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ACCESSORIES & EQUIPMENT Body Exterior - Cabriolet <meta name="InColGX" content=""> </head> <body bgcolor="white" text="black"> <h1>ACCESSORIES & EQUIPMENT</h1> <h1>Body Exterior - Cabriolet</h1><a name="S16766827952008020700000"></a><h2 class="clsHeadOne">00 - General, Technical Data</h2><a name="S15276143322008020700000"></a><h2 class="clsHeadTwo">Wiring, routing and securing</h2> <p>When loosing or removing and installing hydraulic, pneumatic or electrical lines, draw sketches or take pictures. This ensures installation is the same as the original.</p><a name="S25326414032008020700000"></a><h2 class="clsHeadTwo">Contact corrosion</h2><a name="S29706302512008020700000"></a><h2 class="clsHeadThree">Contact corrosion</h2> <p>Contact corrosion can occur if inappropriate connecting elements (bolts, nuts, washers, etc.) are used.</p> <p>For this reason, only connecting elements with a special surface coating are installed.</p> <p>In addition, rubber or plastic parts and adhesives consist of non-conductive materials.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The use of original replacement parts is recommended, they are tested and are compatible with aluminum.</li> <li>The use of Audi accessories is recommended.</li> <li>Damage via contact corrosion is not covered by warranty!</li> </ul> </td> </tr> </table></span></p><a name="S32222581282008020700000"></a><h2 class="clsHeadOne">50 - Body - Front</h2><a name="S39876801752008020700000"></a><h2 class="clsHeadTwo">Body, front</h2><a name="S26190870382008020700000"></a><h2 class="clsHeadThree">Lock carrier with attachments - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020195" name="S38504532652008020700000">Fig. 1: Lock Carrier With Attachments - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Lock carrier</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S14795057122008020700000">Lock carrier with attachments, removing and installing</a>.</li> </ul> <p>2 - Left engine cover</p> <ul class="clsBULLET"> <li>Model variations</li> </ul> <p>3 - Right engine cover</p> <ul class="clsBULLET"> <li>Model variations</li> </ul> <p>4 - Screw</p> <ul class="clsBULLET"> <li>10 Nm</li> </ul> <p>5 - Screw</p> <ul class="clsBULLET"> <li>50 Nm</li> </ul><a name="S14795057122008020700000"></a><h2 class="clsHeadThree">Lock carrier with attachments, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020195" name="S06759186182008020700000">Fig. 2: Lock Carrier With Attachments Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bumper --> <a class="clsHyperlink" href="#S17178247732008020700000">Front bumper (up to model year 2005), removing and installing</a>.</li> <li>Remove sound insulation --> <a class="clsHyperlink" href="#S40877273142008020700000">Noise insulation panel - assembly overview</a>.</li> <li>Disengage hood lock release --> <a class="clsHyperlink" href="#S37832269632008020700000">Hood cable, removing and installing</a>.</li> <li>Remove engine cover - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">3</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove air duct between lock carrier and air filter at lock carrier.</li> <li>Disconnect electrical connectors.</li> <li>Drain coolant.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020198" name="S40068087852008020700000">Fig. 3: Removing Coolant Hose Connecting Flange Retainer On Top Of Cooler And Connecting Flange</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove coolant hose connecting flange retainer on top of cooler and connecting flange - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020199" name="S17769878782008020700000">Fig. 4: Removing Coolant Hose Connecting Flange Retainer On Bottom Of Cooler And Connecting Flange</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove coolant hose connecting flange retainer on bottom of cooler and connecting flange - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Loosen condenser only from water cooler (do not disconnect any lines).</li> <li>Secure A/C system condenser using wire e.g. to front wheel --> <a class="clsExtHyperlink" id="A00278926_S29600620052008020700000">87 AIR CONDITIONING</a> .</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Do not hang condenser on lines. Condenser lines should not be pinched under any circumstances.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Disconnect hoses to power steering oil cooler.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020200" name="S25413408662008020700000">Fig. 5: Disconnecting Hydraulic Oil Cooler</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove power steering oil cooler --> <a class="clsExtHyperlink" id="A00278916_S32803510402008020700000">48 - STEERING</a> .</li> <li>Disconnect hoses from hydraulic oil line.</li> <li>Unscrew power steering line for power-assisted steering on lock carrier.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The power steering oil cooler line must not be bent under any circumstances.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>For cars with automatic transmission, disconnect lines to ATF-cooler --> <ul class="clsBULLET"> <li>37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V</li> <li><a class="clsExtHyperlink" id="A00278909_S00033401322008020700000">37 CONTROLS, HOUSING</a> for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE</li> <li><a class="clsExtHyperlink" id="A00278910_S25998811452008020700000">37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING</a> for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J</li> </ul> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020201" name="S08117376282008020700000">Fig. 6: Disconnecting Hoses For Charge Air Cooler</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>On vehicles with charge air cooler, loosen bolts on hose clamps - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Disconnect hoses.</li> <li>Remove gasket for left and right front flap at juncture of fender at lock carrier.</li> <li>Remove upper lock carrier bolts.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>A 2nd technician will be needed to hold the lock carrier.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove bolt.</li> <li>Pull lock carrier toward front.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Installation is reverse of removal.</p> <ul class="clsDASH"> <li>Bleed cooling system --> <ul class="clsBULLET"> <li>19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB</li> <li><a class="clsExtHyperlink" id="A00278881_S33573201972008020700000">19 - ENGINE - COOLING SYSTEM</a> for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT</li> <li>19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN</li> <li><a class="clsExtHyperlink" id="A00278883_S41376556702008020700000">19 - ENGINE - COOLING SYSTEM</a> for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH</li> <li><a class="clsExtHyperlink" id="A00278885_S21797592792008020700000">19 - ENGINE - COOLING SYSTEM</a> for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS</li> <li><a class="clsExtHyperlink" id="A00278884_S12212760292008020700000">19 - ENGINE - COOLING SYSTEM</a> for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF</li> </ul> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S26190870382008020700000">Lock carrier with attachments - assembly overview</a>.</p><a name="S33828771242008020700000"></a><h2 class="clsHeadThree">Lock carrier service position</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017313" name="S31306585552008020700000">Fig. 7: Support Tool 3369</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Support Tool 3369</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020195" name="S21240097852008020700000">Fig. 8: Lock Carrier Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bumper --> <a class="clsHyperlink" href="#S17178247732008020700000">Front bumper (up to model year 2005), removing and installing</a>.</li> </ul> <ul class="clsDASH"> <li>Remove engine cover - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">3</span> -.</li> <li>Unscrew intake air duct between lock carrier and air cleaner housing at lock carrier and remove.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020196" name="S19569803882008020700000">Fig. 9: Install Support Tool 3369 At Left/Right</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Install Support Tool 3369 at left and right as shown.</li> <li>Remove bolts - <span class="clsEmphBOLD">5</span> - at left and right.</li> <li>Remove bolts - <span class="clsEmphBOLD">4</span> - and pull lock carrier - <span class="clsEmphBOLD">1</span> - toward front.</li> <li>Pull lock carrier forward until rear hole in lock carrier aligns with front threaded hole in fender flange.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020197" name="S35420289472008020700000">Fig. 10: Securing Lock Carrier At Left/Right With Bolts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Secure lock carrier at left and right with bolts - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsEmphBOLD">Assembly is performed in the reverse order of removal.</span> </p> <p>Tightening torques --> <a class="clsHyperlink" href="#S26190870382008020700000">Lock carrier with attachments - assembly overview</a>.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>After assembly of lock carrier, check headlight positioning and adjust if necessary --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278933_S06026331132008020700000">01 - MAINTENANCE</a> </li> <li><a class="clsExtHyperlink" id="A00278934_S29217532172008020700000">01 - MAINTENANCE</a> for MAINTENANCE PROCEDURES - CABRIOLET</li> </ul> .</li> </ul> </td> </tr> </table></span></p><a name="S35350124982008020700000"></a><h2 class="clsHeadThree">Cowl panel trim, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020469" name="S09694337892008020700000">Fig. 11: Cowl Panel Trim Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Cowl panel trim</p> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Removing:</span> </li> </ul> <ul class="clsDASH"> <li>Remove wiper arms --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278929_S20032899222008020700000">92 WINDSHIELD WIPER WASHER SYSTEM</a> </li> <li>92 WINDSHIELD WIPER & WASHER SYSTEM for ELECTRICAL EQUIPMENT, CABRIOLET</li> </ul> .</li> <li>Remove plenum chamber cover.</li> <li>Remove securing pins</li> <li>Remove trim from retaining strip at windshield, bottom.</li> </ul> <ul class="clsDASH"> <li>Remove trim upward.</li> </ul> <ul class="clsBULLET"> <li>When installing, make sure that the trim engages completely into retaining strip.</li> </ul> <p>2 - Support</p> <p>3 - Windshield</p> <p>4 - Securing pin</p> <p>5 - Plenum chamber cover</p> <p>6 - Gasket</p><a name="S37431863912008020700000"></a><h2 class="clsHeadThree">Engine compartment covers</h2> <p><span class="clsEmphBOLD">Model variations</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020470" name="S11211179922008020700000">Fig. 12: Engine Compartment Covers</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Right engine compartment cover</p> <p>2 - Toggle bolt</p> <p>3 - Brake line bracket</p> <p>4 - Left engine compartment cover</p> <p>5 - Ball stud</p> <p>6 - Coolant reservoir</p> <p>7 - Grommet</p> <p>8 - Bolt</p> <ul class="clsBULLET"> <li>3 Nm</li> </ul> <p>9 - Bolt</p> <ul class="clsBULLET"> <li>9 Nm</li> </ul> <p>10 - Grommet</p><a name="S32874638982008020700000"></a><h2 class="clsHeadThree">Front fender - assembly overview</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Bolts and washers are micro-encapsulated and must be replaced after loosening or after removing the fender.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020471" name="S11314319682008020700000">Fig. 13: Front Fender - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Fender</p> <ul class="clsBULLET"> <li>Remove bumper --> <a class="clsHyperlink" href="#S17178247732008020700000">Front bumper (up to model year 2005), removing and installing</a>.</li> <li>Remove wheel housing liner --> <a class="clsHyperlink" href="#S26809231732008020700000">Front wheel housing liner, removing and installing</a>.</li> <li>Remove end plate <a class="clsHyperlink" href="#S22588397882008040700000">Remove and install end plate</a>.</li> <li>Loosen headlamp --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278929_S38838228742008020700000">94 LIGHTS, SWITCHES - EXTERIOR</a> </li> <li>94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET</li> </ul> .</li> </ul> <ul class="clsBULLET"> <li>Disconnect side blinker electrical connections.</li> </ul> <p>2 - Screw</p> <ul class="clsBULLET"> <li>7 Nm</li> </ul> <p>3 - Screw</p> <ul class="clsBULLET"> <li>10 Nm</li> </ul> <p>4 - Screw</p> <ul class="clsBULLET"> <li>10 Nm</li> </ul> <p>5 - Screw</p> <ul class="clsBULLET"> <li>10 Nm</li> </ul> <p>6 - Bolt</p> <ul class="clsBULLET"> <li>10 Nm</li> </ul> <p>7 - Bracket</p> <ul class="clsBULLET"> <li>Removing and installing <a class="clsHyperlink" href="#S42749743242008040700000">Bracket for fender</a>.</li> </ul> <p>8 - Screw</p> <ul class="clsBULLET"> <li>10 Nm</li> </ul><a name="S42749743242008040700000"></a><h2 class="clsHeadFour">Bracket for fender</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020472" name="S20240202432008020700000">Fig. 14: Bracket For Fender</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Fender removed.</li> </ul> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">2</span> - and remove bracket - <span class="clsEmphBOLD">1</span> -.</li> </ul><a name="S36280809402008040700000"></a><h2 class="clsHeadFour">Fender insulation</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020473" name="S23143200522008020700000">Fig. 15: Fender Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Only installed with 3.0L gasoline engine.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Before installation, break out at EVAP canister perforated line.</li> </ul><a name="S23904931272008040700000"></a><h2 class="clsHeadFour">Left fender seal</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020474" name="S28033644692008020700000">Fig. 16: Left Fender Seal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>A new seal must always be installed after removal.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Seal must be broken out at perforated line before installation.</li> <li>Remove protective adhesive film from seal - <span class="clsEmphBOLD">1</span> - , insert in fender and press on firmly.</li> </ul> <p>2 - Fender seal</p><a name="S41310289682008040700000"></a><h2 class="clsHeadFour">Right fender seal</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020475" name="S30849975672008020700000">Fig. 17: Right Fender Seal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>A new seal must always be installed after removal.</li> <li>Both seals are installed on the right side only on vehicles with diesel engine.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove protective adhesive film from seal - <span class="clsEmphBOLD">1</span> - and insert in fender.</li> </ul> <p>2 - Fender seal</p> <p>3 - Seal connecting piece (only on vehicles with TDI engine)</p><a name="S22588397882008040700000"></a><h2 class="clsHeadFour">Remove and install end plate</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020206" name="S05805332532008020700000">Fig. 18: Remove And Install End Plate</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Front wheel removed.</li> <li>Wheel housing liner removed.</li> </ul> <ul class="clsDASH"> <li>Unscrew bolts - <span class="clsEmphBOLD">1</span> - from expanding clip - <span class="clsEmphBOLD">3</span> - and remove end plate - <span class="clsEmphBOLD">2</span> - from fender - <span class="clsEmphBOLD">4</span> -.</li> </ul> <p>1 - Screw (2 Nm)</p><a name="S40877273142008020700000"></a><h2 class="clsHeadThree">Noise insulation panel - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020207" name="S18643331842008020700000">Fig. 19: Noise Insulation Panel - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Quick release screw</p> <ul class="clsBULLET"> <li>Only loosen these quick release screws for lock carrier service position.</li> <li>Qty. 3</li> </ul> <p>2 - Noise insulation, front</p> <p>3 - Wheel spoiler</p> <p>4 - Quick release screw</p> <ul class="clsBULLET"> <li>Qty. 3</li> </ul> <p>5 - Noise insulation panel rear</p> <ul class="clsBULLET"> <li>Installed only with specific engine versions.</li> </ul> <p>6 - Quick release screw</p> <ul class="clsBULLET"> <li>Qty. 2</li> </ul> <p>7 - Noise insulation mount</p> <ul class="clsBULLET"> <li>Marking (recess) must point to left vehicle side.</li> </ul> <p>8 - Screw</p> <ul class="clsBULLET"> <li>7 Nm</li> <li>Qty. 2</li> </ul> <p>9 - Spring nut</p> <ul class="clsBULLET"> <li>Qty. 3</li> </ul> <p>10 - Spring nut</p> <ul class="clsBULLET"> <li>Qty. 2</li> </ul> <p>11 - Clamping pin</p> <ul class="clsBULLET"> <li>Qty. 6</li> </ul> <p>12 - Wheel housing liner</p> <p>13 - Bumpers</p> <p>14 - Lock carrier with attachments</p><a name="S14248299412008020700000"></a><h2 class="clsHeadOne">55 - Hood, Lids</h2><a name="S21381961692008020700000"></a><h2 class="clsHeadTwo">Hood</h2><a name="S34217012912008020700000"></a><h2 class="clsHeadThree">Hood, removing, installing and adjusting (up to model year 2005)</h2> <p><span class="clsEmphBOLD">Up to model year 2005</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020208" name="S36177453692008020700000">Fig. 20: Hood Remove/Install/Adjusting Components (Up To Model Year 2005)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Hood</p> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Removing:</span> </li> </ul> <ul class="clsDASH"> <li>Disconnect line to windshield washer system and unclip line.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>A 2nd technician is needed to support and raise the hood.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove gas-filled strut from hood --> <a class="clsHyperlink" href="#S31017962782008020700000">Gas-filled strut, removing and installing</a>.</li> <li>Remove bolts.</li> <li>Remove hood.</li> </ul> <ul class="clsBULLET"> <li>Install in reverse sequence.</li> <li>Adjusting:</li> </ul> <ul class="clsDASH"> <li>Align hood between fenders.</li> <li>Adjust height of hood at hood lock --> <a class="clsHyperlink" href="#S37626954592008020700000">Lower portion of hood lock, removing and installing</a>.</li> <li>Hood can be adjusted for height relative to fenders by adjusting buffer stops <a class="clsHyperlink" href="#S38988647142008040700000">Buffer stop for height adjustment</a>.</li> </ul> <p>2 - Hood hinge</p> <p>3 - Screw</p> <ul class="clsBULLET"> <li>21 Nm</li> </ul> <p>4 - Nut</p> <ul class="clsBULLET"> <li>21 Nm</li> </ul> <p>5 - Gas strut</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S31017962782008020700000">Gas-filled strut, removing and installing</a>.</li> </ul><a name="S38988647142008040700000"></a><h2 class="clsHeadFour">Buffer stop for height adjustment</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020476" name="S09431038842008020700000">Fig. 21: Buffer Stop For Height Adjustment</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Buffer stops - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - must make contact lightly against lock carrier when hood is closed.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The buffer stops can be used for adjusting the height of the hood.</li> </ul> </td> </tr> </table></span></p><a name="S30126553192008020700000"></a><h2 class="clsHeadThree">Hood, removing, installing and adjusting (from model year 2006)</h2> <p><span class="clsEmphBOLD">From model year 2006</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020209" name="S00724829082008020700000">Fig. 22: Hood Remove/Install/Adjusting Components (From Model Year 2006)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Hood</p> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Removing:</span> </li> <li>Disconnect line to windshield washer system and unclip line.</li> <li>Second person is required to support and lift hood.</li> <li>Remove gas-filled strut - <span class="clsEmphBOLD">5</span> - from hood - <span class="clsEmphBOLD">1</span> - <a class="clsHyperlink" href="#S40544727622008040700000">Gas-filled strut, removing and installing</a>.</li> </ul> <ul class="clsBULLET"> <li>Remove nuts - <span class="clsEmphBOLD">4</span> -.</li> <li>Remove hood.</li> <li><span class="clsEmphBOLD">Installing:</span> </li> <li>Install in reverse order of removal.</li> </ul> <ul class="clsBULLET"> <li>Adjusting:</li> <li>Align hood - <span class="clsEmphBOLD">1</span> - between fenders.</li> <li>Adjust height of hood at hood lock <a class="clsHyperlink" href="#S02078846072008040700000">Removing and installing lower part of hood lock</a>.</li> </ul> <p>2 - Hood hinge</p> <ul class="clsBULLET"> <li>Hood - <span class="clsEmphBOLD">1</span> - must be removed or propped up securely.</li> <li>To remove, remove bolts - <span class="clsEmphBOLD">3</span> - and nuts - <span class="clsEmphBOLD">4</span> -.</li> </ul> <p>3 - Screw</p> <ul class="clsBULLET"> <li>21 Nm</li> </ul> <p>4 - Nut</p> <ul class="clsBULLET"> <li>21 Nm</li> </ul> <p>5 - Gas strut</p> <ul class="clsBULLET"> <li>Tube of gas-filled strut must be installed on body side</li> </ul><a name="S40544727622008040700000"></a><h2 class="clsHeadFour">Gas-filled strut, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020210" name="S00732060592008020700000">Fig. 23: Gas-Filled Strut, Removing/Installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Support hood or secure it from falling down.</li> <li>Gently lift retaining springs at both ends of gas-filled strut using a screwdriver and unclip gas-filled strut.</li> <li>To install, press gas-filled strut onto ball stud and engage.</li> <li>Install with tube end of strut at body.</li> </ul><a name="S02078846072008040700000"></a><h2 class="clsHeadFour">Removing and installing lower part of hood lock</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020216" name="S25630406692008020700000">Fig. 24: Removing/Installing Lower Part Of Hood Lock</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disengage hood release --> <a class="clsHyperlink" href="#S37832269632008020700000">Hood cable, removing and installing</a>.</li> <li>Remove bolts - <span class="clsEmphBOLD">2</span> - (4x).</li> <li>Remove lower part of lock - <span class="clsEmphBOLD">1</span> -.</li> <li>To adjust hood, move lower section of lock up or down as required.</li> </ul> <p>2 - Screw (14 Nm)</p><a name="S31017962782008020700000"></a><h2 class="clsHeadThree">Gas-filled strut, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020210" name="S37341709032008020700000">Fig. 25: Gas-Filled Strut, Removing/Installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Support hood or secure it from falling down.</li> <li>Gently lift retaining springs - <span class="clsEmphBOLD">arrow</span> - at both ends of gas-filled strut using a screwdriver and unclip gas-filled strut.</li> <li>To install, press gas-filled strut onto ball stud and engage.</li> <li>Install with tube end of strut at body.</li> </ul><a name="S11241587622008040700000"></a><h2 class="clsHeadFour">Gas-filled strut, venting</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003458" name="S05956976482008020700000">Fig. 26: Gas-Filled Strut, Venting</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Clamp only within this area, otherwise accident could occur!</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Clamp gas-filled strut in vice area - <span class="clsEmphBOLD">x</span> - = 50 mm (2 in.).</li> <li>Cover area of sawn portion with a rag to absorb oil spraying out.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Always wear eye protection when performing this procedure.</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Cut through cylinder of gas strut within first third of cylinder s overall length using piston rod end of cylinder as reference point.</li> </ul><a name="S21735855152008020700000"></a><h2 class="clsHeadThree">Radiator grille, removing</h2> <p><span class="clsEmphBOLD">Up to model year 2005</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020477" name="S02252744522008020700000">Fig. 27: Radiator Grille, Removing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">1</span> -.</li> <li>Move decorative grille - <span class="clsEmphBOLD">2</span> - forward slightly and pull up out of bumper cover.</li> </ul><a name="S36148355482008020700000"></a><h2 class="clsHeadThree">Catch hook, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020478" name="S30971262332008020700000">Fig. 28: Catch Hook, Removing/Installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>To remove, remove nuts - <span class="clsEmphBOLD">2</span> - and remove catch hook - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p>2 - Nut (11 Nm)</p><a name="S37626954592008020700000"></a><h2 class="clsHeadThree">Lower portion of hood lock, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020216" name="S19820598932008020700000">Fig. 29: Lower Portion Of Hood Lock, Removing/Installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disengage hood release --> <a class="clsHyperlink" href="#S37832269632008020700000">Hood cable, removing and installing</a>.</li> <li>Remove bolts - <span class="clsEmphBOLD">2</span> - (4x).</li> <li>Remove lower part of lock - <span class="clsEmphBOLD">1</span> -.</li> <li>To adjust hood, move lower section of lock up or down as required.</li> </ul> <p>2 - Screw (14 Nm)</p><a name="S35553886182008020700000"></a><h2 class="clsHeadThree">Front hood seal (up to model year 2005) - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020479" name="S21163840332008020700000">Fig. 30: Front Hood Seal (Up To Model Year 2005) - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Lock carrier seal</p> <ul class="clsBULLET"> <li>Position seal at center on lock carrier (note center marking) and slide onto flange at lock carrier and fender at side.</li> </ul> <p>2 - Plenum chamber seal</p> <ul class="clsBULLET"> <li>Bring molded part - <span class="clsEmphBOLD">arrows</span> - into contact and press seal onto flange from above, working from outside toward inside.</li> </ul> <p>3 - Hood</p> <p>4 - Sealing profile</p> <ul class="clsBULLET"> <li>Self-adhesive.</li> <li>Before installing, adhesion surface must be free of dust and grease.</li> </ul> <p>5 - Fender</p><a name="S18751023442008020700000"></a><h2 class="clsHeadThree">Front hood seal (from model year 2006) - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020220" name="S31125755312008020700000">Fig. 31: Front Hood Seal (From Model Year 2006) - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Gasket for lock carrier</p> <ul class="clsBULLET"> <li>Apply gasket at left and right on foam piece.</li> <li>When doing this, make sure it is applied without gaps.</li> <li>Compress excess length of gasket along lock carrier.</li> </ul> <p>2 - Left sealing profile</p> <ul class="clsBULLET"> <li>Self-adhering, adhesion surfaces must be free of dust and grease.</li> </ul> <p>3 - Gasket for plenum chamber</p> <ul class="clsBULLET"> <li>Apply gasket at left and right on foam piece.</li> <li>When doing this, make sure it is applied without gaps.</li> <li>Compress excess length of gasket along front panel of plenum chamber.</li> </ul><a name="S12443559852008020700000"></a><h2 class="clsHeadThree">Front hood trim, removing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020480" name="S30982236252008020700000">Fig. 32: Front Hood Trim, Removing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Unclip clips - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove cover - <span class="clsEmphBOLD">1</span> -.</li> </ul><a name="S37832269632008020700000"></a><h2 class="clsHeadThree">Hood cable, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020222" name="S02699968132008020700000">Fig. 33: Hood Cable Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Hood cable</p> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Removing:</span> </li> </ul> <ul class="clsDASH"> <li>Remove front wheelhousing liner --> <a class="clsHyperlink" href="#S26809231732008020700000">Front wheel housing liner, removing and installing</a>.</li> <li>Remove storage compartment on drivers side (vehicles with knee bolster or Vehicles without knee bolster): --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S29273609722008020700000">68 - INTERIOR EQUIPMENT</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S31130730172008020700000">68 - INTERIOR EQUIPMENT</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove bolt.</li> <li>Remove retaining clip.</li> </ul> <ul class="clsDASH"> <li>Unclip cable for lower part of hood lock and disengage attachment lug - <span class="clsEmphBOLD">arrow A</span> -.</li> <li>Remove cable from retaining clips opened earlier and pull into wheelhousing toward lock carrier.</li> </ul> <ul class="clsBULLET"> <li>Install in reverse sequence.</li> <li>Bring ball on cable for lower part of hood lock into installation position.</li> </ul> <p>2 - Operating lever</p> <p>3 - Screw</p> <ul class="clsBULLET"> <li>2.4 Nm</li> </ul> <p>4 - Retaining clamp</p> <p>5 - Lower part of hood lock</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S37626954592008020700000">Lower portion of hood lock, removing and installing</a>.</li> <li>Can be used to adjust height of hood.</li> </ul> <p>6 - Retaining clip</p><a name="S29282268432008020700000"></a><h2 class="clsHeadTwo">Convertible top compartment cover</h2><a name="S16471903072008020700000"></a><h2 class="clsHeadThree">Convertible top compartment cover, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020481" name="S05405291962008020700000">Fig. 34: Convertible Top Compartment Cover Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Convertible top compartment cover seal</p> <ul class="clsBULLET"> <li>Begin installation at molded parts.</li> <li>Install molded part along flange toward outside, not from above.</li> <li>Install seal on both sides from inside toward outside.</li> </ul> <p>2 - Hydraulic cylinder</p> <p>3 - Ball head pin</p> <ul class="clsBULLET"> <li>21 Nm</li> </ul> <p>4 - Convertible top compartment cover</p> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Removing:</span> </li> </ul> <ul class="clsDASH"> <li>Disengage push rod from hydraulic cylinders at ball stud.</li> <li>Remove bolts on cover side of hinge <a class="clsHyperlink" href="#S30551434452008040700000">Cover side hinge, removing</a>.</li> <li>Remove convertible top compartment cover.</li> </ul> <p>5 - Screw</p> <ul class="clsBULLET"> <li>8 Nm</li> </ul> <p>6 - Hold-down fastener</p> <ul class="clsBULLET"> <li>Remove convertible top compartment cover insulation.</li> <li>Pull hold-down fastener out sideways and remove.</li> </ul> <p>7 - Screw</p> <ul class="clsBULLET"> <li>21 Nm</li> </ul> <p>8 - Tension plate</p> <ul class="clsBULLET"> <li>Striker pin is aligned to convertible top compartment cover latch.</li> <li>It must align with latch housing on inside.</li> <li>When closed, striker pin must have enough clearance in latch cover opening.</li> </ul> <p>9 - Window</p> <p>10 - Ball head pin</p> <ul class="clsBULLET"> <li>21 Nm</li> </ul><a name="S30551434452008040700000"></a><h2 class="clsHeadFour">Cover side hinge, removing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020482" name="S35624256512008020700000">Fig. 35: Cover Side Hinge, Removing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">2</span> - from convertible top compartment cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p>3 - Hinge</p> <p>4 - Cover cap</p> <p>5 - Cover caps for bolts</p><a name="S37948827612008040700000"></a><h2 class="clsHeadFour">Hinge, removing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020483" name="S23687412362008020700000">Fig. 36: Removing/Installing Bolts & Hinge</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Only remove both outer bolts - <span class="clsEmphBOLD">2</span> - to remove convertible top compartment cover or hinges.</li> <li>Hinge base plate must not be removed.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove lid side hinge - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove cover caps from bolts.</li> <li>Remove bolts - <span class="clsEmphBOLD">2</span> - and remove hinge.</li> </ul> <p>2 - Screw (21 Nm)</p><a name="S18421957742008040700000"></a><h2 class="clsHeadFour">Convertible top compartment cover insulation, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020484" name="S11269138222008020700000">Fig. 37: Convertible Top Compartment Cover Insulation Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove clips - <span class="clsEmphBOLD">1</span> - (Qty. 17) and insulation - <span class="clsEmphBOLD">2</span> - from convertible top compartment cover - <span class="clsEmphBOLD">3</span> -.</li> <li>Install stop buffer - <span class="clsEmphBOLD">4</span> - with 2 mm gap to system.</li> </ul><a name="S14518775342008040700000"></a><h2 class="clsHeadFour">Tension plate, removing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020485" name="S30352129872008020700000">Fig. 38: Tension Plate, Removing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Convertible top compartment cover insulation removed.</li> </ul> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - and remove tension plate - <span class="clsEmphBOLD">3</span> - from convertible top compartment cover.</li> </ul> <p>2 - Window</p><a name="S15916924162008040700000"></a><h2 class="clsHeadFour">Hold-down fastener, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020486" name="S36582191772008020700000">Fig. 39: Hold-Down Fastener Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Convertible top compartment cover insulation removed.</li> </ul> <ul class="clsDASH"> <li>Remove bolt - <span class="clsEmphBOLD">1</span> - , slide hold-down fastener sideways out of convertible top compartment cover and remove.</li> </ul> <p>1 - Screw (8 Nm)</p><a name="S19086164242008040700000"></a><h2 class="clsHeadFour">Convertible top compartment cover seal</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020487" name="S11659371302008020700000">Fig. 40: Convertible Top Compartment Cover Seal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Begin installation at outer molded parts.</li> <li>Slide molded parts on not from above, but rather along flange toward outside.</li> <li>Press sealing profile from above onto body flange.</li> <li>Center any excess length to middle of vehicle.</li> </ul><a name="S38987532232008020700000"></a><h2 class="clsHeadThree">Cover for convertible top compartment cover, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020488" name="S04395487652008020700000">Fig. 41: Cover For Convertible Top Compartment Cover Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Cover for convertible top compartment cover</p> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Removing:</span> </li> </ul> <ul class="clsDASH"> <li>Remove convertible top compartment cover insulation <a class="clsHyperlink" href="#S18421957742008040700000">Convertible top compartment cover insulation, removing and installing</a>.</li> <li>Remove trim.</li> <li>Remove sheet metal screws (Qty. 2) from inner side for securing front side of insulation and remove from convertible top compartment cover.</li> </ul> <p>2 - Trim molding</p> <ul class="clsBULLET"> <li>Remove convertible top compartment cover insulation <a class="clsHyperlink" href="#S18421957742008040700000">Convertible top compartment cover insulation, removing and installing</a>.</li> <li>When installing, maintain tightening torque of 6.5 Nm, otherwise impressions will be visible on the trim.</li> </ul> <p>3 - Convertible top</p> <p>4 - Convertible top compartment cover</p> <p>5 - Screw</p> <ul class="clsBULLET"> <li>6.5 Nm</li> <li>Maintain torque, otherwise impressions will be visible on trim.</li> </ul><a name="S24468005922008020700000"></a><h2 class="clsHeadTwo">Rear lid</h2><a name="S29821906522008020700000"></a><h2 class="clsHeadThree">Rear lid, removing and installing and adjusting</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020489" name="S21684919612008020700000">Fig. 42: Rear Lid Remove/Install/Adjusting Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Rear lid</p> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Removing:</span> </li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>A 2nd technician is needed to support and raise the rear lid.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove rear lid cover.</li> <li>Disconnect electrical connectors and remove from lid.</li> <li>Remove the nuts that connect both lid hinges to rear lid --> <a class="clsHyperlink" href="#S18518726432008020700000">Rear lid hinge, removing and installing</a>.</li> </ul> <ul class="clsBULLET"> <li>Install in reverse sequence.</li> <li>Panel gap dimensions <a class="clsHyperlink" href="#S41034808482008040700000">Panel gap dimensions</a>.</li> </ul> <p>2 - Stop buffer</p> <ul class="clsBULLET"> <li>Adjusting --> <a class="clsHyperlink" href="#S31800423832008020700000">Stop buffer, adjusting</a>.</li> </ul> <p>3 - Gas strut</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S23380017962008020700000">Gas-filled strut, removing and installing</a>.</li> </ul> <p>4 - Rear lid hinge</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S18518726432008020700000">Rear lid hinge, removing and installing</a>.</li> </ul> <p>5 - Striker</p> <ul class="clsBULLET"> <li>Removing and installing <a class="clsHyperlink" href="#S12934654452008040700000">Striker, removing and installing</a>.</li> <li>Adjusting <a class="clsHyperlink" href="#S21087358862008040700000">Rear lid, adjusting</a>.</li> </ul> <p>6 - Nut</p> <ul class="clsBULLET"> <li>8 Nm</li> </ul><a name="S12934654452008040700000"></a><h2 class="clsHeadFour">Striker, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020490" name="S03285053552008020700000">Fig. 43: Striker Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"><a name="S40395306722008040700000"></a><li>Remove trim for rear panel --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove bolts - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p>1 - Screw (21 Nm)</p><a name="S21087358862008040700000"></a><h2 class="clsHeadFour">Rear lid, adjusting</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020225" name="S14755650812008020700000">Fig. 44: Rear Lid Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove trim for rear panel --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The gas-filled struts must be attached before installing a new rear lid.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Loosen bolts - <span class="clsEmphBOLD">1</span> - , it must be possible to slide striker - <span class="clsEmphBOLD">2</span> -.</li> <li>Carefully close rear lid until lid is flush with side panels.</li> <li>Carefully open lid and tighten nuts - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p>2 - Nut (8 Nm)</p><a name="S41034808482008040700000"></a><h2 class="clsHeadFour">Panel gap dimensions</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020491" name="S28237674082008020700000">Fig. 45: Panel Gap Dimensions</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Dimension - <span class="clsEmphBOLD">A</span> - = 4.5 mm ± 0.5 mm.</li> <li>Dimension - <span class="clsEmphBOLD">B</span> - = 3.5 mm ± 0.5 mm.</li> <li>Dimension - <span class="clsEmphBOLD">C</span> - = 3.5 mm ± 0.5 mm.</li> <li>Dimension - <span class="clsEmphBOLD">D</span> - = 4.5 mm ± 0.5 mm.</li> </ul> <ul class="clsBULLET"> <li>Dimension - <span class="clsEmphBOLD">E</span> - = 2.5 mm ± 0.2 mm.</li> <li>Dimension - <span class="clsEmphBOLD">F</span> - = 2.5 mm ± 0.2 mm.</li> <li>Dimension - <span class="clsEmphBOLD">G</span> - = 3.3 mm ± 0.2 mm.</li> <li>Dimension - <span class="clsEmphBOLD">H</span> - = 3.0 mm ± 0.2 mm.</li> </ul><a name="S32353778472008020700000"></a><h2 class="clsHeadThree">Rear lid lock and handle mechanism, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020227" name="S29119367142008020700000">Fig. 46: Rear Lid Lock And Handle Mechanism Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Rear lid lock</p> <ul class="clsBULLET"> <li>To remove, unclip operating rod from swiveling bush and disengage.</li> </ul> <p>2 - Swiveling bush</p> <ul class="clsBULLET"> <li>After installing rear lid lock, engage operating rod and secure.</li> </ul> <p>3 - Nut</p> <ul class="clsBULLET"> <li>8 Nm</li> </ul> <p>4 - Operating rod</p> <p>5 - Release</p> <p>6 - Lock cylinder</p> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Removing:</span> </li> </ul> <ul class="clsDASH"> <li>Disconnect electrical connectors.</li> <li>Disengage release from lock cylinder.</li> <li>Remove bolt.</li> <li>Twist lock cylinder 90°.</li> </ul> <ul class="clsDASH"> <li>Remove lock cylinder from handle mechanism.</li> </ul> <p>7 - Screw</p> <ul class="clsBULLET"> <li>8 Nm</li> </ul> <p>8 - Motor</p> <ul class="clsBULLET"> <li>Country versions</li> </ul> <p>9 - Handle</p> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Removing:</span> </li> </ul> <ul class="clsDASH"> <li>Remove rear lid trim.</li> <li>Remove lock cylinder.</li> <li>Remove bolts.</li> <li>Press in catches - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove grip piece.</li> </ul> <p>10 - Nut</p> <ul class="clsBULLET"> <li>8 Nm</li> </ul><a name="S23380017962008020700000"></a><h2 class="clsHeadThree">Gas-filled strut, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020492" name="S27486408462008020700000">Fig. 47: Gas-Filled Strut Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When removing or installing the gas-filled strut, push back the opened rear lid only slightly so as to avoid damaging components.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Lift retaining springs in succession on both ends using screwdriver and remove gas-filled strut - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <ul class="clsDASH"> <li>Clip in gas-filled strut at bottom first, then at top.</li> <li>Install with tube end of strut at rear lid.</li> </ul><a name="S19269005692008040700000"></a><h2 class="clsHeadFour">Gas-filled strut, venting</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003458" name="S30273449472008020700000">Fig. 48: Gas-Filled Strut, Venting</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Clamp only within this area, otherwise accident could occur!</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Clamp gas-filled strut in vice area - <span class="clsEmphBOLD">x</span> - = 50 mm (2 in.).</li> <li>Cover area of sawn portion with a rag to absorb oil spraying out.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Always wear eye protection when performing this procedure.</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Cut through cylinder of gas strut within first third of cylinders overall length using piston rod end of cylinder as reference point.</li> </ul><a name="S18518726432008020700000"></a><h2 class="clsHeadThree">Rear lid hinge, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020493" name="S10720218012008020700000">Fig. 49: Rear Lid Hinge Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>For easier adjustment of the rear lid hinges, use gradations marked on the hinges.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Loosen nut - <span class="clsEmphBOLD">1</span> -.</li> <li>Unscrew nut - <span class="clsEmphBOLD">2</span> -.</li> <li>Lift off lid from hinge.</li> </ul> <p>3 - Height adjusting screw</p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">4</span> - and - <span class="clsEmphBOLD">6</span> -.</li> <li>Only loosen center bolt - <span class="clsEmphBOLD">5</span> -.</li> <li>Remove hinge - <span class="clsEmphBOLD">7</span> -.</li> </ul> <p>Installation is reverse of removal.</p> <p>1 - Nut (21 Nm)</p> <p>2 - Nut (21 Nm)</p> <p>4 - Screw (21 Nm)</p> <p>5 - Screw (21 Nm)</p> <p>6 - Screw (21 Nm)</p><a name="S06957940592008020700000"></a><h2 class="clsHeadThree">Rear lid seal, installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020494" name="S16342710162008020700000">Fig. 50: Rear Lid Seal, Installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Rear lid seal butt joint - <span class="clsEmphBOLD">item A</span> - must be aligned on left hinge ball socket - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Press seal on.</li> </ul><a name="S31800423832008020700000"></a><h2 class="clsHeadThree">Stop buffer, adjusting</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020234" name="S20100809802008020700000">Fig. 51: Stop Buffer, Adjusting</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Open rear lid.</li> <li>Remove rubber cap.</li> <li>Screw in buffer stops until they reach stop.</li> <li>Unscrew stop again in steps.</li> </ul> <ul class="clsDASH"> <li>Press rubber cap on.</li> </ul> <ul class="clsBULLET"> <li>When adjusted correctly and with lid closed, buffer stops must make contact lightly on luggage compartment edge.</li> </ul><a name="S27445654902008020700000"></a><h2 class="clsHeadTwo">Fuel filler flap</h2><a name="S03820186562008020700000"></a><h2 class="clsHeadThree">Fuel filler flap, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020495" name="S41584659112008020700000">Fig. 52: Fuel Filler Flap Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Screw</p> <ul class="clsBULLET"> <li>1.5 Nm</li> </ul> <p>2 - Fuel filler flap</p> <p>3 - Circlip</p> <ul class="clsBULLET"> <li>Remove before removing filler neck cup.</li> </ul> <p>4 - Filler neck cup</p> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Removing:</span> </li> </ul> <ul class="clsDASH"> <li>Remove securing clip.</li> <li>Raise cup out of opening slightly.</li> <li>Remove drain hose from lower guide piece and completely remove from opening with cup.</li> </ul> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Installing:</span> </li> </ul> <ul class="clsDASH"> <li>Coat cup with lubricant (e.g. soap solution).</li> <li>Slide drain hose into body opening.</li> <li>Press cup completely into opening.</li> <li>Insert circlip.</li> </ul> <ul class="clsDASH"> <li>Insert drain hose into lower guide piece <a class="clsHyperlink" href="#S05067034832008040700000">Insert filler neck cup drain hose into guide piece.</a>.</li> </ul> <ul class="clsBULLET"> <li>Panel gap dimensions <a class="clsHyperlink" href="#S41034808482008040700000">Panel gap dimensions</a>.</li> </ul><a name="S05067034832008040700000"></a><h2 class="clsHeadFour">Insert filler neck cup drain hose into guide piece</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020496" name="S14554731842008020700000">Fig. 53: Insert Filler Neck Cup Drain Hose Into Guide Piece</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rear wheel housing liner bolts in guide piece area.</li> <li>Pull wheel housing liner back slightly and insert drain hose - <span class="clsEmphBOLD">2</span> - for cup - <span class="clsEmphBOLD">1</span> - in bumper guide piece eyelet - <span class="clsEmphBOLD">3</span> -.</li> </ul><a name="S13393199062008020700000"></a><h2 class="clsHeadOne">57 - Front doors, Central locking system</h2><a name="S14541808672008020700000"></a><h2 class="clsHeadTwo">Front door</h2><a name="S28624891982008020700000"></a><h2 class="clsHeadThree">Door, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020497" name="S39229035262008020700000">Fig. 54: Door Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>For various assembly work, the entire door can be completely raise from the door hinges after electrical connectors on lower A-pillar have been disconnected.</li> <li>Adjustments must not be made after installation.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Pull bellows down from A-pillar.</li> <li>Disconnect electrical connectors on bottom of A-pillar.</li> <li>Loosen bolt - <span class="clsEmphBOLD">1</span> - on upper door hinge - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove lower bolt - <span class="clsEmphBOLD">4</span> - on bottom door hinge - <span class="clsEmphBOLD">3</span> -.</li> </ul> <ul class="clsDASH"> <li>Raise door with a second technician.</li> </ul> <p>Installation is reverse of removal.</p> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S30082530532008020700000">Door hinge - assembly overview</a>.</p><a name="S27370049262008020700000"></a><h2 class="clsHeadThree">Window regulator - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020498" name="S11686359362008020700000">Fig. 55: Window Regulator - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Side impact member</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S16669940732008020700000">Side impact absorber, removing and installing</a>.</li> </ul> <p>2 - Front door</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S28624891982008020700000">Door, removing and installing</a>.</li> <li>Adjusting --> <a class="clsHyperlink" href="#S22820841662008020700000">Front door, adjusting</a>.