41 31 100 Replace Roof Outer Skin With Slide/Tilt Sunroof

Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE 

Following new body parts are required (refer to OVERVIEW OF CONSUMABLES ):

• (1) Roof outer skin panel, panorama glass sunroof

Following CONSUMABLES  are required:

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

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Removing roof outer skin: 

Open welded connections in area (1).

Fig 2: Identifying Roof Outer Skin Welded Connections Area

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Open brazed connections in areas (1) by grinding.

Open welded connections in areas (2).

Fig 3: Identifying Brazed Connections Areas

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Release screws (1).

Fig 4: Identifying Roof Outer Skin Screws

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OPEN  bonded connections in areas (1).

Take off roof outer skin.

Fig 5: Identifying Roof Outer Skin Bonded Connections Areas

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Preparation of new part: 

Adjust roof outer skin to fit and secure.

In area (1) drill 1 Ø 4.2 mm hole for blind rivet.

Shown on left side, right side identical.

Remove new part again and deburr bore holes.

Fig 6: Identifying Roof Outer Skin Area

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Installing roof outer skin: 

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

Fig 7: Identifying Roof Outer Skin Bonding Surfaces Area On Vehicle

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In areas (1), apply sealant D1 in the same way as in series standard.

Apply adhesive in area (2).

Apply a little more adhesive to node of A-pillar.

Place roof outer skin with helpers evenly and centrally on vehicle, adjust to fit and secure.

Rivet roof outer skin with blind rivets.

Insert screws (1) and tighten down

Tightening torque 41 31 3AZ .

Fig 8: Identifying Roof Outer Skin Screws

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Secure roof outer skin with screws and nuts M6 at mounting holes (1) of roof rails.

Fig 9: Identifying Roof Outer Skin With Screws And Nuts M6 At Mounting Holes

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In area (1) rivet roof outer skin with 9 N4 punch rivets.

Fig 10: Identifying Rivet Roof Outer Skin With 9 N4 Punch Rivets Area

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Use N4 punch rivets in areas (1) to (3).

Fig 11: Identifying N4 Punch Rivets Areas

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A-pillar nodes: Adapt step (1) between roof outer skin (2) and A-pillar with emerging adhesive. Remove excess adhesive.

Do not leave any traces of sharp edges as this could compromise the tightness of the subsequent bond.

Fig 12: Identifying Step Between Roof Outer Skin And A-Pillar

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Install hinges for tailgate until the adhesive has hardened.

Avoid contact between emerging adhesive and hinges!

Remove excess adhesive.

Seal adhesive areas and blind rivets with sealant D1.

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

Graphic similar.

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

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

Fig 13: Identifying EMC Screw Adhesive Applying Area

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