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

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Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE

Procedure OBSERVE repair stage 2!

Following new body parts are required (refer to ELECTRONIC PARTS CATALOGUE ):

(1) Roof outer skin panel, panorama glass sunroof
(2) hexagon screws: 4 pieces order number: 07 14 7 225 250 (not shown)

Following CONSUMABLES are required:

Fig 1: Identifying Roof Outer Skin Panel, Panorama Glass Sunroof

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Material	Quantity
Adhesive K5b	1
Adhesive K5a	1
Punch rivets N5	16
EMC screws	2
Cleaning agent R1	1
Sealant D1

Tools also required:

Roof pliers set, order number: 81 43 2 158 707
Sourcing reference:

Removing roof outer skin

Release 4 hexagon screws (1) in roof channel.

Fig 2: Identifying Roof Channel Hexagon Screws

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Fig 3: Identifying Spot-Welded Adhesive Joints Areas, Adhesive Area

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Open welded connections in areas (1).

LOOSEN spot-welded adhesive joints in areas (2).

Detach adhesive area (3).

Take off roof outer skin.

New part preparation

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

Remove new part again.

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

Installing roof outer skin

Fig 4: Identifying Roof Outer Skin, Adhesive Area

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

Apply sealant D1 in areas (1) analogously to Series.

Apply adhesive in areas (2).

Apply a little more adhesive to nodes 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.

Fit roof strips for positioning.

Screw in 4 hexagon screws (1) hand-tight.

Fig 5: Identifying Roof Channel Hexagon Screws

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Fig 6: Mounting Roof Pliers

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

NOTE: Pictured on version without slide/tilt sunroof.

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

Fig 7: Identifying Roof Pliers Without Slide/Tilt Sunroof

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Rivet roof outer skin with 16 punch rivets N5 in areas (1).

Fig 8: Riveting Roof Outer Skin With 16 Punch Rivets

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After adhesive has hardened, install one EMC SCREW in each case in areas (2).

When doing so observe installation position of roof trim strip!

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.

Fig 9: Identifying Step Between Roof Outer Skin And A-Pillar With Emerging Adhesive

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IMPORTANT: Spread excess adhesive in roof trim strip channel. Mounting surfaces of clips for roof trim strips must not be coated with adhesive.
Tighten 4 hexagon screws.
Tightening torque 41 31 2AZ .

After hardening of the adhesive, seal adhesive areas, hexagon screws and EMC screws with sealant D1.

Mounting surfaces of clips for roof trim strips must not be coated with sealant.