</li> <li>Panel gap dimensions <a class="clsHyperlink" href="#S37906779272008040700000">Panel gap dimensions</a>.</li> </ul> <p>3 - Screw</p> <ul class="clsBULLET"> <li>8 Nm</li> <li>Qty. 2</li> </ul> <p>4 - Screw</p> <ul class="clsBULLET"> <li>For impact member</li> <li>30 Nm</li> </ul> <p>5 - Nut</p> <ul class="clsBULLET"> <li>For window regulator</li> <li>8 Nm</li> </ul> <p>6 - Screw</p> <ul class="clsBULLET"> <li>4 Nm</li> <li>3x</li> </ul> <p>7 - Window regulator motor</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S25747154852008020700000">Motor for window regulator, removing and installing</a>.</li> </ul> <p>8 - Window regulator</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S22603625532008020700000">Window regulator, removing and installing</a>.</li> <li>Basic setting --> <a class="clsHyperlink" href="#S12561667862008020700000">Window regulator, basic setting</a>.</li> </ul> <p>9 - Nut</p> <ul class="clsBULLET"> <li>For window regulator</li> <li>8 Nm</li> </ul> <p>10 - Screw</p> <ul class="clsBULLET"> <li>For impact member</li> <li>30 Nm</li> </ul> <p>11 - Nut</p> <ul class="clsBULLET"> <li>For window regulator</li> <li>8 Nm</li> </ul><a name="S22603625532008020700000"></a><h2 class="clsHeadThree">Window regulator, removing and installing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Position of adjusting screws and nuts should be marked before loosening.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove door trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Mark position of screws and nuts.</li> <li>Run window all the way up.</li> <li>Remove window --> <a class="clsHyperlink" href="#S29494715822008020700000">Door window - assembly overview</a>.</li> </ul> <ul class="clsDASH"> <li>Remove window regulator motor --> <a class="clsHyperlink" href="#S25747154852008020700000">Motor for window regulator, removing and installing</a>.</li> <li>Remove bass speaker.</li> <li>Remove rearview mirror --> <a class="clsHyperlink" href="#S13120415952008020700000">Side mirror, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020499" name="S31107092632008020700000">Fig. 56: Window Regulator, Removing And Installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - , - <span class="clsEmphBOLD">3</span> - and - <span class="clsEmphBOLD">4</span> -.</li> <li>Unclip cables.</li> <li>Tip rear lower linkage - <span class="clsEmphBOLD">5</span> - forward.</li> <li>Tip front upper linkage - <span class="clsEmphBOLD">2</span> - back.</li> </ul> <ul class="clsDASH"> <li>Remove window regulator from door.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Installation is reverse of removal.</p> <ul class="clsDASH"> <li>After installation, perform basic setting --> <a class="clsHyperlink" href="#S12561667862008020700000">Window regulator, basic setting</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S27370049262008020700000">Window regulator - assembly overview</a>.</p><a name="S16669940732008020700000"></a><h2 class="clsHeadThree">Side impact absorber, removing and installing</h2> <ul class="clsDASH"> <li>Remove door trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove window regulator --> <a class="clsHyperlink" href="#S22603625532008020700000">Window regulator, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020500" name="S12318000762008020700000">Fig. 57: Side Impact Absorber, Removing And Installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">4</span> -.</li> <li>Rotate side impact absorber - <span class="clsEmphBOLD">3</span> - 180° and remove it toward rear from door - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p>Installation is performed in the reverse order of removal.</p> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S27370049262008020700000">Window regulator - assembly overview</a>.</p><a name="S12561667862008020700000"></a><h2 class="clsHeadThree">Window regulator, basic setting</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <ul class="clsBULLET"> <li>Caliper</li> <li>Steel ruler</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When removing regulator or working with extreme adjusted values, it is necessary to perform a window regulator basic setting. The door trim, window regulator motor, speaker and door insulation are removed for this --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> </ul> </td> </tr> </table></span></p><a name="S21163363832008040700000"></a><h2 class="clsHeadFour">Window tension, checking</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020501" name="S39532943062008020700000">Fig. 58: Window Tension, Checking</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Close convertible top.</li> </ul> <ul class="clsDASH"> <li>Open door.</li> <li>Raise window (window is in short lift).</li> <li>Close door until upper edge of window touches side window seal - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Measure gap between side window and inner edge of door window with steel ruler.</li> </ul> <ul class="clsBULLET"> <li>Specified dimension - <span class="clsEmphBOLD">a</span> - = 6-8 mm.</li> </ul><a name="S10136688912008040700000"></a><h2 class="clsHeadFour">Window tension, adjusting (rear lifting unit)</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020502" name="S01688587572008020700000">Fig. 59: Window Tension, Adjusting (Rear Lifting Unit)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>To adjust rear lifting unit - <span class="clsEmphBOLD">1</span> - , door does not need to be disassembled.</li> <li>Adjust front lifting unit - <span class="clsEmphBOLD">2</span> - <a class="clsHyperlink" href="#S15269887352008040700000">Adjusting (front lifting unit)</a>.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Raise window (window is in short lift).</li> <li>Remove rubber stops - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Loosen rear lifting unit lower nut through opening - <span class="clsEmphBOLD">1</span> -.</li> <li>Slide lifting unit in elongated hole toward door outer panel as far as stop.</li> </ul> <ul class="clsDASH"> <li>Tighten rear lifting unit and seal opening with rubber plugs.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S27370049262008020700000">Window regulator - assembly overview</a>.</p><a name="S15269887352008040700000"></a><h2 class="clsHeadFour">Adjusting (front lifting unit)</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020503" name="S07020387932008020700000">Fig. 60: Adjusting (Front Lifting Unit)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove window regulator motor, speaker and door insulation --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Raise window (window is in short lift).</li> <li>Remove rubber stops - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Loosen front lifting unit lower nut through opening.</li> </ul> <ul class="clsDASH"> <li>Slide lifting unit in elongated hole until frame aligns with door inner notch.</li> <li>Tighten front lifting unit and seal opening with rubber plugs.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S27370049262008020700000">Window regulator - assembly overview</a>.</p><a name="S38372796062008040700000"></a><h2 class="clsHeadFour">Shaft dimension, checking and adjusting (rear lifting unit)</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020504" name="S32787542002008020700000">Fig. 61: Shaft Dimension, Checking And Adjusting (Rear Lifting Unit)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disengage door trim as shown in illustration.</li> <li>Lay aside door seal - <span class="clsEmphBOLD">1</span> - in B-pillar area.</li> <li>Raise window (window is in short lift).</li> <li>Using a caliper, measure shaft dimension (it must be possible to pull the gap gauge through with firm resistance).</li> </ul> <ul class="clsBULLET"> <li>Shaft dimension - <span class="clsEmphBOLD">a</span> - = 6 mm.</li> </ul> <ul class="clsDASH"> <li>Loosen lock nut - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Adjust shaft dimension by turning threaded pin.</li> <li>Tighten lock nut.</li> </ul> <p>Tightening torques --> <a class="clsHyperlink" href="#S27370049262008020700000">Window regulator - assembly overview</a>.