Removing and installing sliding sunroof frame

Special tools and workshop equipment required

Double cartridge gun -VAS 5237-

Electric cutter -V.A.G 1561A-

Materials

L-shaped blade, 19 mm -V.A.G 1561/21-

2-component glass adhesive		→ Remark1 → Remark2 → Remark4
Activator		→ Remark1
Glass and paint primer		→ Remark1
Cleaning solution		→ Remark1
Applicator		→ Remark1
Adhesive remover		→ Remark1
Cutting cord		357 853 999

1 Observe manufacturer's instructions enclosed in the packaging. 2 Observe minimum curing period. 3 Double cartridge gun -VAS 5237- must be used to apply these materials. Removing

• Remove glass panel → Chapter.
• Remove moulded headliner → General body repairs, interior; Rep. gr.70.
• Remove front trim → Chapter.
• Use masking tape to cover roof rail and edge of roof -3- in order to protect paintwork.
• Stick electric cutter -V.A.G 1561A- with L-shaped 19 mm blade -V.A.G 1561/21- into rear adhesive bead -2- and cut through bead.

Note

In the middle at the rear, there is a centring lug made of plastic.

• Take the cord -357 853 999--2- through under the assembly frame -3-.

The needle -1- from the windscreen removal kit -V.A.G 1755- can be used for this.

• Secure a handle from windscreen removal kit -V.A.G 1755- to each end of the cord.

The cutting of the adhesive bead -2- is only possible with the help of a second mechanic.

• One person pulls from the outside, the other pulls from the inside.

Note

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

Keep the cord close to the assembly frame so that it is not cut by the surrounding edges.

• The adhesive bead -2- must be cut through, starting from the rear -arrow a-, as far as the middle of the roof cross member -3-.
• Move cord to other side.
• The adhesive bond is cut through, starting from the rear -arrow b-, as far as the roof cross member.
• Remove assembly frame -3-.

Note

• The exact position of the adhesive bead on the new assembly frame must taken from the adhesive bead on the removed assembly frame.

• The position of the adhesive bead on the metal flange must also be the same if a new roof is fitted.

Installing Minimum curing period WARNING Special standards must be adhered to when replacing bonded assembly frame One of these standards is, for example, that a freshly bonded assembly frame 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. For 2-component glass adhesive the minimum curing period is 2 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). Preparing body flange for bonding

Cut back remaining material on body flange with U-shaped blade -V.A.G 1561/3-, but do not remove completely. Note Remaining material serves as adhesion base for newly applied adhesive sealing compound. Keep dirt and grease off of bonding surfaces. WARNING Activator must not have contact with paint or the paintwork will be damaged. Exception: If bonding is not performed immediately after cutting back, the remaining residual material must be activated with activator. If the window flange has been repaired or partially renewed, the area concerned must be cleaned and primed again after painting. Installation instructions

Apply adhesive sealing material in continuous bead, holding applicator at right angle to frame. WARNING Frame 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 frame into aperture, align and press in onto 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. WARNING When cleaning freshly installed glass from the inside in the vehicle, do not press assembly frame outwards. 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.

Note

If the assembly frame is new, the trim has already been glued in.

If a frame is to be re-used, the residual material serves as the adhesion base for the new adhesive sealant to be applied.

Cut adhesive sealing material back to 1 mm just before gluing in again to ensure that the primer is not damaged.

WARNING Do not prime bonding surface for adhesive bead and do not treat it with a cleaning solution. Keep bonding surface free of dirt and grease.

Exception: If bonding is not performed immediately after cutting back, the remaining residual material must be activated with activator D 181 801 A1.

Work to be carried out for a new frame:

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

Work to be carried out for all frames:

• Fit glass panel -1- into frame -4-.
• Check number of -3- vertical stops.
• Apply 2-component glass adhesive. Dimensions for adhesive bead -5-: width = 12 mm; height = 10 mm

WARNING Frame must be installed within 10 minutes after adhesive has been applied, otherwise the adhesive properties of the adhesive sealing compound will be impaired.

Note

Install glass panel -1- in assembly frame before installing assembly frame.

• Insert frame together with glass panel into roof aperture.

New frame

• The centring lug -3- aligns frame within aperture.
• Press frame downwards as far as the stops, check height setting in relation to roof → Chapter.

Existing frame

• As the centring lug no longer exists, the frame is aligned in relation to the roof aperture -2-.
• Press frame downwards as far as the stops, check height setting in relation to roof → Chapter.
• Observe minimum curing period → Anchor.