Replacing roof page 1. c Carrera (996) Body centre, roof, frame
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1 911 Carrera (996) Body centre, roof, frame Replacing roof The following spare body parts are required for the repair "Replacing roof": A = Roof Printed in Germany -42, page 1
2 Body centre, roof, frame 911 Carrera (996) Disconnecting roof -- \ "i I.,... fi-5, ; '" ' c 0 ( c CC v \ hi '< page 2 -; \ --- 1JI. =7 ;,fi: '"B "
3 911 Carrera (996) Body centre, roof, frame & Warning! During body repairs, the following safety instructions and the general information and quality instructions must be followed. Rep. Gr. 5; Safety instructions rn Note!.The accessories in the repair area should be removed, depending on the extent of the damage..all straightening work on the body in this area must have been completed before the damaged parts are removed. 2 3 Separating the spot-welded joints between the outer roof panelouter side section Separating the spot-welded joints between the outer roof panelrear roof frame Separating the bonded joint between the cowl panel frame on the outer roof panel rear roof frame Separate the spot-welded joints between the outer roof panel and the outer side section -C, D- and on the cowl panel frame -A- with the spotweld cutter. Separate the spot-welded joint between the outer roof panel and the rear roof frame -8- with the spotweld cutter. Heat up the bonded joint between the outer roof panel and the cowl panel frame or the rear roof frame with the hot-air gun. Insert a metal spatula between the bonded joints and separate them. Lift the outer roof panel upwards out of the body page 3
4 Body centre, roof, frame 911 Carrera (996) Preparation of roof for installation and fitting 0 "'"... """ x I II,"
5 911 Carrera (996) Body centre, roof, frame 2 Cleaning the welding areas 3 Fitting the outer roof panel 4 Inserting roof joint strips Remove the factory-applied primer on the welding areas of the spare part -A, B, C, D- using the rotary brush. Remove underbody coating and paint layers, etc. from the welding areas of the body with a hot-air gun or rotary brush. Insert outer roof panel into the body. Measure the dimension -x = 25.2 mm- on the left and right of the roof channel. It is necessary to measure dimension X between four corner points on the outer roof panel and the outer side section. As a check, install the roof joint strips on the left and right. Rep. Gr ; Removing and installing roof joint strip. If necessary, centre the outer roof panel once more page 5
6 Body centre, roof, frame 911 Carrera (996) Welding in roof """ page 6
7 911 Carrera (996) Body centre, roof, frame 2 Welding the outer roof panelouter side section under shielding gas 3 Welding the outer roof panelrear roof frame under shielding gas Observe the working time of the adhesive: 5-1 "Safety instructions for body repair" For ordering address, see: "Tools and materials" in page 7 Apply the adhesive evenly to the inside of the cowl panel frame and the rear roof frame as a triangular bead -dimension X = approx. 8 mm-. Spot-weld the outer roof panel to the outer side section -C, D-. Ensure that the spot-welding is carried out within the corrugated cut-out of the inner roof frame -E-. Spot-weld the outer roof panel to the rear roof frame -8-. Tools and materials Item Designation of the special tool Explanation Teromix component adhesive 2 Teromix processing nozzle 3 Basic straightening attachments for 911 Carrera (996) 4 Star gauges Nr MIG welder 6 Multispot spotwelder 7 Multispot spotweld cutter 8 Pneumatic body saw 9 Angle grinder Manufacturer: Henkel Teroson GmbH Postfach Heidelberg Hans-Bunte-StraBe 4 Tel.: (066221) 7040 Fax: (066221) Manufacturer: Henkel Teroson GmbH Postfach Heidelberg Hans-Bunte-StraBe 4 Tel.: (066221) 7040 Fax: (066221) =} Rep. Gr. 2.4; Workshop Equipment Printed in Germany page 7
8 Item Designation of the special tool Explanation Oscillating body saw (special electrical cutter) 11 Hole punch 12 Hot-air gun 13 Rotary brush 14 Spotweld cutter (2) 7 mm Nr. 129 Rep. Gr. 3; Workshop Equipment Rep. Gr. 2.4; Workshop Equipment Rep. Gr. 3; Workshop Equipment Rep. Gr. 3; Workshop Equipment Rep. Gr. 2.4; Workshop Equipment page 8
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