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

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Special tools required:

2 289 807 (drill bushing)

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.

The following tools are required:

Drill bushing 2 289 807
DRILL 6.8 X 74 MM
DRILL 6.8 X 156 MM
Conical drill

Fig 1: Required Tools

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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 2: Side Frame Recesses

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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 3: Drilling Mounting Holes Through Drill Bushing Into Roof Outer Skin

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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).

Fig 4: Enlarging Bore Holes

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Remove roof rails.

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

Maximum diameter of bores 13.5 mm.

NOTE: If the diameter of the bore is too small, this can lead to a creaking.

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

Fig 5: New Bore Hole Diameter 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 .