41 31 010 Replacing Outer Roof Skin (Version With Slide/Tilt Sunroof)

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Read contents of BODY, GENERAL and observe relevant procedures.

STRIP DOWN vehicle

Following new body parts are required:

(1) Roof outer skin, slide/tilt sunroof

Fig 1: Identifying Roof Outer Skin, Slide/Tilt Sunroof

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Carry over the work step shown symmetrically to the other side of the vehicle.

Open brazed joints in areas (1).

Open weld joints in areas (2).

Fig 2: Identifying Weld Joints Area And Brazed Joint Areas

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Open spot-welded adhesive joints in area (1)

Fig 3: Identifying Brazed Joint Areas

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NOTE:

Shown without roof outer skin for purposes of clarity.

Detach bonded connection (1) (sealant) and remove roof outer skin.

Fig 4: Identifying Sealant Bonded Connection

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Preparation of new part:

If necessary, place roof outer skin in position and fit in conjunction with roof trim strips.

Take off roof outer skin.

IMPORTANT: Do not grind/sand new part in area of bonding surfaces.

Installing roof outer skin:

Clean all bonding surfaces on vehicle and on new part with cleaning agent R1.

Apply adhesive in areas (1).

Fig 5: Identifying Sealing Compound Areas

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Apply sealant in areas (1) analogously to Series.

Apply adhesive in area (2).

Apply a little more adhesive to nodes (3) of A-pillar.

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

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

For positioning, set up roof drip moldings and windscreen.

Fig 6: Identifying Weld Joints Area

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

NOTE: Pictured on version without slide/tilt sunroof.

Fig 7: Securing Tensioning Strap Using Roof Pliers

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NOTE: To generate an optimum contact pressure, mount roof pliers according to the graphics as left.

Fig 8: Identifying Correct Position For Clamping Tool

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Fix roof outer skin in areas (1) with M8 screws.

(2) Roof pliers with tensioning strap.

NOTE: When inserting screws, make sure no adhesive gets into the screwed joint!

Fig 9: Fixing Roof Outer Skin With M8 Screws And Roof Pliers

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In area (1) rivet roof outer skin with 7 N4 punch rivets.

Set punch rivets in corners starting at a distance of approx. 200 mm.

Use 7 punch rivets N4 in area (2).

Fig 10: Identifying Rivet Areas

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Adapt step (1) between roof outer skin (2) and A-pillar with emerging 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.

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

Fig 11: Identifying Roof Outer Skin And Adapt Step

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

Fit an EMC SCREW after adhesive has hardened in area (1).

In so doing, bear in mind subsequent fitting of roof trim strip!

Fig 12: Identifying EMC Screw On Adhesive Hardened Area

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