Replacing The Roof Outer Skin Including The Panorama Glass Roof (Cooper Clubman F54)

Observe procedure of REPAIR STAGE 2 !

The following new parts are required (see applicable BMW Parts Catalog).

Roof outer skin, panorama glass roof

Following CONSUMABLES are required:

Material	Quantity
Adhesive K5b	2
Blind rivet N3	22
Punch rivet N4	8
Cleaning agent R1	1
Sealant D2

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Removal

Operation is partially described on the left side.

Right side identical.

Fig 1: Roof Panel Component Location

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Open welded connections in areas (1) and (2).

LOOSEN spot-welded adhesive joints in area (3).

Undo bonded connection in this area (4).

Open welded connections in areas (1).

Open bonded connections in areas (2).

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Loosen the bonded connections in the areas (1) and (2) and remove the roof outer skin.

New part preparation

Operation is partially described on the left side. Right side identical.

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Adjust the new part with helpers.

In areas (1), set 4.2 mm dia. bores for the blind rivet according to the schematic diagram.

NOTE: The bores must be set centrally between the existing installation holes.
If necessary, the cover strip (2) must be adapted in these areas (3) (blind rivet positions).

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In areas (1) and (2), drill bores with 0 4.2 mm for the blind rivet as per the schematic diagram.

NOTE: The bores must be set centrally between the existing installation holes. If necessary, adjust the cover strip.

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Prepare joining by bonding in this area (1).

Prepare 10 mm long MAG weld seams (3) on the component edge in this area (2).

Remove roof outer skin and deburr bores.

IMPORTANT: Do not grind/sand new part in area of bonding surfaces.

Installation

Operation is partially described on the left side. Right side identical.

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Clean all bonding surfaces with cleaning agent R1.

Apply adhesive in areas (1).

Apply sealant D2 in areas (2).

NOTE: Observe the drying time of the materials!

Two persons must simultaneously apply adhesive and sealant.

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Apply adhesive in area (1).

Spread adhesive over approximately 40 mm as per new part preparation in these areas (2).

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Install the roof outer skin with helpers and rivet with blind rivet N3 in this area (1).

In this area (2) use 8 x punch rivet N4.

Secure the roof outer skin area (3) using two clamps until the adhesive has hardened.

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Produce 10 mm long MAG weld seams on the component edge in this area (2).

NOTE: Risk of damage to adjacent adhesive area (1)! Avoid excessive application of heat.

Adapt step (1) between roof outer skin (2) and A-pillar with emerging adhesive. Remove excess adhesive.

IMPORTANT: Do not use any cleaning agents containing solvents.

Do not leave any sharp edges as this could compromise the tightness of the subsequent bonding of the windshields.

Remove excess adhesive.

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IMPORTANT: Do not use any cleaning agents containing solvents.

Seal adhesive areas and blind rivets with sealant D2.