Removing and installing pop-up roof drive unit — VW

Removing and installing pop-up roof drive unit
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
Removing
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.
Half-open pop-up roof.
Switch off ignition.
Secure pop-up roof at front to prevent it from dropping.
Remove front interior light
Electrical system
Rep. gr.
96
Lights; Removing and installing front interior light/reading light
.
Remove
operating and display unit for camping equipment
E153
Chapter
.
Remove grab handles from A-pillars
General body repairs, interior
Rep. gr.
68
Equipment; Removing and installing grab handle
.
Remove A-pillar trims
Chapter
.
Remove upper B-pillar trims
Chapter
.
Remove sun visors
General body repairs, interior
Rep. gr.
68
Equipment; Removing and installing sun visor
.
Remove moulded headliner
Chapter
.
Unscrew bolt.
Remove cap
1
.
Unscrew bolts
arrows
.
Release bearing bracket
2
and hydraulic cylinder
3
from bracket.
Loosen securing bolt on outer tab of mounting bracket
arrow
.
Pull out pin
1
.
Loosen securing bolt on inner tab
2
.
Pull out pin.
Remove mounting bracket
3
from bracket.
Remove inner circlip.
Pull out pin
4
.
Unscrew bolts
arrows
.
Remove upper part of mounting
1
.
Unscrew bolts
arrows
from lower part of mounting
1
.
Unscrew 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.
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.
Unscrew bolts
1
and
2
.
Remove
roof hydraulics control unit
J768
3
from bracket in roof.
Note
When disconnecting the connectors on the
roof hydraulics control unit
J768
, the connector with the black housing
1
must be pulled off first.
Unscrew front bolts
arrows
from retaining plate
4
.
Unscrew rear bolts from retaining plate.
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 Nm
Lower part of mounting
5 Nm
Roof hydraulics control unit
3 Nm