Roof Module
Roof Module
• The complete roof module is glued to the body and must be removed using electric cutter (V.A.G 1561A) and various cutting blades or with a cutting wire.
Tools for removal:
Special tools, testers and auxiliary items required
• Electric cutter (V.A.G 1561A)
• Cutting blade (58 mm) (V.A.G 1561/2)
• Cutting blade (110 mm) (V.A.G 1561/24)
• Universal cutting blade (V.A.G 1561/11)
• Cutting blade (L-shaped, 25.4 mm) (V.A.G 1561/22 )
• Cutting blade (L-shaped, 38 mm) (V.A.G 1561/23)
• 2 xpull handle (V.A.G 1351/1)
Tools for installation:
• Due to the brief processing time of the adhesive (total of 10 minutes), 2 adhesive sets DA 004 600 A2 and 2 double cartridge gun ( VAS 5237) are required for the installation and 2 people must apply adhesive onto adhesive residue on body starting from the same point and working in opposite directions.
• The beginning and the end of the adhesive bead must be applied continuously.
Special tools, testers and auxiliary items required
• 2 x double cartridge gun (VAS 5237)
• Tensioning strap (T10038)
Materials For Installation
• 2 sets of window adhesive DA 004 600 A2 are needed when installing the roof module.
* Observe minimum curing time
Removing Roof Module
1 Cover - 1 -
• Part of the roof module.
• Cannot be removed undamaged without removing windshield.
• If the windshield is removed, then the entire roof module - 11 - can be removed without destroying the cover - 1 -.
• Removing and installing => [ Sunroof Panel ] Service and Repair
2 Cover - 2 -
• Removing and installing moving cover => [ Removing and Installing Moving
Panel ] Service and Repair
3 Cover - 3 -
• Already glued to module on a new roof module.
• Removing and installing => [ Sunroof Panel ] Service and Repair
• Dimension - a = 5 mm - between rear edge of glass panel and forward edge of sheet metal panel
4 Rear cover
• Sheet metal panel
• It is not possible to remove without destroying.
• Before disassembling, protect the upper part of the rear lid around the cover from damaging the paint with two sided adhesive tape.
• Bent the back edge of the cover approximately 90° upward with pliers.
• Cut the side bead of adhesive - 6 - using the cutting knife (L-shape, 25.4 mm) (V.A.G 1561/22) on both side of the cover lengthwise.
• Cut the rear bead of adhesive - 6 - using the universal cutting blade (V.A.G 1561/11) straight through to the vehicle.
• Bend the cover approximately 90° upward and cut the front bead of adhesive - 6 - from the cover straight through to the vehicle using the universal cutting blade (V.A.G 1561/11).
• Dimension - b = 4.5 mm - with rear lid closed between rear edge of sheet metal panel and rear lid.
5 Rear lid
6 Felt strips
• Self-adhesive, affix on the same location=> [ Butyl Seal for the Panel ]
7 Adhesive bead for sheet metal panel
• Cut back residual bead when installing a new panel.
- Cut flat the remaining adhesive material on flange using electric cutter (V.A.G 1561) and scraper (V.A.G 1561/10), do not remove all residue under any circumstances.
- Residual material acts as a base for the new adhesive sealing material.
• Apply at center on residual adhesive bead
8 Butyl cord
• After removing panel, remove residual butyl cord and apply a new one onto the same location again.
• The butyl cord seals the cover from the body and must be completely sealed. Route the ends so that they meet up.
• Diameter of butyl cord = 8 mm.
9 Supportive beads
• The support beads have been discontinued starting with VIN 8 P5A 126 517.
• Cut back residual beads when installing a roof module.
• Do not seal a new roof at these locations.
• Use a self-adhering felt strip 100 mm x 1 mm x 10 mm and affix it at the same location.
10 Adhesive bead for roof module
• Cut back residual beads when installing a roof module.
• Apply adhesive to body on the same location.
11 Sunroof module
Removal:
• The cover - 1 - is destroyed by removing the molding when removing the entire sunroof module.
• Do not remove the headliner, just lower it => Body
Interior 70 Removal and Installation
- Remove the pillar trim A; the sun visors, the handles, the roof trim and the interior lamps.
- Remove the rear headliner in the center.
- Pull the headliner forward out of the pillar C-D trim.
• Remove the sunroof cross member=> [ Sun Roof Cross Member ]
• Remove roof trim molding
• Cover thoroughly all neighboring body surfaces to sunroof module all around using fabric-reinforced adhesive tape to protect paintwork.
CAUTION!
When removing the cover molding - 1 - be sure not to damage the windshield molding.
• Remove the molding on the edge of the glass with a sharp knife on the front of the cover - 1 - and on the sides.
• Insert the cutting knife (L-shaped, 38 mm) (V.A.G 1561/23) into the electric cutter (V.A.G 1561A ) and cut through the adhesive bead on the side of the roof module around the cover.
• Then change the cutting knife (L-shape, 38 mm) ( V.A.G 1561/23) for the cutting knife (L-shape, 25.4 mm) (V.A.G 1561/22) and cut through the adhesive at the front of the roof module.
• Cut through the bead of adhesive- 9 - along the roof module up to the cover.
