41 31 000 Replacing Roof Outer Skin (Carbon-Fibre-Reinforced Roof Version)

Special tools required: 

• 41 3 200
• 41 3 201
• 41 3 202
• 41 3 203
• 41 3 204

Read contents of BODY, GENERAL .

Read and comply with General cementing instructions.

The following components are required:

• Roof outer skin (1)

Following CONSUMABLES  are required:

• K3 glue (1 cartridge, use only the mixing tube supplied with the product)
  Fig 1: Identifying Roof Outer Skin

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• Scotchbrite Multiflex 51 91 0 402 967
• Window adhesive (1 cartridge)
• Cleaning agent R1

Tools also required:

• GLUE GUN 81 49 0 443 166  for adhesive K3

Installation note: 

Prior to installation, roof outer skin and vehicle for at least 12 hours at room temperature (15 °C to 25 °C).

The working temperature of the adhesive must be at least 18°C.

Removing roof outer skin 

Detach glued joints of underlining in areas (1) (similar to window bonding).

Installation note:

If the primer is damaged, proceed as follows:

Pretreat damaged areas in same way as BONDING STEEL ON STEEL .

Apply adhesive K1 to the bright-finish areas with a spatula. Apply a thin and uniform coating.

The roof outer skin can be bonded after a curing period of 24 hours.

Adhesive area (2) must not be painted over.

Fig 2: Identifying Adhesive Area And Glued Joints

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View of bottom: 

Use adhesive tape to transfer positions of marked spacers (1) to top.

These markings are used later to position the clamps for securing the roof outer skin.

Fig 3: Locating Spacer Positions

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New part preparation: 

Place roof outer skin in position on vehicle and adjust to fit.

Fit rear window and roof trim strips to check correct position of roof outer skin.

(2) = bonding surface for reference bead.

Fig 4: Identifying Bonding Surfaces

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Fix roof outer skin at marked positions with pliers 41 3 202 and shaped elements 41 3 204.

Fig 5: Securing Roof Outer Skin Using Pliers And Shaped Elements

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Secure roof outer skin at marked points in area of windscreen and rear window with locking pliers 41 3 201.

Fig 6: Securing Roof Outer Skin In Area Of Windscreen/Rear Window Using Locking Pliers

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Overview of clamping tools:

Fasten the roof outer skin at the marked positions.

• (1) 4 x roof pliers 41 3 202/203/204
• (2) 2 x C-gripping pliers (long version)
• (3) 8 x gripping pliers 41 2 201

After adjusting the clamping tools, remove the roof outer skin.

Fig 7: Identifying Roof Out Skin Fastening Positions

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Preparation of adhesive flanges on new part:

1. Pre-clean areas (2) and (3) with cleaning agent R1.
2. Roughen areas (2) and (3) thoroughly with grinding pad.
3. Clean areas (1) to (3) with cleaning agent R1.

Air drying time > 1 minute.

After air drying, all adhesive areas must be a uniform dull grey; repeat the roughening procedure if necessary.

Preparation of adhesive flanges on car:

Clean areas (1) and (2) with cleaning agent R1.

Air drying time > 1 minute.

Installing roof outer skin 

Lay out the following components/materials ready:

• Adhesive gun 81 49 0 443 166
• K3 glue (use only the mixing tube supplied with the product)
• Window glass adhesive
Fig 8: Applying Adhesive To Flange Of Roof
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1. Underlining on roof in convertible top bow areas: 

   Apply window glass adhesive in a triangular pattern to convertible top bow (height 15+1.0 mm) (1).

2. Step compensation on vehicle: 

   In areas (2) apply window glass adhesive (step compensation) and smooth.

   Fig 9: Applying Window Glass Adhesive

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   Steps  3 to  5 described below must be completed within 10 minutes  .

3. Adhesive application 

   Guide nozzle at an angle of max. 60° along adhesive flange.

   Apply adhesive K3 in a bead shape centrally to adhesive flange of roof (2) (bead width 6+0.5 mm).

   Fig 10: Applying Adhesive To Flange Of Roof

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   Apply adhesive extensively in corners (1).

   Fig 11: Applying Adhesive In Corners

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4. Reference bead 

   Apply adhesive in a bead shape in area (1).

   Fig 12: Applying Adhesive In A Bead Shape

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5. Joining and fixing roof outer skin 

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

   If necessary, fit windscreens and roof trim strip to check correct position of roof outer skin.

   Fit clamping tools at the marked points.

   Align stages between roof and A-pillar or roof and C-pillar with emerging adhesive. Remove excess adhesive.

   IMPORTANT: Never use cleaning agents.

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

   IMPORTANT: Do not move  the vehicle with clamping tools attached.

Check whether reference bead has hardened after 2 hours curing time (15 °C to 25 °C).

Then remove clamping tools.

Mechanically remove vertically protruding adhesive from roof trim strip channel in areas (1).

Mechanically remove adhesive that has escaped in areas (2).

The endurance strength of the structural bond is achieved after 12 hours at 20 °C.

Carry out a leak test on entire vehicle.

Fig 13: Identifying Adhesive Areas

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STICK ON clips (1) for roof trim strip.

Clips must not be stuck to adhesive residue.

The endurance strength of the structural bond is achieved after 12 hours at 20 °C.

Carry out a leak test on entire vehicle.

Fig 14: Identifying Stick On Clips For Roof Trim Strip

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