Removing and installing front trim for sliding sunroof

Special tools and workshop equipment required

Cartridge gun -V.A.G 1628- Electric cutter -V.A.G 1561A-

Saw blade, 63 mm in diameter -V.A.G 1561/25-

Wire reel -VAS 6452/1- Materials

1-component assembly adhesive		→ Remark1 → Remark2
Glass and paint primer		→ Remark1
Cleaning solution		→ Remark1
Applicator		→ Remark1
Adhesive remover		→ Remark1
Cutting cord

1 Observe manufacturer's instructions enclosed in the packaging. 2 Observe minimum curing period → Anchor. Removing Note The front trim is damaged when it is removed and cannot be reused. Protect any surrounding components against damage. The glass panel is not to be removed. The installation position of the glass panel is required as a reference for determining the height when installing the front trim.

• Pull seal off front trim -1-.
• If fitted, bond windscreen seal to windscreen, and press it on firmly.
• Mark a line along the entire length of the trim at a distance -b- = 10 mm from the front edge.
• Mark a line on both sides at a distance -a- = 30 mm from the rear edge.

Caution Due to the small clearance between the front trim and the frame, only make a cut with a max. depth of 5 mm.

• Using electric cutter -V.A.G 1561A- and saw blade, 63 mm in diameter -V.A.G 1561/25-, separate the front trim along the markings -3 and 5-.
• Make a cut with a width of approx. 5 mm along line -4- on left and right to allow for inserting cutting cord.
• With front trim edges removed, the adhesive beads of the trim are accessible.

Seal -4- has been pulled off.

• Insert cutting cord -1- all round on one side, and secure it to wire reel -VAS 6452/1-.
• Cut through adhesive bead -3-, and remove part of front trim -2-.
• Fit wire reel -VAS 6452/1- on other side, and repeat the procedure.

• Secure a handle -1- from window removal kit -V.A.G 1755- to each end of cord -2-.

The cutting of the adhesive bead is only possible with the help of a second mechanic. Note

• There are 3 adhesive beads on the roof cross member and increased resistance will be encountered here.

• Pull on cutting cord -arrow- evenly like using a saw.

• Now, cut through adhesive beads -5- on roof cross member at front as far as the middle -3- on one side.
• Then, cut through adhesive beads as far as the middle -3- on the other side.
• Remove front trim -4-.

Note The exact positions of the adhesive beads of the piece of front trim cut out must be used for the new trim.

Installing Minimum curing period WARNING Special standards must be adhered to when replacing bonded front trims. One of these standards is, for example, that a freshly bonded front trim must comply with the safety requirements, even in an accident, following the minimum prescribed curing period. It is safe to use vehicle only after the curing period is completed. Observe minimum curing period. The minimum curing period for the 1-component adhesive is 3 hours. The minimum curing period is the time from bonding until the vehicle can be used. During this time, the vehicle must stand on a level surface at room temperature (at least 15 °C). Installation instructions Apply adhesive sealing material in continuous bead, holding applicator at right angle to front trim. WARNING Front trim must be installed within 10 minutes, or adhesive properties of glass adhesive will be impaired. Adhesive bead should not be applied too thick and frame should not be pressed too forcibly on body flange. Fit front trim into aperture, align it, and press it in as far as spacer rib. Touching up paint damage If paintwork is damaged, paint structure must be restored according to specifications in “Paint” workshop manual. Cleaning off excess adhesive sealing material Use adhesive remover as a cleaning solution. Observe the appropriate safety precautions when performing this work. First clean painted surface as well as possible using a dry cloth. Remove residue using adhesive remover. Cleaning plastic trim: allow adhesive sealant to cure (approx. one hour) and then peel off.

WARNING Only use the adhesive indicated in the → Electronic Parts Catalogue (ETKA)“ETKA” as it matches the elasticity of the trim. The minimum curing time until the vehicle can be operated safely is 3 hours.

l	The glass panel has been built into the frame.

• Slightly roughen the bonding surface with fine emery paper.
• Clean around bonding surface -2- thoroughly, using cleaning solution.
• Now apply glass and paint primer evenly in one stroke using applicator.
• Drying time for glass/paint primer is 10 minutes.
• Apply 1-component adhesive.

Width of adhesive bead: 8 mm.

Height of adhesive bead: 12 mm.

• Insert trim into roof aperture and centre it. Fix in place with adhesive tape.
• Observe minimum curing period → Anchor.