Luggage / Roof Rack Frame: Service and Repair

41 31 ... Installing roof rack reinforcement







Special tools required:

- 41 2 101
- 41 2 102
- 41 2 103
- 41 2 104
- 41 2 105
- 41 3 010







Read contents of Body, General.







Necessary preliminary tasks:

- Remove both rear side windows







IMPORTANT: In order to achieve the required flow behaviour of the foam in the cavity, a cartridge temperature of approx. 65 °C to 70 °C is required.







WARNING: Danger of scalding.

Lay 2 cartridges in a heat-resistant container and weight down.
Filling container with approx. 3 litres boiling water.
Insert cartridges for approx. 30 minutes.







Carry over the work step shown symmetrically to the other side of the vehicle.
Screw drilling hole template 41 2 101 in area of front side windows into screw fastening points of roof trim strip (1). Positioning at second and third screw fastening points from front.

IMPORTANT:
- Risk of damage.
- Immersion depth of drill max. 1 cm.

Drill holes (2) with drill 41 2 105.
Unscrew drilling hole template.
Deburr holes.







Carry over the work step shown symmetrically to the other side of the vehicle.
Slide in drilling hole template 41 2 102 in area of rear side windows between retaining clips of roof trim strip (1) up to stop. Positioning at second and third retaining clips from front.
Hold down drilling hole template and spot-drill holes (2) with drill 41 2 105 only. Do not drill through.
Remove drilling hole template.

IMPORTANT:
- Risk of damage.
- Immersion depth of drill max. 1 cm.

Drill through holes.
Deburr holes.







Cut an M8 thread into all 8 bore holes (1).







IMPORTANT: Use only bolt with hexagon head.

Insert M5x10 bolt (8 x) with hexagon head and washer (1) hand-tight in threaded insert (2).







WARNING: Danger of scalding.

Insert heated cartridge shortly before processing in cartridge pistol 41 3 010, remove cap and allow both components to emerge.
Wipe adhesive components uniformly and attach new mixing tube.







Tip of fill level indicator (1) indicates the current position of the plunger.
Allow mixed structural foam to emerge up to marking (2).







Fill each bore (1) with 75 ml of structural foam.
Repeat procedure on right side of car with second cartridge.







Screw in bolt (1) with threaded insert (2) into all bores.
Continue inserting bolt (1) with threaded insert (2) until foam emerges (approx. 5 turns).

NOTE: Threaded insert (2) cannot be tightened down.

Structural foam (3) must emerge all round between collar (2) and roof outer skin.

IMPORTANT: Only structural foam which has emerged all round provides adequate corrosion protection.







Carry over the work step shown symmetrically to the other side of the vehicle.
Screw retaining strip 41 2 103 in area of front side windows into screw fastening points of roof trim strip (1).
Collar of threaded insert must be pressed uniformly onto roof outer skin.







Carry over the work step shown symmetrically to the other side of the vehicle.
Slide retaining plates 41 2 104 in area of rear side windows into locators of retaining clips of roof trim strip (1) up to stop.
Collar of threaded insert must be pressed uniformly onto roof outer skin.







Operational strength of car is achieved after 24 hours.
Then remove all retaining plates.
Remove all 8 bolts with washers (1).







Screw down all 4 retaining plates for roof rack (1) with opening facing upwards with Torx screws (2).

Tightening torque

Installation:
Windows are cemented and roof strips fitted after completion of body repair work.