Fitting roof panel and roof rail into body No Operation

Instructions

Clean welding areas

Using a hot air gun or a rotary wire brush, remove sealant residue, paint etc. from welding areas of body. Remove factory primer from welding areas of spare panels.

Fit rear roof rail to body and weld into place

Fit rear roof rail to body using Special Tool P 9121 and attach with clamps. MIG-weld rear roof rail to outer rear side panel, running a full seam. Spotweld rear roof rail to roof rail. MIG-weld and spotweld rear roof rail to rear inner side panel, running an intermittent full seam.

Fit closing panel, roof rail and inner side panel to body and weld into place

Fit closing panel, roof rail and inner side panel to body according to door contours, using Special Tool P 9120, and clamp into place with suitable clamps. Tack-weld closing panel and roof rail to body. Remove inner side panel from body. Spotweld closing panel, roof rail and B-pillar. MIG-weld roof rail of body A-pillar to spare roof rail, running an intermittent full seam.

Fit upper side panel and inner side panel to body and weld into place

Fit upper side panel and inner side panel to body, using Special Tool P 9160, and clamp into place with suitable clamps. Spotweld upper side panel and inner side panel to roof rail and closing panel. MIG-weld upper spare side panel to body side panel and inner side panel, running a full seam. MIG-weld inner spare side panel to inner body side panel, running a full seam.

No. Operation

4 Fit windshield frame to body and weld into place

5 Fit reinforcement to body and weld into place

6 Fit roof outer panel to body and weld into place

Instructions

Fit windshield frame into body, using Special Tool P 9120, and attach with clamps. MIG-weld windshield frame to closing panel, running a full seam. MIG-weld spare windshield frame panel to body windshield frame, running a full seam. MIG-weld windshield frame to inner side panel, running an intermittent full seam. Spotweld windshield frame to inner side panel and roof rail.

Fit reinforcement into roof rail and MIG-weld from outside and inside, running an intermittent full seam.

Fit roof outer panel into body, using Special Tools P 9120 and P 9121, and attach with clamps. Spotweld roof outer panel to roof rail. MIG-weld roof outer panel to windshield frame and rear outer side panel, running a full seam.

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