Removing front roof reinforcement — AUDI

🧭 Before you start

Fits: VW Transporter T5 (7H), VW Transporter T6 (7E)

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: locking pin

Don't miss

• Removing the end caps without damaging them is not possible.Proceed carefully when removing the end caps in order to avoid damage to the paintwork.
• The rear hinges for pop-up roof are coated with adhesive sealant from below and bonded to the roof frame.The old adhesive sealant must be removed prior to installation.
• Removing the pin (6) separates the piston rod of the hydraulic cylinder (5) from the hinge unit (1).
• Make sure that the inner roof frame trim does not become damaged on the removal of the caps (1).
• The roller blind guide (3) is bonded to the front roof reinforcement. It is therefore not possible to remove the roller blind guide without damaging it.

📋 Procedure

1. Use appropriate workshop equipment (e. g. vehicle seat coverVAS 6217) to cover driver and front passenger seats, rear bench seat, kitchen unit and dash panel.
2. Remove canopy (if fitted) .
3. Remove pop-up roof
4. Fold up slatted frame and mattress.
5. Use hot air blowerV.A.G 1416 to heat end caps of canopy rail (1).

6. Using pull handleV.A.G 1351/1 and cutting cord, cut through adhesive bead in direction of (arrow) as far as canopy rail.
7. Remove end covers (1).
8. Cut back adhesive residue (2) using scraperVAS 5301/21.
9. Remove adhesive residue (3) using adhesive strip removerVAS 6349. [Note: Removing the end caps without damaging them is not possible.Proceed carefully when removing the end caps in order to avoid damage to the paintwork.]
10. In order to protect the painted surface, mask off the entire area (around the front roof reinforcement, along the roof pillars and up to the rear roof reinforcement) using textile-reinforced adhesive tape.
11. Remove bolts (3).
12. Unscrew nut (2).
13. Carefully release and remove hinge for pop-up roof (1). [Note: The rear hinges for pop-up roof are coated with adhesive sealant from below and bonded to the roof frame.The old adhesive sealant must be removed prior to installation.] [Note: When removing the hinges as per "“scenario 1”", the hydraulic fluid lines must be disconnected, and the hydraulic cylinder needs to be removed prior to the removal of the front roof reinforcement. The front roof reinforcement is then removed with hydraulic fluid lines disconnected (but sealed properly!).The advantage of this scenario is that the removal of the roof reinforcement is much easier with bulky and heavy hydraulic cylinders removed.The hydraulic fluid lines must be sealed immediately after disconnection from the hydraulic cylinder (using, for example, dust caps of brake caliper bleeder valves).Ensure that no hydraulic fluid gets into the vehicle interior. To ensure this, certain rules for cleanliness must always be observed.]
14. Unscrew bolt (3), and remove cover (1).
15. Cut through cable ties (arrows).
16. Remove both securing clips (4).
17. Remove hydraulic fluid lines (5) from hydraulic cylinder (2), and seal them immediately.
18. Unclip and remove roof hydraulics sender 1G491 and roof hydraulics sender 4G494(6) from hydraulic cylinder.
19. Remove circlip (3), and pull pin (2) out of hinge part (1).
20. Unscrew bolts (4) and (5). Remove hinge part (1) with hydraulic cylinder from hinge carrier.
21. Unscrew bolts (2), and remove hinge parts (1) and (3) from hinge carrier (6).
22. Unscrew bolts (4) and (5) Remove hinge carrier (6) from roof frame. [Note: When removing hinges as per "“scenario 2”", the hydraulic fluid lines remain connected for the time being. The hydraulic cylinders are separated from the front hinges. The front roof reinforcement is then removed with hydraulic fluid lines still connected.The advantage of this scenario is that no hydraulic fluid can get into the vehicle interior.To facilitate the removal of the bolts (2), heat should by applied to them prior to the removal.]
23. Unscrew bolts (2).
24. Unscrew bolts (1) and (4) from mounting bracket (3).
25. Remove circlip (2).
26. Slightly raise hinge unit (1), mounting bracket (3) and hydraulic cylinder (5). Pull out pin (6), and remove plastic washers (7). Remove hinge unit (1). [Note: Removing the pin (6) separates the piston rod of the hydraulic cylinder (5) from the hinge unit (1).]
27. Pull locking pin (4) of hydraulic cylinder (5) out of mounting bracket (3).
28. Remove mounting bracket (3).
29. Unscrew bolts (2), and remove hinge units (1) and (3) from hinge carrier (6).
30. Unscrew bolts (4) and (5) Remove hinge carrier (6) from roof frame.
31. Remove hydraulic lines (with or without hydraulic cylinder) on left and right from roof frame.
32. Secure hydraulic lines with hydraulic cylinder to front roof reinforcement, as shown in illustration.
33. Secure hydraulic lines (1) without hydraulic cylinder to front roof reinforcement (2), as shown in illustration. [Note: When performing any work in which hydraulic lines and hydraulic cylinders are involved, ensure in particular that these components do not become kinked or damaged.Damaged hydraulic lines must always be renewed to ensure proper function of the pop-up roof.]
