Sunroof Overview
Sunroof
• 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 cutting wires.
Tools for Removal:
Special tools, testers and auxiliary items required
• Window Cutter (V.A.G 1561A)
• Blade Offset (V.A.G 1561/2)
• Blade Long (V.A.G 1561/24)
• Universal Blade (V.A.G 1561/11)
• Blade (L-shaped, 25.4 mm) (V.A.G 1561/22)
• Blade U-Shaped (V.A.G 1561/23)
• 2 x Pull 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 pistols (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 so that there are no gaps in the bead to assure proper sealing.
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 for installing the roof module.
* Observe minimum curing time.
Removing the Roof Module
1 Panel - 1 -
• Included with the roof frame.
• Cannot be removed undamaged without removing windshield.
• Once the windshield is removed, the entire roof module - 11 - can be removed without damaging the panel - 1 -.
• Removing and installing, refer to => [ Sunroof Panel ] Service and Repair
2 Panel - 2 -
• Removing and installing moving panel => [ Removing and Installing Moving Panel ] Service and Repair
3 Panel - 3 -
• Already glued to module on a new roof module.
• Removing and installing, refer to => [ Sunroof Panel ] Service and Repair
• Dimension - a = 5 mm - between rear edge of glass panel and forward edge of sheet metal panel
4 Rear Panel
• Sheet metal panel
• It is not possible to remove without damaging it.
• Protect the top of the rear lid near the panel from damaging the paint with two-sided table before removing.
• Bend the rear corner of the metal cover approximately 90° upward with pliers.
• Cut through the side of the adhesive bead - 6 - with a (V.A.G 1561/22) on both side of the metal panel.
• Cut through the rear adhesive bead - 6 - with the (V.A.G 1561/11) straight through to the vehicle.
• Bend the metal panel approximately 90° upward and cut through the front adhesive bead - 6 - with a (V.A.G 1561/11) straight through to the vehicle.
• 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-adhering, apply to the same location.
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 (V.A.G 1561) and (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 Adhesive Sealing Cord
• After removing panel, remove residual butyl sealing cord and apply a new one onto the same location again.
• The butyl sealing cord seals the lid to the body and must be absolutely impermeable. Route the ends so that there are no gaps.
• Butyl sealing cord diameter = 8 mm.
9 Supportive Beads
• The support beads have been discontinued as of VIN 8 P5A 126 517.
• Cut back residual beads when installing a roof module.
• Do not bond the roof on these places.
• Use a 100 mm x 1 mm x 10 mm self-adhesive felt strip in its place. Refer to the electronic parts catalog ETKA.
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
Removing
• The panel - 1 - will get damaged when removing the molding.
• Do not remove the headliner, but rather just lower it.
- To do this, remove the trim panels for the A-pillar, the sun visors, the grab handles, the rear roof panel trim and the interior lamps.
- Unclip the rear headliner in the center.
- Pull the headliner forward out of the trim on the C- and D-pillars and lay it in the vehicle.
• Remove the crossmember for the sunroof. Refer to => [ Sunroof Crossmember ] Sunroof Shade.
• Remove roof trim molding.
• Cover thoroughly all neighboring body surfaces to sunroof module all around using fabric-reinforced adhesive tape to protect paint work.
Be careful not to damage the molding on the windshield when removing the molding on the panel - 1 -.
• Remove the molding on the edge of the glass with a sharp knife, on the front of the panel - 1 - and on the sides.
• Insert the (V.A.G 1561/23) into the (V.A.G 1561A) and cut the adhesive beads on the roof module near the panel.
• Replace the (V.A.G 1561/23) with a (V.A.G 1561/22) and cut through the adhesive on the front of the roof module.
• Cut the side of the adhesive bead - 9 - along the roof up to the metal panel.
• Be careful not to damage the seal on the back of the cover - 3 -.
• Cut the adhesive bead for the roof between the cover 3 and the metal panel.
• Cut through the support beads first if the vehicle has these.
• For easier access, remove the bolts form the cable guide. Refer to => [ Guide and Cable ] Guide and Cable.
• Cut through the left and right support beads with the (V.A.G 1561/24).
• Install the bolts for the cable guide.
• Remove the complete roof off the vehicle with four people.
• If there is any adhesive that did not get cut, use a cutting wire, replacement part number 357 853 999 A and two pull handles (V.A.G 1351/1) to cut through it now.
• Lift sunroof module (four people required) out of vehicle.
Installing
• If the same roof is going to be installed again, be sure to cut the remaining bead back right before assembly.
• Cut back remaining adhesive sealant material on roof module and body flange using (V.A.G 1561A) and (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.
• Clean the surface with D 009 401 04 and then prime it with D 009 200 02.
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 pistols 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 spacers in the same place on the module as they were on the roof when it was removed.
• 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.
• Apply the D 009 200 02 glass/paint primer on the module-side of the adhesive surface if this is a new roof module.
• Let the glass/paint primer air out for 10 minutes.
• Apply the adhesive on the body side with a second person.
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 plastic blocks (Styrofoam) onto panel 1 and panel 3, place (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.
Installing the Spacers (quantity: 6)
- Pull the protective fill off the spacers - 2 - and press them onto the module - 1 - as illustrated.
Butyl Seal for the Metal Panel
- Before assembling a new metal panel, apply the butyl sealing cord (8 mm diameter) - 2 - as shown around the opening for the vehicle antenna and, if necessary, the felt strips - 1 -. Refer to the electronic parts catalog ETKA.
• Make sure to create a solid seal and route the ends of the butyl sealing cord smoothly onto each other so that there are no gaps.
- Peel the protective film off the felt strip and apply it to the body as illustrated.
Removing the Panel - 1 -
• You must first remove the windshield to assure safe removal of the cover panel.
1 Panel - 1 -
• Before removing, use a sharp carpet knife to remove the molding.
2 Panel Molding - 1 -
• Delivery
• Remove the molding as close as possible to the edge of the glass using a sharp carpet knife - arrows -.
Do not damage the windshield molding - 3 -.
3 Windshield Molding
• Be careful not to damage the windshield molding when removing the panel - 1 -.
4 Windshield
5 Adhesive Bead for Panel - 1 -.
6 Adhesive Bead For Roof Module
Handles for Cutting
- Use the 2 (V.A.G 1351/1) and the cutting wire (357 853 999A) to cut through any adhesive that was not completely cut before.
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.
• 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