• Be careful not to damage the rear seal on the cover - 3 -.
• Cut through the bead of adhesive for the roof module between the cover 3 and the steel cover.
• If the vehicle has a supporting bead, cut through this first.
• For better access, remove the screws from the cable guide => [ Cable Guide ] and push it slightly from the roof.
• Cut through the supporting bead left and right using the universal cutting blade (V.A.G 1561/24).
• Re-install the cable guide screws.
• With four technicians, lift the entire roof from the vehicle.
• Cut through any uncut adhesive with cutting wire, part number 357 853 999 A and two pull handles pull handle (V.A.G 1351/1) if necessary.=> [ Pull handle for cutting ]
• Lift sunroof module (four people required) out of vehicle.
Installing:
• If the same roof is to be reinstalled, then the remaining bead must only be cut just before installing.
• Cut back remaining adhesive sealant material on roof module and body flange using electric cutter (V.A.G 1561A) and scraper (V.A.G 1561/10), do not remove all residue under any circumstances.
• Residual material acts as a base for the new adhesive sealing material.
• If windshield flange has been repaired or replaced, paint structure should be restored according to specifications in Repair Information, Vehicle-Paint and if necessary, corrosion repair measures should be taken according to guidelines in Surface Technology/Chemical Materials Folder.
• First clean the area with D 0090 401 04, then prime it with D 009 200 02.
CAUTION!
Keep adhesive surface free of dirt and grease. Only cut back adhesive surface shortly before installation. Do not prime or use a cleaning solution on the adhesive surface.
• Two people using two double cartridge gun are required to apply the adhesive.
• Two window adhesive sets DA 004 600 A2 are required.
• When inserting roof, four people are required to lift module into vehicle and align.
• Install the spacer for the module at the same location where it was when the roof was removed=> [ Affixing Module Spacers (Qty. 6) ].
• For a new roof module, remove adhesive covers on spacers.
• Pull off cover strips on roof module adhesion surfaces.
• Clean adhesion areas with cleaning solution D 009 401 04.
• For a new roof module, apply primer D 009 200 02 to adhesion area on the module.
• Allow primer to air dry for 10 minutes.
• With two people, apply the adhesive on the body side on the remaining bead.
CAUTION!
Make sure there is a slight overlap at adhesive joining points, otherwise there may be leaks in these areas.
Sunroof module must be inserted in the vehicle within a maximum of 10 minutes after start of application, otherwise the bonding properties of adhesive sealant material will be impaired.
• When inserting roof, 4 people are required to lift roof over vehicle and insert into body.
• Insert roof module into vehicle.
• Distance - a - to sheet metal panel must be 5 mm.
• Press in roof completely onto spacers in roof cutout.
• Secure roof flush to body contour using tension straps at front and rear through the opened doors.
• For stronger pre-tension of sunroof module against vehicle, place e.g. plastic blocks (Styrofoam) onto panel 1 and panel 3, place tensioning strap (T10038) over it and tighten.
• After installing, perform a leak test before installing the headliner.
• If a removed roof is reinstalled, panel 1 must also be installed in roof module => [ Removing And Installing Bonded
Cover ] Service and Repair.
12 Adhesive bead for panel 1
• Cut residual bead only just before installing panel 1.
• Affix adhesive for panel 1 onto residual bead on body.
Affixing Module Spacers (Qty. 6)
- Pull the protection strip off the spacers - 2 - and press them onto the module as illustrated- 1 -.
Butyl Seal for the Panel
- Before installing a new panel, install the butyl cord ( dia. 8 mm ) - 2 - around the cut-out for the roof antenna, and felt strips if necessary - 1 -.
• Make sure it is sealed and route the ends of the butyl cord so that they join each other.
- Remove the protective strip from the felt strip and apply it to the body as shown.
Remove the cover- 1 -.
• It is not possible to remove the cover without damaging it if the windshield has not been removed.
1 Cover - 1 -
• Remove the molding with a sharp carpet knife before removing.
2 Cover molding - 1 -
• Circumference
• Remove the molding as close as possible to the edge of the glass - arrows - with a carpet knife.
CAUTION!
Do not damage the windshield molding - 3 -.
3 Windshield molding
• Must not be damaged when removing the panel - 1 -.
4 Windshield
5 Adhesive bead for panel - 1 -.
6 Adhesive bead for roof module
Pull handle for cutting
- Cut through any adhesive not cut completely with 2 xpull handle (V.A.G 1351/1)and cutting wire.
Removing and installing roof molding
1 Roof molding
• To remove, unclip roof molding carefully clip by clip, starting at rear.
• To install, insert roof molding at front beneath panel - 1 - of sunroof module.
• When installing, press in roof molding in steps into roof, beginning from front.
2 Clip
• 10 x per side, adhered with double-sided adhesive tape - 3 -.
• Adhesion surface of clips must be free of dust and grease.
• When installing, clips must be positioned as shown at sides on side wall frames and then pressed onto body.
3 Double sided adhesive tape
• Adhesion surface must be free of dust and grease, clean with cleaning solution D 009 401 04 or equivalent.
• After installing, clip must contact side wall frame as shown in magnified area of illustration.
4 Panel 3 of sunroof module
5 Panel 1 of sunroof module