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

Scraping blade -V.A.G 1561/20

Cartridge gun -V.A.G 1628

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:

Safety precautions when working on the cooling system
Risk of scalding by hot coolant When the engine is warm, the cooling system is under pressure. Danger of scalding due to steam and hot coolant. – Always wear safety gloves. – Always wear safety goggles. – ...

Checklist
Using seat belts : Check the condition of all seat belts regularly. Keep the seat belts clean. Never let any foreign bodies and liquids get on to the seat belt, the latch plate or into the slot for the seat belt buckle. Do not trap or damage the seat belt and latc ...

Aquaplus system (pearlescent and heliochrome)
Designation: Pearlescent waterborne base coat -LPW 040 ...- Heliochrome waterborne base coat -LHW 046 ...- Pearlescent waterborne mixing paint -LWM 076 ...- Issued 11.2 ...