Body - Convertible Top Frame Modification
Group: 61Number: 03-03
Date: Sept. 25, 2003
Subject:
Convertible Top Frame, Modifying to Accept New Roof Leading Edge Trim
Model(s):
New Beetle Convertible 2003 > 3M308194
Condition
If the roof leading edge trim panel for the convertible top requires replacement, the convertible top frame must be modified to accept the service replacement part.
Production
Applies to 2003 vehicles up to and including VIN 3M308194.
Service
^ Trim attachment points -A- of replacement part have been moved inboard approx. 19 mm.
WARNING!
Wear safety goggles to protect your eyes during this procedure!
^ Modify outermost attachment point (arrow) of the convertible top frame (on both the left and right sides) to accept the roof leading edge trim panel as follows:
^ Prior to starting procedure, protect interior from metal shavings and chips.
- Partially open convertible top (approx. 1/3 open).
- Locate outermost trim attachment slots (arrow indicates right side) at metal frame (left and right).
^ Procedure must be performed on left and right sides.
Extend slot as follows:
- Locate the centerline of the slot.
- Measure inboard, 17.9 mm from inboard radius of the existing slot.
- Mark this location.
- Drill a 5 mm hole -A- at this location.
- Scribe top and bottom edges of slot to the hole (this will be the material to be removed).
- Mark and drill three additional holes approx. 3.5 mm in diameter between the edge of the existing slot and the 5 mm hole as shown
- Carefully remove material to the scribed lines using a 4.5 mm edge mill or small carbide burr bit.
Modified slot
Note:
When removing aluminum material, a file that is only used for aluminum must be used to prevent corrosion.
- After drilling and milling the new area, proceed to shave off the remain chips and burrs from all edges using a flat file.
- Finish edges by applying black touch-up paint, to avoid possible corrosion to the modified area.
- Clean interior of any removed material.
Warranty Information