Installing

Flow Of Operation:

Installing roof assembly

Before the assembly is installed, the adhesive areas of the body and the assembly must be cleaned with cleaning solution.

Caution: no traces of the cleaning solution must be left on the body or the assembly. Primer must be applied to any damage to the paint work on the parts of the body and assembly which are not visible following installation.

1. Check rubber seal
- Check the rubber seal between the body at the front and the roof assembly for wear. If necessary, replace the seal.

2. Insert cover strips between roof rails and rear side parts.
- Place the roof assembly on the body to mark the edges. Mark the position of the edges of the roof rails on the rear side parts and remove the roof assembly from the body. Take the protective backing oft the cover strips. Bond the cover strips to the marked areas of the rear side parts at the left and right.

Activate adhesive areas.
Activate the adhesive areas on the body and the roof assembly (F5).
Caution: Allow the parts at least 10 minutes to air!

3. Clip cartridges with components A and B together.
- Clip the component B cartridge to the component A cartridge.

4. Open assembled cartridge.
- Cut the closures of the two cartridges oft level using a knife.

5. Install mixing tube.
- Push mixing tube (F3) into the groove on the assembled cartridge and screw it into place using the union nut.

6. Place cartridges in bonding gun.
- Place the assembled cartridge with mixing tube in the bonding gun.

Caution: observe open time of 15 minutes!

The open time is the time in which the adhesive must be applied and the roof assembly must be positioned on the body.

7. Apply adhesive to body.
- Apply a triangular bead of adhesive, height 13 mm, to the rear side parts and the rear central part of the body. When applying the adhesive, you must make sure that it overlaps.

8. Place roof assembly on body.
- As you place the roof assembly on the body, insert the drain hoses of the roof assembly into the drain hoses of the rear central part of the body. Align the roof assembly in accordance with the dimensions given on the illustration.

9. Fasten roof assembly in place at rear.
- Screw the roof assembly to the rear wall using the M6 fastening nuts - tightening torque 8 Nm (6.0 ftlb).

10. Fasten roof assembly at front (lower mount).
- Screw front lower part of roof assembly to cowl panel using M 8 x 16 pan head screws and washers - tightening torque 23 Nm (17 ftlb).

11. Fasten roof assembly at front (upper mount).
Screw front upper part of roof assembly to cowl panel using M 6 x 16 Allen screws with washers - tightening torque 9.7 Nm (7.0 ftlb).

12. Fasten roof assembly to B-pillar.
- Even out gap between roof assembly mounting point and B-pillar using spacers. Fasten the roof assembly to the B-pillars using M 6 hexagonal nuts - tightening torque 9.7 Nm (7.0 ftlb).

13. Attach mounting plate for drive motors.
- Hook the mounting plate into the fixed bolts at the rear. Align the mounting plate on the mounts on the rear wall. Fasten mounting plate in position on the rear wall using M 5 x 10 hexagonal bolts with washers - tightening torque 9.7 Nm (7.0 ftlb) and M6 nuts - tightening torque 9.7 Nm (7.0 ftlb).

14. Establish electrical connections.
- Establish electrical connections between drive motors and control unit.

15. Install cover strip.
- Clip the cover strip between the rear window pane and the rear central part of the body into the retaining bracket.