34. Use front-end hook3370 and plastic wedge (5) to remove caps (1) of front roof reinforcement in direction of (arrow). [Note: Make sure that the inner roof frame trim does not become damaged on the removal of the caps (1).]
35. Remove reading light (2).
36. Remove felt strips covering riveted joint (4). Drill out riveted joints (4) on both sides.
37. Use front-end hook3370 to pull roller blind guide (3) off front roof reinforcement. [Note: The roller blind guide (3) is bonded to the front roof reinforcement. It is therefore not possible to remove the roller blind guide without damaging it.]
38. Remove any seals/sealant from mounting profiles and bolt heads on both sides.
39. Drill out riveted joints (2) at front and rear of mounting profile (1).
40. Remove bolts (3).
41. Using hot air blowerVAS 1978/14A or hot air blowerV.A.G 1416, heat front and rear sections of mounting profile (1) until light smoke is visible.
42. Use front-end hook3370 to separate the bonded joint at front and rear of mounting profile (lift in direction of (arrow)). Screw bolt (5) into mounting profile (1) for assistance. The roof frame acts as a counter-support for the bolt causing the mounting profile to be raised while the bolt is being screwed in.
43. Completely release mounting profiles on left and right from roof frame, and remove them. [Note: All washers (4) must be removed after the removal of the mounting profiles, and must be bonded to the roof frame again.The bonding surfaces need to be cleaned. Use adhesive sealantD 511 500 A2 for bonding the washers to the roof frame.] [Note: When removing the moulded headliner, either the B-pillar trim or the A-pillar trim may remain installed.]
44. Disconnect battery (does not apply for California Beach models) 27.
45. Remove moulded headliner .
46. Unscrew bolts (4) with retainers (3) from front roof reinforcement (1).
47. Disconnect water drain hoses (arrows) from front roof reinforcement.
48. Disconnect connectors and wiring harnesses (5) and (6) from front roof reinforcement.
49. On vehicles with roof aerial, disconnect connectors.
50. Unscrew bolts (2) from front roof reinforcement (1) from above. Remove any sealant from bolt heads. [Note: The front roof reinforcement is also bonded.Proceed carefully during further removal work in order to avoid damage to the paintwork.A second mechanic is required for further removal of the front roof reinforcement.]
51. ⚠ Make sure to wear safety goggles and leather gloves. — Using hot air blowerVAS 1978/14A or hot air blowerV.A.G 1416, heat front roof reinforcement (1) (starting at rear section) until light smoke is visible. [Note: The smoke is not an indicator for the body adhesive being burnt, but for the separation of the bonded joint from the paintwork structure of the front roof reinforcement.Pay particular attention to hydraulic lines and hydraulic cylinders when applying heat to the roof reinforcement. Make sure these components are not exposed to excessive heat while doing so.]
52. Fit lever-off device(4) onto canopy rail. Using assembly lever(3), carefully lever off front roof reinforcement (1), starting at rear. Screw bolt (2) into front roof reinforcement (1) for assistance. The roof frame acts as a counter-support for the bolt causing the front roof reinforcement to be raised while the bolt is being screwed in.
53. Insert plastic wedges (5) in areas where the roof reinforcement has been levered off already in order to maintain tension so that the roof reinforcement can be released from the vehicle body all round.
54. ⚠ To avoid damage to the vehicle body (dents, in particular), plastic wedges must not be used directly for levering off the front roof reinforcement, but may only be inserted in the areas where the lever-off process has already taken place.Please note that the bonded joint of the front roof reinforcement must not be cut through (using a cutter knife, for example). There is a risk of damage to the hydraulic lines. — After the bonded joint of the front roof reinforcement has been separated all round, remove front roof reinforcement from the vehicle body with the assistance of a second mechanic.
55. Using scraperVAS 5301/21, cut back adhesive residue all round vehicle body.
56. Then, clean front area of vehicle body with cleaning solutionD 009 401 04. [Note: Proceed with caution when cutting back the body adhesive in order to prevent paintwork damage.If paintwork is damaged, paint structure must be restored according to specifications in the Paint Workshop Manual.]
57. Using scraperVAS 5301/21, cut back adhesive residue on rear roof reinforcement (2).
58. Drill out remaining riveted joints (1).
59. Using scraperVAS 5301/21, cut back adhesive residue on mounting profiles (3) and (4). To facilitate the cleaning of the mounting profiles, a cordless screwdriver with wire brush attachment can be used.
60. Then, clean rear roof reinforcement and mounting profiles with cleaning solutionD 009 401 04.

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