41 31 100 Replacing roof outer skin with panorama glass roof

Read contents of BODY, GENERAL .

STRIP DOWN  vehicle

Follow procedure for REPAIR STAGE 2 .

• (1) Roof outer skin panel, panorama glass sunroof
Fig 1: Identifying Panorama Glass Roof Outer Skin
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The following CONSUMABLES  are required:

Removing roof outer skin 

Operation is partially described on the left side.

Right side identical.

Open welded connections in areas (1).

Open spot-welded adhesive joints in area (2)

Fig 2: Identifying Spot-Welded Adhesive Joints Area And Welded Connections Areas

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Open welded connections in areas (1).

Fig 3: Identifying Welded Connections 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.

Fig 4: Identifying Bonded Connections Areas And Oscillating Knife

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New part preparation 

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

Adjust roof outer skin to fit and secure.

Set two 4.2 mm diameter bore holes for blind rivets in area (1).

Fig 5: Identifying Blind Rivets Area

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In areas (1), set 7 4.2 mm dia. holes for blind rivets.

Remove new part again and deburr bore holes.

Fig 6: Identifying Blind Rivets Area

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Installing roof outer skin 

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.

Fig 7: Identifying Adhesive Areas And Sealant Area

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In area (1), rivet roof outer skin with 8 punch rivets N5  .

Fig 8: Identifying Punch Rivets Area

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In area (1), rivet roof outer skin with 2 punch rivets N5  .

Fig 9: Identifying Punch Rivets Area

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In area (1), rivet roof outer skin with 8 punch rivets N5  .

Use 6 punch rivets N5  in areas (2).

Fig 10: Identifying Punch Rivets Areas

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Install hinges for tailgate until the adhesive has hardened.

Avoid contact between adhesive and hinges.

Remove excess adhesive.

Seal adhesive areas and blind rivets with sealant D1.

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

Fig 11: Identifying EMC Screw Installation Area

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