41 31 100 Replace Roof Outer Skin With Slide/Tilt Sunroof

41 31 100 Replace Roof Outer Skin With Slide/Tilt Sunroof







Read contents of Body, General.

Strip down vehicle







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

The following new body parts are required (refer to Electronic Parts Catalogue).
- (1) Roof outer skin, panorama glass roof







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)

Release 1 rivet connection in area (2).

Open welded connections in areas (1).










Open bonded connections in areas (1).

Take off roof outer skin.







New part preparation







Adjust roof outer skin to fit and secure.

Set 10 4.2 mm dia. holes for blind rivets in areas (1).

IMPORTANT: Centre bore holes for blind rivets on line (2) of holes (3) on new part. This is necessary for the later installation of the cover strip.

Remove new part again and deburr bore holes.







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







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.







In area (1) rivet roof outer skin with 7 punch rivets.







In area (1), rivet roof outer skin with 3 punch rivets.







In area (1) rivet roof outer skin with 8 N4 punch rivets.







Install hinges for tailgate until the adhesive has hardened.

Avoid contact between adhesive and hinges.

Remove excess adhesive.

IMPORTANT: Do not use any cleaning agents containing solvents.

Seal adhesive areas and blind rivets with sealant D1.







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