41 31 000 Replacing Roof Outer Skin (Normal Roof)

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Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE

Observe procedure for REPAIR STAGE 2 .

The following new body parts are required:

(1) Roof outer skin

Following CONSUMABLES are required:

Fig 1: Identifying Roof Outer Skin

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Material	Quantity
Adhesive K5b	1
Punch rivets N4	8
Punch rivets N5	8
EMC screws	2
Cleaning agent R1	1
Sealant D1

Tools also required:

Roof pliers set, part number: 2 158 707

Removing roof outer skin

Open welded connections in areas (1).

Detach adhesive areas (sealant) in area (2).

Take off roof outer skin.

Fig 2: Identifying Adhesive Areas And Welded Connections

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New part preparation

Place roof outer skin in position and fit in conjunction with roof trim strips.

Remove new component.

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 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 at the nodes is later used for spreading to side frame.

Fig 3: Identifying Sealant And Adhesive Application Areas

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

Adjust new parts with add-on parts in accordance with new part preparation procedure.

In area (1), rivet new part with punch rivets N5 .

Use N4 punch rivets in area (2).

Fig 4: Identifying Rivet Areas

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Area	Number
1	8
2	8

Fit roof pliers (1) in the middle of roof outer skin and secure with tensioning strap (2).

Fig 5: Fitting Roof Pliers In Middle Of Roof Outer Skin

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

Fig 6: Identifying Proper Position For Mounting Roof Pliers

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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.

Same procedure for all steps.

Fig 7: Identifying Step Between Roof Outer Skin And A-Pillar

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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.

After hardening of the adhesive in the roof trim strip channels install 2 EMC SCREWS .

In so doing, bear in mind subsequent fitting of roof trim strips.

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

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