BMW 7 Series: Replace Roof Outer Skin

Read contents of BODY, GENERAL.

STRIP DOWN VEHICLE

NOTE: Observe new procedure for bonding and riveting (REPAIR STAGE 2).

Following parts are required:

• Roof outer skin

Additional required parts (not pictured):

SOUND INSULATION CHART

Following consumables are required:

MATERIAL CHART

Fig. 271: Identifying Roof Outer Skin

Tools also required:

• Roof pliers set, order number: 81 43 2 158 707 Sourcing reference: BMW Workshop Equipment Catalogue.

NOTE: Store adhesive at room temperature.

Prior to installation, store roof outer skin and vehicle for at least 12 hours at room temperature (17ºC to 35ºC).

Removing roof outer skin

View of passenger compartment above driver's seat.

Operation is described on the left side. Right side identical.

Release screw (1).

Release rivets (2) and remove holder (3).

Fig. 272: Identifying Rivets, Screw And Holder

Release rivets (1) and remove earth strap (2).

NOTE: Do not damage earth strap.

Replace if necessary, part number 61 12 7 213 377

Also release earth straps on left and right above rear seat.

IMPORTANT: Only the special rivets may be used to fit the earth straps!

Fig. 273: Identifying Rivets And Earth Strap

Fig. 274: Identifying Bonded Connection

Heat bonded connection (5) with hot-air blower until adhesive is loosened and release.

In so doing, proceed in sections (1 to 4), starting at rear left.

IMPORTANT: Extract vapors and gases.

Do not use any metallic tools.

Carefully drive in plastic or wooden wedge at heated section. The wedge creates tension between roof outer skin and body.

IMPORTANT: Do not exert force to drive in wedge. If the wedge cannot be driven in, continue heating roof outer skin on adhesive flange over a large area (max. 180ºC).

Carry out operation with a 2nd person helping.

Heat next section until roof outer skin has detached from body. Reapply plastic wedge. Repeat procedure until roof outer skin is completely detached.

Take off roof outer skin.

Fig. 275: Taking Off Roof Outer Skin

Installing roof outer skin

Remove adhesive residues (1) to 0.5 mm.

Primed surface must not be damaged.

Smaller damage to 5 mm or scratch marks can be ignored.

In the event of larger damage to primer (greater than 5 mm), proceed as follows:

Fig. 276: Identifying Roof Outer Skin Adhesive Residues

In the event of larger damage to primer, the following procedure applies: Clean damaged area with cleaning agent R1.

Apply adhesive K5a to the bare areas with a spatula or a brush. Apply a uniformly thin layer (max. 0.5 mm).

The roof outer skin can be bonded after a curing period of 24 hours.

The adhesive flange area must not be painted over when the roof frame is being repaired or replaced.

Fit new sound insulation in areas (1).

Fig. 277: Identifying Sound Insulation Areas

Clean bonding surface (1) on body and on new part with cleaning agent R1. Observe an air drying time of 2 minutes.

Fig. 278: Identifying Bonding Surface On Body

Lay out following parts ready:

• Adhesive in adhesive gun and 2nd glue cartridge
• Rear window
• Roof trim strips
• Preset roof pliers with tensioning straps
• 3 large fixing pliers (windscreen area)
• 3 small fixing pliers (rear window area)

Steps 1 to 3 described below must be completed within 15 minutes!

1. Applying adhesive
2. Joining and fixing roof outer skin
3. Applying adhesive to nodes on A- and C-pillars. Removing excess adhesive.

NOTE: To ensure that the processing time of 15 mins. is observed, make sure that the clamping tools are pre-adjusted. To do so, lay on roof outer skin without adhesive.

Then mount and adjust all clamping tools. In so doing, position roof pliers close to roof frame. (Arrangement, see Fig. 283)

IMPORTANT: Position roof pliers only in areas of stiffening impressions.

Fig. 279: Identifying Correct Position Of Roof Pliers

1. Applying adhesive

Apply adhesive K2 in area (1).

Guide nozzle at an angle of max. 60º along adhesive flange.

Cross-section of adhesive bead approx. 4 - 5 x 10 mm.

Apply a short reference bead at an appropriate point for later checking.

Fig. 280: Identifying Adhesive K2 Area

Apply a little more adhesive K2 to nodes (1) of A and C-pillars.

NOTE: Excess material is later used for spreading to side frame.

Fig. 281: Identifying A And C-Pillars Adhesive K2 Applying Area

Apply a little less adhesive (2) in area of holders (1).

Fig. 282: Identifying Adhesive Area And Holders

2. Joining and fixing roof outer skin

Fig. 283: Securing Roof Pliers With Tensioning Strap

Place roof outer skin with 3 helpers evenly and centrally on vehicle.

Fit rear window and roof trim strips to check correct position of roof outer skin.

Mount roof pliers (1) and secure with tensioning strap (2).

IMPORTANT: Position clamping tools only on stiffening impressions (1) in adhesive flange area of roof outer skin.

This ensures that correct distance and thus the correct amount of adhesive between the roof outer skin and the roof frame.

Fig. 284: Identifying Roof Outer Skin Adhesive Flange Area

Secure roof outer skin at 3 areas with roof pliers and tensioning straps.

Fig. 285: Identifying Roof Outer Skin Securing Areas

Secure roof outer skin in windscreen area 3 times with large fixing pliers (1).

In rear window area use small fixing pliers (2) 3 times.

Fig. 286: Identifying Roof Outer Skin Securing Area In Windscreen

IMPORTANT: Risk of damage! Use a suitable support (1) (approx. 50 x 50 mm) in windscreen area, as otherwise roof pillar (2) may be pressed in when the fixing pliers are secured.

(3) Roof outer skin

Fig. 287: Identifying Support, Roof Pillar And Roof Outer Skins

3. Applying adhesive to nodes on A- and C-pillars. Removing excess adhesive

Adjust stage (1) between roof outer skin (2) and A-pillar or roof outer skin (2) and C-pillar with emerged adhesive. Remove excess adhesive.

IMPORTANT: Do not use any cleaning agents containing solvents.

Do not leave any traces of sharp edges as this could compromise the tightness of the subsequent bond.

Fig. 288: Identifying Stage And Roof Outer Skin

Spread excess adhesive in roof trim strip channel. Mounting surfaces of clips for roof trim strips must not be moistened with adhesive.

Clamping tools must remain on the vehicle for at least 1 hour. Do not move the vehicle during this period. Only then is it permitted to proceed with subsequent installation work.

Check whether reference bead has hardened after 2 hours hardening time (15-38ºC).

After bonding, the vehicle must remain parked for at least 12 hours at room temperature (15-38ºC).

The vehicle is then ready for operation.

READ NEXT: