41 31 001 Replacing Roof Outer Skin (Version With Panorama Glass Roof)

41 31 001 Replacing Roof Outer Skin (Version With Panorama Glass Roof)







Read contents of Body, General.
Strip down vehicle







NOTE: Observe new procedure for bonding and riveting (repair stage 2).







Following new body parts are required (refer to Electronic Parts Catalogue - EPC):
- (1) Roof outer skin panel, panorama glass sunroof
- (2) Star screws: 4 pcs. order no. 07 14 7 153 767 (not shown)
- (3) Blind rivets, roof outer skin on roof frame: 2 pcs. order no. 07 14 9 202 131 (not shown)

Following consumables are required:












Removing roof outer skin:







Release 4 screws (1) in roof channel.







Interior, area of C-pillar:
Operation is described on the left side. Right side identical.
Release rivet connection (1).







Open spot-weld adhesive joints in areas (1).
Detach bonding surfaces (2) from vehicle interior.







Open welded connections in areas (1).
Open brazed connections in areas (2).
Take off roof panel.







Preparation of new part:







Place roof outer skin in position and adjust to fit and secure in conjunction with roof trim strips.
Set four 4.2 mm dia. holes for blind rivets in areas (1).
Remove new part again and deburr holes.







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







Installing roof outer skin:







Clean all bonding surfaces on vehicle and on new part with cleaning agent R1.
Apply sealant D1 in areas (1) analogously to Series.
Apply adhesive in areas (2).
Apply a little more adhesive to nodes of A-pillar.

NOTE: Excess material is later used for spreading to side frame.







Place roof outer skin with helpers evenly and centrally on vehicle.
Insert 4 star screws (1) hand-tight.







Rivet roof outer skin in C-pillar area with blind rivet.







In area (1) rivet roof outer skin with 7 N4 punch rivets.
Set punch rivets in corners starting at a distance of approx. 200 mm.







Rivet roof outer skin in areas (1) with blind rivets.
Use 8 punch rivets N4 in area (2).







Adapt step (1) between roof outer skin (2) and A-pillar with emerging adhesive. Remove excess adhesive.

IMPORTANT: Do not use any cleaning agents containing solvents.

Do not leave any traces of sharp edges as this could compromise the tightness of the subsequent bond.







IMPORTANT:
- Spread excess adhesive in roof trim strip channel. Mounting surfaces of clips for roof trim strips must not be moistened with adhesive.
- Tighten 4 star screws.
- Tightening torque 41 31 2AZ.







Operation is described on the left side. Right side identical.
After hardening of the adhesive in area (1), install a EMC screw.
In so doing, bear in mind subsequent fitting of roof trim strip (clips).