41 31 100 REPLACING THE ROOF OUTER SKIN (WITH PANORAMA GLASS ROOF) REP-REP-RAF6041-4131100_KLEBEN - V.3 (Countryman 2017-2023, except PHEV)
Read contents of BODY, GENERAL .
Procedure OBSERVE repair stage 2!
STRIP DOWN vehicle.
The following new body parts are required (see Electronic Parts Catalog):
- (1) Roof outer skin, panorama glass roof
Following CONSUMABLES are required:
| Material | Quantity |
|---|---|
| Adhesive K5a | 1 |
| Adhesive K5b | 1 |
| Blind rivet N3 | 12 |
| Punch rivet N4 | 19 |
| Punch rivet N5 | 6 |
| EMC screw | 2 |
| Cleaning agent R1 | 1 |
| Sealant D2 | 1 |
Removal
Operation is partially described on the left side. Right side identical.
Open welded connections in area (1).
Open welded connections in areas (1).
OPEN spot-welded adhesive joints in area (2).
Open bonded connection in areas (1).
Release the sealant in these areas (2).
Take off roof outer skin.
New part preparation
Set 6 bores 0 4.2 mm for the blind rivet in the areas (1).
The procedure is the same for the right side of the vehicle.
Remove new part and deburr holes.
Installation
Clean all bonding surfaces with cleaning agent R1.
Apply adhesive in areas (1).
In areas (2), apply sealant D2 in the same way as in series standard.
Install the roof outer skin with helpers. Rivet the area (1) with a blind rivet N3 according to the mew part preparation process.
In this area (2) use 8 N4 punch rivets.
In this area (3) use 3 N5 punch rivets.
In this area (1) rivet the roof outer skin using 3 N5 punch rivets.
In this area (1) rivet the roof outer skin using 7 N4 punch rivets.
In this area (2) use 2 N4 punch rivets each.
Install the tailgate hinge until the adhesive hardens.
Avoid contact between adhesive and hinges.
Remove excess adhesive.
Seal adhesive areas and blind rivets with sealant D2.
Fit an EMC SCREW after adhesive has hardened in area (1).
Do not place the EMC screw in the area of the adhesive application (2) of the side window bonding.