41 31... Additional bores for roof rails in roof outer skin

Special tools required: 

• 2 289 807 (drill bushing)

Fig 1: Drill Bushing And Conical Drill

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Read contents of BODY, GENERAL .

Follow procedure for REPAIR STAGE 1 .

When replacing the roof outer skin, the installation holes for the roof rails must be drilled additionally.

Following tools are required:

1. Drill bushing 2 289 807
2. DRILL 6.8 X 74 MM 
3. DRILL 6.8 X 156 MM 
4. Conical drill

Fig 2: Drill Bushing And Conical Drill

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The holes for the installation of the roof rails need to be drilled through the various recesses in the side frame.

Fig 3: Locating Roof Rails Installation Holes

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Join in drill bushing (1) into recess and use locking pliers to keep in position.

Use a drill Ø 6.4 mm to drill the mounting holes through the drill bushing (1) into the roof outer skin.

Fig 4: Drilling Bushing Into Recess

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Fig 5: Locating Roof Outer Skin Bushing

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Use roof rails to check if the bores are located centered on top of the recesses in the roof frame.

If necessary, slightly rework bores until all threaded bolts fit centrically through the holes.

Mark diameter for enlargement of bores (1).

Remove roof rails.

Use conical drill to enlarge bores according to mark (1).

Maximum diameter of bores 13.5 mm.

If the diameter is too large, this leads to leaks!

Fig 6: Locating Enlarge Bores Mark

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Place roof rails on roof outer skin for checking purposes.

Deburr bores.

Carry out CORROSION PROTECTION .

Tightening torque 41 31 1AZ .