Removing and installing drive unit for pop-up roof — VW

Removing and installing drive unit for pop-up roof
Special tools and workshop equipment required
Universal working platform
Torque wrench
V.A.G 1783
The pop-up roof drive unit consists essentially of the following components:
The control unit
The
roof actuation hydraulic pump
V118
Two hydraulic cylinders with
roof hydraulics sender 1
G491
and
roof hydraulics sender 4
G494
Note
The hydraulic pump and the two cylinders are connected by lines. Ensure that the lines never become kinked, squashed or trapped. This will ensure the pop-up roof functions fault free.
A working platform is required for the subsequent work.
Removing
Half-open pop-up roof.
Switch off ignition.
Secure pop-up roof at front to prevent it from dropping.
Remove
interior light switch
E317
Rep. gr.
96
.
Remove
operating and display unit for camping equipment
E153
Chapter
.
Remove A-pillar grab handles
Rep. gr.
68.
.
Remove A-pillar trims
Chapter
.
Remove upper B-pillar trims
Chapter
.
Remove sun visors
Rep. gr.
68
.
Remove moulded headliner
Chapter
.
Remove cap
1
from left hydraulic cylinder (on vehicles as of model year 2010, caps are secured to hydraulic cylinders by means of bolts). Unscrew bolt and remove cap
1
.
Remove 3 screws
arrows
.
Release bearing bracket
2
and hydraulic cylinder
3
from bracket.
Loosen securing bolt
arrow
on outer web of mounting bracket and pull out pin
1
.
Loosen securing screw on inner web
2
and pull out pin.
Remove mounting bracket
3
from bracket.
Remove internal circlip and withdraw pin
4
.
Unscrew 4 bolts
arrows
, and remove upper part of mounting
1
.
Remove 3 front bolts
arrows
from lower part of mounting
1
.
Remove 3 rear bolts
arrows
from lower part of mounting
1
.
Remove lower part of mounting
1
from bracket.
Disconnect supply and return lines from hydraulic cylinder and seal openings.
Remove fitted seals from holes using a blunt hook.
Note
Always use new seals when reinstalling.
Remove Hall sender from hydraulic cylinder.
Note
This concludes the dismantling of the left drive unit.
Follow the procedure described above to remove the right drive unit.
Remove bolts
1
and
2
Remove
roof hydraulics control unit
J768
3
from bracket in roof.
Note
When disconnecting connectors on
roof hydraulics control unit
J768
, connector with black housing
1
must be pulled off first.
Unscrew two front bolts
arrows
from retainer
4
.
Unscrew two rear bolts from retainer.
Remove
convertible roof actuation hydraulic pump
V118
5
from bracket in roof.
Remove drive unit for pop-up roof from vehicle.
Installing
Install in reverse order, but note the following:
Note
Ensure that the lines never become kinked, squashed or trapped. This will ensure the pop-up roof functions fault free.
Specified torques
Component
Specified torque
Mounting bracket and upper part of mounting
8.0 Nm
Lower part of mounting
5.0 Nm
Roof hydraulics control unit
3.0 Nm