Removing front left and front right hinges for pop-up roof, scenario 1 — VW

Removing front left and front right hinges for pop-up roof, scenario 1
Removing
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.
Remove bolt
3
.
Remove cover
1
.
Cut through cable ties
arrows
.
Remove both securing clips
4
.
Remove hydraulic fluid lines
5
from hydraulic cylinder
2
, and seal them immediately.
Unclip and remove
roof hydraulics sender 1
G491
and
roof hydraulics sender 4
G494
6
from hydraulic cylinder.
Remove circlip
3
.
Pull pin
2
out of hinge part
1
.
Unscrew bolts
4
and
5
Remove hinge part
1
with hydraulic cylinder from hinge carrier.
Remove bolts
2
.
Remove hinge parts
1
and
3
from hinge carrier
6
.
Unscrew bolts
4
and
5
Remove hinge carrier
6
from roof frame.
Installing
Install in reverse order, but note the following:
Disconnect hydraulic lines from front roof reinforcement, and carefully route them in mounting profiles. To secure the hydraulic lines in the mounting profiles, a small amount of
adhesive sealant
D 511 500 A2
may be applied.
Apply
adhesive sealant
D 511 500 A2
to all holes in roof frame where bolts of hinge carrier
6
will be inserted.
Fit hinge carrier
6
onto roof frame.
Tighten bolts
4
and
5
.
Fit hinge parts
1
and
3
on hinge carrier
6
.
Tighten bolts
2
.
Note
All holes in hinge carrier
6
must be coated with
adhesive sealant
D 511 500 A2
prior to installation, to ensure that the vehicle interior is sealed properly.
Fit hinge part
1
with hydraulic cylinder onto hinge carrier.
Tighten bolts
4
and
5
.
Insert pin
2
into hinge
1
, and secure hinge parts with circlip
3
.
Fit
roof hydraulics sender 1
G491
and
roof hydraulics sender 4
G494
4
onto hydraulic cylinder, and clip in both senders.
Remove sealing caps from hydraulic lines, and renew seals
2
.
Insert hydraulic lines
1
on front and rear into hydraulic cylinder and secure them with securing clips
3
inserted in direction of
arrow
.
Note
Make sure that wiring harnesses and hydraulic lines
1
are routed as shown in illustration. Pay particular attention to the fact that Hall sender wiring harness is always positioned above hydraulic line.
Secure wiring harnesses and hydraulic lines
1
to hydraulic cylinder by means of cable tie
7
.
Install caps
6
for hydraulic cylinders.
Tighten bolt
5
.
Specified torques
Chapter
“
Assembly overview - pop-up roof
”