

In the event of larger damage to primer (greater than 5 mm), proceed as follows:

Fig 1: Identifying Roof Outer Skin Adhesive Residues

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In the event of larger damage to primer, the following procedure applies:

Clean damaged area with cleaning agent R1.

Apply adhesive K5a to the bare areas with a spatula or a brush. Apply a uniformly thin layer (max. 0.5 mm). The roof outer skin can be bonded after a curing period of 24 hours.

The adhesive flange area must not be painted over when the roof frame is being repaired or replaced.

Fit new sound insulation in areas (1).

Fig 2: Identifying Sound Insulation Areas

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Clean bonding surfaces (1) on body and on new part with cleaning agent R1. Observe an air drying time of 2 minutes.

Fig 3: Identifying Bonding Surfaces On Body

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Lay out following parts ready:

• Adhesive in adhesive gun and two further glue cartridges.
• Rear window
• Roof trim strips
• Preset roof pliers with tensioning straps
• 3 large fixing pliers (windscreen area)
• 3 small fixing pliers (rear window area)

Steps 1 to  3 described below must be completed within 15 minutes. 

1. Applying adhesive
2. Joining and fixing roof outer skin
3. Applying adhesive to nodes on A- and C-pillars. Removing excess adhesive.

Fig 4: Identifying Correct Position Of Roof Pliers

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