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Volkswagen Golf Service & Repair Manual: Installing roof reinforcement to body, estate without sliding sunroof

Volkswagen Golf Service & Repair Manual / General body repairs, interior / Trim, noise insulation / Roof trims / Installing roof reinforcement to body, estate without sliding sunroof

Special tools and workshop equipment required
   
   

Electric cutter -V.A.G 1561A
Electric cutter -V.A.G 1561A

   

Scraping blade -V.A.G 1561/20
Scraping blade -V.A.G 1561/20

   

Cartridge gun -V.A.G 1628
Cartridge gun -V.A.G 1628

   

Release lever -T10039
Release lever -T10039

Removing
–  Remove moulded headliner → Chapter.
–  Cut roof reinforcements -1- and -2- into approx. 6 cm wide strips -3--dot-dash lines-, using a cutter knife.
–  Pull strips -3- from roof.
–  Trim back adhesive residues with electric cutter -V.A.G 1561A- and scraping blade -V.A.G 1561/20-.
  Note
If the paint structure has been damaged on removal of roof reinforcements, repair paint damage according to guidelines of → Paint workshop manual.
Installing
  Note
Observe adhesive processing instructions when installing the roof reinforcement.
 

Installing roof reinforcement to body, estate without sliding sunroof

–  Use hand-cartridge gun -V.A.G 1628- to apply single-component assembly adhesive ( → Electronic Parts Catalogue) to roof reinforcements. Observe the following dimensions while doing so.
  •   Dimension -a- = 35 mm
  •   Dimension -b- = 31 mm
  •   Dimension -c- = 58 mm
 

Installing roof reinforcement to body, estate without sliding sunroof

–  Measure roof reinforcements -1- and -2- to width and mark centre of both sides.
–  Guide roof reinforcement -1- into vehicle.
–  Position roof reinforcement -1- according to -dimension a- centrally on roof and press it on across entire surface.
Dimension -a- for saloon = 50.5 ± 3 mm from front sheet-metal edge.
Dimension -a- for estate without sliding sunroof = 25 ± 1 mm from front sheet-metal edge.
–  Guide roof reinforcement -2- into vehicle.
–  Position roof reinforcement -2- according to -dimension b- centrally on roof and press it on across entire surface.
Dimension -b- for saloon = 61 ± 3 mm from rear sheet-metal edge.
Dimension -b- for estate without sliding sunroof = 25 ± 1 mm from rear sheet-metal edge.
 

Installing roof reinforcement to body, estate without sliding sunroof

Removing and installing moulded headliner, estate
Special tools and workshop equipment required         Removal lever -80 - 200 &nbs ...

Installing roof reinforcement to body, estate with sliding sunroof
Special tools and workshop equipment required         Electric cutter -V.A.G 1561A ...

Other materials:

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1 -  Windscreen Removing and installing → Chapter 2 -  PUR adhesive sealant Cross section of bead: -width b- = 7 mm, -height a- = 10 mm (including precoating, residual material on window glass and window ...

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