41 31 001 Replacing Roof Outer Skin (Version With Slide/Tilt Sunroof)

Special Tools Required

41 3 010

Refer to relevant service information in BODY, GENERAL .

STRIP DOWN VEHICLE

Observe procedures in REPAIR STAGE 2 .

The following new body parts are required:

(1) Roof outer skin, panorama sunroof

Fig 1: Identifying Roof Outer Skin - Panorama Sunroof
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Fig 2: Identifying Welding Spots In Areas (1 Of 2)

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Open welding spots in areas (1).

Open weld seams in areas (2).

Fig 3: Identifying Welding Spots In Areas (2 Of 2)

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Open adhesive bonds in areas (1).

Open welding spots in area (2).

Take off roof panel.

Preparation of new part:

Cut all four roof rack reinforcements (1) along lines (2).

IMPORTANT: Do not roof outer skin (3).

Fig 4: Identifying Roof Rack Reinforcements

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

Adjust roof outer skin to fit and secure.

Set two Ø 4.2 mm bore holes for blind rivets in areas (1).

Remove new part again and deburr bore holes.

Fig 5: Identifying Areas For Bore Holes

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

Installing roof outer skin:

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

Apply adhesive in area (1) as standard and in area (2).

Fig 6: Identifying Adhesive Application Areas

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Apply adhesive in areas (1).

Fig 7: Identifying Adhesive Application Areas

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

Mount roof outer skin and rivet with N3 blind rivets (1).

Fig 8: Identifying Rivet Areas

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

Fig 9: Identifying Area For Punch Rivets (1 Of 3)

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In area (1) rivet roof outer skin with 8 N4 punch rivets.

Fig 10: Identifying Area For Punch Rivets (2 Of 3)

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In areas (1) and (2) rivet roof outer skin with N4 punch rivets.

Area	Number
1	4
2	2

Fig 11: Identifying Area For Punch Rivets (3 Of 3)

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NOTE:

After adhesive has hardened:

Use 2 EMC SCREWS in suitable areas of roof outer skin.

IMPORTANT: In order to achieve the required flow behavior of the foam in the cavity, a cartridge temperature of approx. 65 °C to 70 °C is required.

WARNING: Risk of scalding!

Lay 2 cartridges in a heat-resistant container and weight down.

Fill container with approx. 3 liters boiling water.

Insert cartridges for approx. 30 minutes.

Insert heated cartridge shortly before processing in cartridge pistol 41 3 010, remove cap and allow both components to emerge. Wipe adhesive components uniformly and attach new mixing tube.

Tip of fill level indicator (1) indicates the current position of the plunger.

For optimum mixing of components, allow structural foam to emerge up to marking (2) and discard.

Fig 12: Identifying Fill Level Indicator Position Of Plunger

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Fill all 4 areas of roof rack reinforcements with foam.

Threaded inserts

Starting at front left, fill square holes (2) with 75 ml of structural foam each.

In so doing, hold mixing tube at an angle of approx. 30°.

Immediately after applying foam, press expansion nuts into square holes.

Repeat procedure on right side of car with second cartridge.

Operational strength of car is achieved after 24 hours.

Fig 13: Filling Areas Of Roof Rack Reinforcements With Foam

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