Rails

Rails

INTRODUCTION
- NOTE! Read through the whole installation instruction before starting the work.
- The front page gives the date of this edition and the edition it replaces
- The second page shows the tools needed for the installation and the contents of the installation kit
- The illustrations display the procedure in order of operation. The order of operation is repeated in the text section
- Cut out the text page in order to follow the illustrations and text at the same time.

Rails

Preparations

- Clean the roof along the sides where the rails will be secured
- Secure two pieces of tape opposite each other on the roof and roof trim strip to mark the position of the trim strip.

- Remove the roof trim (it is secured by eight clips). First grasp the inside using the finger tips of one hand and pull it out towards the edge of the roof. Then, use the other hand to carefully pry up the outer side using a plastic weatherstrip tool. Unhook the roof edge trim from the clips.

Note! The roof trim is securely installed, therefore force is required to remove it. If necessary, lubricate the tip of the weatherstrip tool to facilitate removing the rubber strip. Use rubber lubricant, P/N 1161150-6. Do not damage the roof trim strip or painted surfaces.

- Remove the four screws in the roof joint and put them to one side. They will not be used again
- Clean the roof joint
- Replace the clips holding the roof trim for new ones from the kit.

Replacing clips

Illustration A

- Slide the clip until the T-shaped lug is in the large hole in the clip. Remove the clip.

Illustration B

- Take the new clip from the kit. Position the clip on the T-shaped lug with the large hole turned to the rear for the left-hand side. For the right-hand side, the large hole in the clip must be turned to the front.

Illustration C

- Slide the clip backwards / forwards until the vertical pin in the clip is against the inner vertical edge of the roof joint.

Illustration D

- Pry off the clip pin.

Cutting the roof trim

Cutting the front edge, right-hand roof trim

Note! Do not damage the painted roof trims. They scratch easily.

- Measure the front edge of the right-hand roof trim for cutting as illustrated. Measure from the ends (1) of the two profiles on the inside of the roof trim
- Mark the same dimensions on top of the two profiles and at the sides so that the cut on the top of the roof trim can be marked.

- Carefully mark the top of the roof trim where it will be cut
- Pull off the rubber strip between the markings on both sides of the roof trim strip so that the rubber strips can be cut off
- Cut the rubber strips so that they protrude approximately 5mm (3/16 ") from the edge of the sections of the roof trim strip which are to remain in place.

- Wrap the section of the roof trim to be secured in the vice. Use plenty of paper or cloth to protect the paintwork on the roof trim
Note! Use jaw protectors with a recess in the centre on the vice.

Position the roof trim in the recesses in the vice.

Note! Do not over-tighten the vice or the roof trim may deform.

- Carefully cut at the marking furthest in on the roof trim, gently pressing the roof trim. Hold the other end of the roof trim with your free hand to keep the trim stable whilst cutting.

- Measure the rear edge of the right-hand roof trim for cutting as illustrated. Measure from the ends (1) of the two profiles on the inside of the roof trim
- Then mark the same dimensions on top of the two profiles and at the sides so that the cut on the top of the roof trim can be marked.

- Remove the long section of the roof trim from the vice
- Secure the cut off section with the section (1) to be cut off in the vice
- Cut the roof trim in the same way as in the previous point.

- Smooth off the two shorter end pieces and the long section of the roof trim. Use a fine toothed file
- Remove the swarf from the different sections
- Check that the rubber strips are seated in their grooves. If necessary use a small screwdriver to press the trim strips back into the grooves by the protruding ends
- Repeat points 5-13 on the left-hand roof trim.

Installing the roof trim

- Press the cut sections of the roof trim into the clips in the roof joint. Check that the marking on the long roof trim (1) is opposite the marking on the roof (2). Also check that the front and rear angled ends of the roof trim align in the rounded section of the roof.

Installing the rails

- Check that the rubber spacing is correctly positioned under the feet of the rails
- Carefully position the rails over the holes in the roof join
- Install the screws from the kit
- Tighten the screws alternately at the front and rear edges to prevent deformation. Tighten the screws. Tighten to 10 Nm (7.7 lbf.ft).

- Install the cover on the front mounting for the rail
- Insert the two locating pins for the cover in the rail, as illustrated
- Fold the cover down towards the front mounting. Press it into place
- Repeat the operation for the rear mounting cover
- Remove the tape on the roof and the roof trim
- Repeat on the other side.