Removing front left and front right hinges for pop-up roof, scenario 2 — VW

Removing front left and front right hinges for pop-up roof, scenario 2
Removing
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.
Unscrew bolts
2
.
Unscrew bolts
1
and
4
from mounting bracket
3
.
Note
Removing the pin
6
separates the piston rod of the hydraulic cylinder
5
from the hinge unit
1
.
Remove circlip
2
.
Slightly raise hinge unit
1
, mounting bracket
3
and hydraulic cylinder
5
.
Pull out pin
6
.
Remove plastic washers
7
.
Remove hinge unit
1
.
Pull locking pin
4
of hydraulic cylinder
5
out of mounting bracket
3
.
Remove mounting bracket
3
.
Remove bolts
2
.
Remove hinge units
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 together with hydraulic cylinder from front roof reinforcement, and carefully route hydraulic lines 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.
Insert locking pin
4
for connecting hydraulic cylinder
5
to mounting bracket
3
.
Use
lithium grease
G 052 150 A2
to locate plastic washers
7
on hinge unit
1
.
Insert pin
6
.
Secure hinge unit
1
using circlip
2
.
Fit hinge unit
1
, mounting bracket
3
and hydraulic cylinder
5
on hinge carrier.
Secure mounting bracket
3
by tightening bolts
1
and
4
.
Tighten securing bolts
2
.
Secure wiring harnesses and hydraulic lines to hydraulic cylinder by means of cable tie.
Install caps for hydraulic cylinders.
Specified torques
Chapter
“
Assembly overview - pop-up roof
”