Removal and Replacement

41 31 000 Replace roof outer skin







Read contents of Body, General.
Strip down vehicle.







Observe (repair stage 2) procedure.







Following new body parts are required (refer to Electronic Parts Catalogue):
- (1) Roof outer skin

Following consumables are required:

Material Quantity
Adhesive K5b 1
Blind rivets N3 4
Punch rivets N4 43
Punch rivets N5 6
EMC screws 4
Cleaning agent R1 1
Sealant D1







Removing roof outer skin
Operation is partially described on the left side. Right side identical.







Open brazed connections in areas (1) by grinding.
Open welded connections in areas (2).
Release adhesive areas (sealant) in the areas (3).







Open brazed connections in areas (1) by grinding.
Open welded connections in areas (2).
Take off roof outer skin.







New part preparation







Adjust roof outer skin to fit and secure.
Set one 4.2 mm bore hole for blind rivets in each of areas (1).
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 on new part and on vehicle with cleaning agent R1.
Apply adhesive in area (1).
In areas (2), apply sealant in the same way as in series standard.
Mount roof outer skin and rivet with blind rivets in the hinge areas (1).












In areas (1) and (2) rivet roof outer skin with punch N4rivets.
Use N5 punch rivets in area (3).












In areas (1) to (3) rivet roof outer skin with punch N4rivets.

Area Number
1 4
2 total of 6
3 3







After adhesive has hardened, install one EMC screw in each case in areas (1).