LEMON Manuals: Even more car manuals for everyone
Home >> Saab >> 2005 >> 9-5 Linear, Automatic >> Repair and Diagnosis (Single Page) >> Accessories & Equipment >> Interior/Exterior Trim >> Body - 9-5 >> Adjustment-Replacement >> Roof 4D >> Fitting

Roof 4D: Fitting

NOTE: Be careful not to damage the paintwork on the outer side panel when the seal string is adjusted.
  1. Mask off the outer side panel. Cut away the center section of putty towards the edge of the side panel using Cutting tool, roof joint 4D.

    Use 82 93 474 REMOVAL TOOL  to cut away the rest of the putty. Angling the putty knife will make it easier to remove the putty. Be sure to remove the putty at the bottom of the joint.

    Fig 1: Cutting Centre Section Of Putty
    G03865713Courtesy of SAAB-SCANIA OF AMERICA, INC.
  2. Grind all the surfaces that are to be welded.
  3. Apply welding primer to the surfaces that are to be welded.
  4. Fit the new roof and fixate with a few welding clamps.
  5. Spot-weld the roof.
    Fig 2: Illustration For Step 6
    G03865714Courtesy of SAAB-SCANIA OF AMERICA, INC.
  6. Seam weld the roof to the A and C pillars.
  7. Grind the welds.
  8. Remove any remaining welding primer. Welding primer reduces adhesion of paint, filler and sealant.
  9. Apply etching primer to all surfaces that have been ground clean.
  10. Wipe the seal joints clean with Teroson FL T875.
  11. Apply Teroson Teromix 6700 T305 in the seal joint between the side panel and roof.
    Fig 3: Applying Teroson Teromix 6700 T305 In Seal Joint
    G03865715Courtesy of SAAB-SCANIA OF AMERICA, INC.
    IMPORTANT: Avoid air bubbles when applying the sealant as this may cause problems during hardening or painting.
    The air in the gap between the panels must be ventilated to prevent air bubbles forming in the bottom of the roof joint.
  12. Then use the PLASTIC SCRAPER  to remove excess material. Adjust the shape at the rear window flange and the roof moulding flanges.
    Fig 4: Applying Sealant
    G03865716Courtesy of SAAB-SCANIA OF AMERICA, INC.
  13. Inspect the seal joint as regards quality and finish.
  14. Allow the material to harden 2 hours at a minimum of 20° C (68 °F).
  15. After hardening inspect the joint as regards quality and finish.
  16. Seal joints and seams with sealant.
  17. Apply anti-corrosion agent to the edge of the roof after painting. Use Terotex HV 400 or Mercasol 1.
  18. Apply anti-corrosion agent in the holes for the carrier rack and on the nuts.
    Fig 5: Illustration For Step 18
    G03865717Courtesy of SAAB-SCANIA OF AMERICA, INC.
  19. Fit the carrier rack nuts on the edge of the roof.
    IMPORTANT: Do not heat too quickly when painting, as this will cause the paint on the sealant to crack. The sealant does not absorb as much heat as the sheet metal around it.
scientia non olet · About LEMON Manuals