41 31 100 Replace roof outer skin with panoramic glass roof

Read contents of SAFETY INFORMATION and BODY, GENERAL .

STRIP DOWN vehicle

Procedure OBSERVE repair stage 2.

The following new body parts are required.

(1) Roof outer skin, panorama glass roof

Following CONSUMABLE are required:

Fig 1: Identifying Panorama Glass Roof Outer Skin

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Material	Quantity
Adhesive K5a	1
Adhesive K5b	1
Blind rivets N3	14
Punch rivets N4	23
EMC screws	2
Cleaning agent R1	1
Sealant D1

Removing roof outer skin:

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

Fig 2: Identifying Roof Outer Skin Welded Connection Areas

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Open welded connections in areas (1).

Open spot-welded adhesive joints in area (2)

Release 1 rivet connection in area (2).

Open welded connections in areas (1).

Fig 3: Identifying Roof Outer Skin Welded Connection Areas

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Fig 4: Identifying Oscillating Knife And Roof Outer Skin Bonding Areas

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Loosen bonded connections in the areas (1) with an oscillating knife (2) (compare with removal of windscreen).

Take off roof outer skin.

New part preparation:

Adjust roof outer skin to fit and secure.

Set one 4.2 mm bore hole for blind rivets in each of areas (1).

Fig 5: Identifying Area For Setting Blind Rivet Bore Holes

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In area (1) set 5 bore holes dia. 4.2 mm for blind rivets.

NOTE: Bore holes must be set on center line (2) of holes (3) present on new part.

The procedure is the same for the right side of the vehicle.

Remove new part again and deburr bore holes.

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

Fig 6: Identifying Areas For Setting Blind Rivet Bore Holes

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Installing roof outer skin:

Fig 7: Identifying Adhesive Application Areas And Sealant Application Area

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Clean all bonding surfaces with cleaning agent R1.

In area (1), apply sealant D1 in same way as standard procedure.

Apply adhesive in areas (2).

Install roof outer skin and rivet with blind rivets.

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

Fig 8: Locating Area For Punch Rivets (Front)

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In area (1), rivet roof outer skin with 3 punch rivets.

Fig 9: Locating Area For Punch Rivets (Rear)

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

Use one punch rivet each in these areas (2).

IMPORTANT: Note the indentation on the bottom in the areas (2).

Fig 10: Identifying Punch Rivet Areas

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Install hinges for tailgate until the adhesive has hardened.

Avoid contact between adhesive and hinges.

Remove excess adhesive.

IMPORTANT: Do not use any cleaning agents containing solvents.

Seal adhesive areas and blind rivets with sealant D1.

After adhesive has hardened in area (1), fit an EMC SCREW .

Fig 11: Identifying Area For Installing EMC Screw

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