Removing Roof Assembly

→ Do not collect magnesium grinding dust, magnesium chips or abraded material in open containers. Use containers that can be sealed tightly.

→ A small amount of chips produced when re-cutting threads, for example, is not important.

→ If larger amounts of magnesium chips and dust are produced, these must not be stored dry.

→ The dust and chips must be removed by suction during extensive grinding work.

→ Avoid making sparks when working with magnesium.

→ Extinguish magnesium fires using fire extinguishers for metal fires rather than water.

→ Wear personal protective gear.

Information 

Cover adjacent areas.

• Cover accessories adjacent to the repair area on the vehicle. 
• Cover any accessories remaining on the vehicle. 

Information 

Information on magnesium components 

• Magnesium will corrode in the event of contact with steel, copper or aluminum containing copper. 
• Magnesium components must only come into contact with screws (aluminum screws, coated screws), lubricants and sealing compounds that have been approved by Porsche (risk of corrosion). 
• Magnesium components must not come into contact with steel parts (panels, clamps, etc.) (risk of corrosion). 
• Only use type-specific accessories and spare parts approved by Porsche. Previously used parts must not be used. 
• Keep contact surfaces of magnesium components dry. 

1. Loosen fastening nuts.
   1. 1.1. Unscrew fastening nuts -1- on the roof assembly at front and rear.
   Fig 2: Identifying Roof Assembly Fastening Nuts

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Prepare front cover for removal.
   1. 2.1. Mark holes at the left and right.

   Windshield to roof, front, outer Length 40 mm 

   Roof pillar to roof, front. Length 45 mm 

   Windshield to roof Length 120 mm 

   Front roof cover, center axis/right. Length 300 mm 

   Front roof cover, center axis/left. Length 100 mm 

   Fig 3: Marking Holes In Front Cover

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Drill holes using spotweld cutter Spotweld cutter Nr. 128-2. 

3. Cut slits parallel to the edge of the cover -1- Electric panel shears WE 1478.
   Fig 4: Cutting Parallel Slits

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Prepare rear cover for removal.
   1. 4.1. Mark holes at the left and right.

      Roof pillar to roof, rear. Length 45 mm 

      Rear window to roof, rear. Length 30 mm 

   Fig 5: Marking Holes In Rear Cover
   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 4.2. Drill holes using spotweld cutter Spotweld cutter Nr. 128-2.
5. Cut a slit parallel to the edge of the cover -1- Electric panel shears WE 1478. 
   Fig 6: Cutting Parallel Slit

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Cut through beads of adhesive.
   1. 6.1. Cut through beads of adhesive on the front and rear covers -1-  using Special electric cutter - Fine Special Electric Cutter - Fine WE 1137  complete with blade 207 (VAG 1561/22).
      Fig 7: Cutting Through Adhesive Beads

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Cut through inner bead of adhesive.
   1. 7.1. Cut through bead of adhesive all around the inner roof assembly -1-  using Special electric cutter - Fine Special Electric Cutter - Fine WE 1137. 
      Fig 8: Cutting Through Bead Of Adhesive

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Get another person to help you to remove the roof assembly.