Removing Outer Roof Rail

Information 

Mark cuts in accordance with the new part. Make sure to leave an overlap of approx. 30 mm with respect to the body.

1. Mark cuts.
   1. 1.1  Mark cut -A-  on the C-pillar. Cut from plate recess to plate recess.

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      Marking

   2. 1.2  Mark cut on the D-pillar in the window aperture area at -Dimension B-  . Mark > distance 90 mm  .

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      Marking

   3. 1.3  Mark cut on the D-pillar in the water drainage channel area at -Dimension A-  > Distance 27 mm  .

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      Marking on D-pillar, rear

   4. 1.4  Mark cut on the B-pillar at -Dimension A-  > Distance 145 mm  .

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      Marking on B-pillar

   5. 1.5  Mark cut on the A-post at -Dimension A-  > Distance 100 mm  .

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      Marking on A-pillar

      Information 

      Only make cuts in the top plate. Make sure not to damage the plate underneath when doing this.

2. Make cuts.
3. Disconnect connection points.
   1. 3.1  Drill through resistance spotwelds -1-  on the A-pillar. > diameter 6.6 mm 

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      Resistance spot welds on A-post

   2. 3.2  Remove front punch rivets using > VAS 852 001 - dent removal unit  and > VAS 6790 - compact booster  . > Front punch rivets 

      > 5X00IN23 REPLACE PUNCH RIVETS AND PENETRATED JOINTS

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      Front punch rivets

   3. 3.3  Remove rear punch rivets using > VAS 852 001 - dent removal unit  and > VAS 6790 - compact booster  .

      > 5X00IN23 REPLACE PUNCH RIVETS AND PENETRATED JOINTS

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Rear punch rivets

      Remove punch rivets D-pillar with > VAS 852 001 - body dent removal system, aluminium  and > VAS 6790 - Compact Booster  .

      > 5X00IN23 REPLACE PUNCH RIVETS AND PENETRATED JOINTS

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Punch rivets on D-pillar

4. Remove punch rivets on C-pillar and D-pillar -A-  and -B-  with > VAS 852 001 - body dent removal unit, aluminium  and > VAS 6790 - Compact Booster  . > Punch rivets on C-pillar and D-pillar 

   > 5X00IN23 REPLACE PUNCH RIVETS AND PENETRATED JOINTS

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   Punch rivets on C-pillar and D-pillar

5. Rend up sheetmetal brackets.

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   Sheet metal tabs

   1. 5.1  Heat connection areas using > V.A.G 1416 - hot-air blower  .
   2. 5.2  Bend up sheetmetal brackets in the door apertures using > VAS 6635 - crimping pliers set, 4-piece  .
6. Heat bonding areas on the roof using > V.A.G 1416 - hot-air blower  .

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   Bonding areas on roof

7. Heat bonding areas in the door apertures using > V.A.G 1416 - hot-air blower  .

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   Bonding areas in door apertures

8. Heat bonding area on rear foam part using > V.A.G 1416 - hot-air blower  .

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   Bonding area on rear foam part

9. Remove outer roof rail.