Removing Roof

Installation Location:

Fig 1: Roof Component Location

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Fig 2: Milling off spotwelds

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1. Milling off spotwelds

1.1. Mill off front spotwelds in area -A- using a spotweld cutter. See Fig 2.

Fig 3: Milling off spotwelds

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2. Milling off spotwelds

2.1. Mill off spotwelds at the left and right in area -A- using a spotweld cutter. See Fig 3.

Fig 4: Milling off spotwelds

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3. Milling off spotwelds

3.1. Mill off rear spotwelds in area -A- from above using a spotweld cutter. See Fig 4.

Fig 5: Milling off spotwelds

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4. Separating spotwelds

4.1. Separate rear spotwelds in area -A- from the inside using a parting grinder. See Fig 5.

NOTE: Separating body parts

In the case of bonded panel joints with a hardened bonded layer on the outer panel, apply a generous amount of heat to heat up the outer panel in the area of the spotwelds. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .
After removing the loosened body part, old adhesive must be removed and any uneven spots sanded down. The flange area must then be pre-treated for bonding. For the procedure see: Information on the use of structural adhesive in vehicle manufacturing. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

Fig 6: Loosening bonded joint

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5. Loosening bonded joint

5.1. Heat up bonded joint in the areas -A, B, C, D- between the roof and cowl panel frame or roof frame at the rear using the Leister Elektron hot-air gun; see Gr. 3.5, Workshop Equipment Manual 00000 . See Fig 6.

5.2. Insert a metal spatula between the bonded joints and separate them.

5.3. Lift the roof upwards out of the body.