Renewing front roof reinforcement — AUDI

🧭 Before you start

Fits: platform code SG

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• Attach front seal (1) using assembly tool T50054(2) (seal is self-adhesive). When doing this, make sure the seal is attached straight.
• After press nuts have been pressed in, they must be bonded/fixed in place all round using 2-component polyurethane adhesiveD 180 KD2 A1.
• Observe the flash-off period of the 2-pack adhesive.
• Use wooden rail (2) (14 mm) to ensure seal (1) is bonded evenly as per dimension (a).
• The hydraulic lines (1) must be routed and secured in exactly the same way and at exact same positions as they were routed and secured when the old component was used.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Place painted front roof reinforcement on clean surface/work plate where it is protected against being scratched.
2. Deburr centring pin (1) of front roof reinforcement.
3. Cut M8 thread (2) for securing front roof reinforcement.
4. On vehicles with roof aerial, drill hole (3), secure roof aerial (6), and route wiring harnesses.
5. Drill holes (4) for manual roof locking mechanism on both sides, and drill another hole for additional 12 V socket U5(5).

6. Rivet bracket for manual roof locking mechanism using pop rivet pliersVAS 5072A.
7. Insert 12 V socket U5(5) into front roof reinforcement, and secure it.
8. Insert nuts (7) for canopy bracket into relevant mountings on front roof reinforcement (arrow), and fix them in position using adhesiveAMV 195 KD1 01. Screw additional bolts into nuts from rear. [Note: The bolts are used to locate the nuts (7) and will be removed after installing the front roof reinforcement.The nuts (7) must be installed under all circumstances, even if there is no canopy fitted in the vehicle. Not installing these nuts means making any canopy retrofitting at a future point impossible.When using a new convertible roof actuation hydraulic pump V118 or roof hydraulics control unit J768, cutting threads is not necessary. The securing bolts for these components are self-locking.When drilling holes in a new part, ensure that all dimensions correspond to those of the old part. If necessary, make drilling templates.] [Note: New seals are supplied in excess length and must therefore be shortened/cut to appropriate length depending on individual requirements.]
9. Attach front seal (1) using assembly tool T50054(2) (seal is self-adhesive). When doing this, make sure the seal is attached straight.
10. Seal nuts of canopy bracket with adhesive sealantD 511 500 A2(6) before inserting the side seal (3).
11. Insert side seal (3) into front roof reinforcement. When doing this, attach seal at the positions indicated (arrows) using adhesiveAMV 195 KD1 01.
12. Use glass/paint primerD 009 200 02 to prime bonding surfaces of press nuts (4), and allow primer to flash off for 10 minutes.
13. Start press nuts (4) by means of bolt (5).
14. Tighten bolt (5). When doing this, the press nut will be pressed into the front roof reinforcement.
15. After press nuts have been pressed in, they must be bonded/fixed in place all round using 2-component polyurethane adhesiveD 180 KD2 A1.
16. After the 2-component polyurethane adhesive has cured, unscrew bolt (5). [Note: Observe the flash-off period of the 2-pack adhesive.]
17. Prime bonding groove of beading strips (1) and mounting edge (2) with glass/paint primerD 009 200 02, and allow primer to flash off for 10 min.
18. Apply adhesive sealantD 511 500 A2 all round in a bead (4) next to mounting edge (2).
19. Apply 2-component polyurethane adhesiveD 180 KD2 A1 in bonding groove of beading strips (1) using hand cartridge gunVAS 5155(3).
20. Fit beading strips (1) onto mounting edge (2), and apply light blows with a plastic hammer to allow the beading strips to settle completely.
21. At positions marked with (arrows), beading strips (1) are fixed in position by means of commercially available screw clamps.
22. After installing beading strips (1), smooth the adhesive sealant bead (4) all round with an appropriate, commercially available smoothing tool. If necessary, apply more adhesive sealant. [Note: Before bonding, clean bonding surface of seal (1) with cleaning solutionD 009 401 04.New seals are supplied in excess length and must therefore be shortened/cut to appropriate length depending on individual requirements.Make sure that the seal (1) is aligned flush with the gutter grommets (3).On California Beach vehicles, openings for hydraulic lines in the gutter grommets (3) are sealed with plugs Electronic Parts Catalogue.]
23. Insert gutter grommet (3) into front roof reinforcement on both sides.
24. Use wooden rail (2) (14 mm) to ensure seal (1) is bonded evenly as per dimension (a).
25. Firmly press on seal (1) using roller T10314.
26. Attach additional protective film (self-adhesive, qty. 2)7H0.853.405(4) to front roof reinforcement making sure it is free of kinks. Cut the ends of the protective film so that they match the contour of the front roof reinforcement.
27. The protective films may overlap in the middle. [Note: If the hydraulic cylinders have not yet been disconnected from the hydraulic lines (see chapter on the removal of front left and front right hinges for pop-up roof ), disconnect them now.The plastic bush (4) is bonded to hydraulic lines (2). The bonded joint determines the correct installation length of the hydraulic lines relative to the hydraulic cylinders.The bonded joint between the hydraulic lines (2) and the plastic bush (4) must not be separated, broken or damaged.During the entire procedure of converting the hydraulic components, it is essential to observe rules for cleanliness and to ensure that the hydraulic lines are not damaged when being installed (2).]
28. Disconnect hydraulic lines (2) together with old gutter grommet (1) from old part.
29. Remove old gutter (3) from old gutter grommet (1).
30. Cut back old gutter grommet (1) until only plastic bush (4) remains.
31. Remove convertible roof actuation hydraulic pump V118(2) and roof hydraulics control unit J768(3) from old part, and install them to new part.
32. The hydraulic lines (1) must be routed and secured in exactly the same way and at exact same positions as they were routed and secured when the old component was used.
33. On both sides, insert hydraulic lines with permanently bonded plastic bush (4) into new gutter grommets (5).
34. Clip roof hydraulics sender 1G491 and roof hydraulics sender 4G494 back onto hydraulic cylinders.
35. Insert hydraulic lines back into hydraulic cylinders using new seals, and secure hydraulic lines with of securing clips.
36. Secure hydraulic cylinders to front roof reinforcement making sure not to damage paintwork.
37. Carefully secure wiring harnesses and hydraulic lines to front roof reinforcement. [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.]
38. Apply several spots of adhesiveAMV 195 KD1 01 to additionally secure gutter grommets (5).
39. Also use adhesiveAMV 195 KD1 01 to secure new water drain hoses (6) to union of gutter grommet (5). To aid installation, commercially available long-nose pliers may be used to "“spread”" new water drain hoses prior to installation.
40. Secure water drain hoses (6) by means of cable tie and retainer (7) to front roof reinforcement. [Note: Proceed very carefully when additionally sealing the gutter grommets in order to prevent ingress of water in future.Factory-provided guide pins are a little bit too short. With longer guide pins (2) screwed in, the front roof reinforcement (with 2-component window adhesive applied) can be guided easier when being fitted to the vehicle body.The guide pins (2) are unscrewed after installing the front roof reinforcement.]
41. On both sides, additionally seal gutter grommet (arrow) with adhesive sealantD 511 500 A2, and spread any excess adhesive sealant.
42. Apply glass/paint primerD 009 200 02(1) all-round to front roof reinforcement, and allow it to flash off for 10 minutes.
43. To aid guidance/positioning of front roof reinforcement, screw in self-produced (approx. 50-60 mm long) guide pins/threaded rods (2) at both outer mounting points.

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