</p><a name="S25747154852008020700000"></a><h2 class="clsHeadThree">Motor for window regulator, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove door trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Motor for window regulator can be removed or installed in every position of motor or side window.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Disconnect electrical connectors.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020258" name="S11403916672008020700000">Fig. 62: Removing Bolts And Motor</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">2</span> - and remove motor - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <ul class="clsDASH"> <li>Ensure threaded pins - <span class="clsEmphBOLD">arrows</span> - are engaged in door inner panel.</li> <li>Slide on window regulator motor - <span class="clsEmphBOLD">1</span> - and secure with bolts - <span class="clsEmphBOLD">2</span> -.</li> <li>Attach electrical connector.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>After installing motor, switch ignition on and off again with wires connected.</li> <li>Then move door window upward to stop and keep pressing switch for window regulator for approx. 2 seconds longer.</li> <li>This position is the base position and the high- and low-running function is activated.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S27370049262008020700000">Window regulator - assembly overview</a>.</p><a name="S29494715822008020700000"></a><h2 class="clsHeadThree">Door window - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020505" name="S00910388372008020700000">Fig. 63: Door Window - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Window regulator</p> <ul class="clsBULLET"> <li>Must not be removed when door window is removed.</li> <li>Basic setting --> <a class="clsHyperlink" href="#S12561667862008020700000">Window regulator, basic setting</a>.</li> </ul> <p>2 - Clamping brackets</p> <ul class="clsBULLET"> <li>With attached bolt.</li> <li>6 Nm</li> </ul> <p>3 - Locking screw</p> <ul class="clsBULLET"> <li>6 Nm</li> </ul> <p>4 - Door window</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S12320001532008020700000">Door window, removing and installing</a>.</li> <li>Adjusting --> <a class="clsHyperlink" href="#S11768195352008020700000">Door window, adjusting</a>.</li> </ul> <p>5 - Fastener</p> <p>6 - Pressure plate</p><a name="S12320001532008020700000"></a><h2 class="clsHeadThree">Door window, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove door trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove inner shaft strip.</li> <li>Run window all the way up.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020506" name="S11684343022008020700000">Fig. 64: Door Window Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Loosen clamping bracket connection - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove bolt - <span class="clsEmphBOLD">2</span> - and remove fastener - <span class="clsEmphBOLD">4</span> - and pressure plate - <span class="clsEmphBOLD">5</span> -.</li> <li>Remove window - <span class="clsEmphBOLD">3</span> - upward.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Installation is reverse of removal.</p> <ul class="clsDASH"> <li>After installing, check window adjustment --> <a class="clsHyperlink" href="#S11768195352008020700000">Door window, adjusting</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S29494715822008020700000">Door window - assembly overview</a>.</p><a name="S11768195352008020700000"></a><h2 class="clsHeadThree">Door window, adjusting</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <ul class="clsBULLET"> <li>Masking tape</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020507" name="S06423814312008020700000">Fig. 65: Window Immersion Depth, Determining</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Window immersion depth, determining</span> </p> <ul class="clsBULLET"> <li>Close convertible top.</li> </ul> <ul class="clsDASH"> <li>Raise window.</li> <li>Tape masking tape - <span class="clsEmphBOLD">arrows</span> - overlapping on window with door open.</li> <li>Close door completely.</li> </ul> <ul class="clsBULLET"> <li>Dimension - <span class="clsEmphBOLD">a</span> - = 80 mm.</li> <li>Dimension - <span class="clsEmphBOLD">b</span> - = 40 mm.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020508" name="S07208216942008020700000">Fig. 66: Identifying Convertible Top Fabric & Applying Marking To Making Tape At Front And Back Directly Below Roof Frame Seal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Raise convertible top fabric - <span class="clsEmphBOLD">1</span> - in place.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Apply a marking - <span class="clsEmphBOLD">arrow</span> - to making tape at front and back directly below roof frame seal.</li> <li>Open door.</li> <li>Measure distance between marking and upper end of window.</li> </ul> <ul class="clsBULLET"> <li>Front immersion depth: max. 5 mm.</li> <li>Rear immersion depth: max. 7 mm.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020509" name="S12371446542008020700000">Fig. 67: Window Immersion Depth, Adjusting</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Window immersion depth, adjusting</span> </p> <ul class="clsDASH"> <li>Lower window.</li> <li>Remove front and rear rubber stops - <span class="clsEmphBOLD">arrow</span> - at bottom of door.</li> <li>Insert a thin 5 mm hex socket head wrench through opening on door.</li> </ul> <ul class="clsBULLET"> <li>Door seal - <span class="clsEmphBOLD">1</span> - does not need to be removed to insert hex socket head wrench.</li> </ul> <ul class="clsDASH"> <li>Adjust front and rear window immersion depth by evenly turning both lifting units.</li> </ul> <ul class="clsBULLET"> <li>Turn right = greater immersion depth.</li> <li>1 turn corresponds to approx. 1.2 mm.</li> </ul> <ul class="clsDASH"> <li>Seal off openings with rubber plugs.</li> <li>Raise window and measure change.</li> <li>Ensure window is parallel to side window, adjust if necessary --> <a class="clsHyperlink" href="#S39891246712008020700000">Side window, adjusting</a>.</li> </ul><a name="S30082530532008020700000"></a><h2 class="clsHeadThree">Door hinge - assembly overview</h2><a name="S23195691282008040700000"></a><h2 class="clsHeadFour">Bottom door hinge</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020510" name="S24288876882008020700000">Fig. 68: Door Hinge - Assembly Overview (Bottom Door Hinge)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Lower A-pillar</p> <p>2 - Screw</p> <ul class="clsBULLET"> <li>32 Nm</li> </ul> <p>3 - Screw</p> <ul class="clsBULLET"> <li>32 Nm</li> <li>Installed from vehicle interior.</li> </ul> <p>4 - Bottom door hinge</p> <ul class="clsBULLET"> <li>Two-part</li> <li>Mark hinge location before removal.</li> </ul> <p>5 - Pop rivet</p> <ul class="clsBULLET"> <li>Qty. 2</li> </ul> <p>6 - Backing</p> <p>7 - Impact member mount</p> <p>8 - Front door</p> <p>9 - Screw</p> <ul class="clsBULLET"> <li>32 Nm</li> </ul><a name="S15372098532008040700000"></a><h2 class="clsHeadFour">Upper door hinge</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020255" name="S12203414442008020700000">Fig. 69: Door Hinge - Assembly Overview (Upper Door Hinge)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ol class="clsARABICNUM"> <li>Bolt (installed from inside of vehicle) (32 Nm)</li> <li>Upper door hinge</li> <li>Cover cap</li> <li>Screw (32 Nm)</li> <li>Screw (32 Nm)</li> </ol><a name="S22820841662008020700000"></a><h2 class="clsHeadThree">Front door, adjusting</h2><a name="S37906779272008040700000"></a><h2 class="clsHeadFour">Panel gap dimensions</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020511" name="S38550790722008020700000">Fig. 70: Panel Gap Dimensions</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Panel gap dimensions can be checked with Adjusting Gauge 3371.</li> <li>Dimension - <span class="clsEmphBOLD">a</span> - = 3.5 mm ± 0.5 mm.</li> <li>Dimension - <span class="clsEmphBOLD">b</span> - = 3.5 mm ± 0.5 mm.</li> <li>Dimension - <span class="clsEmphBOLD">c</span> - = 5.0 mm ± 1 mm.</li> </ul> </td> </tr> </table></span></p><a name="S34144440642008020700000"></a><h2 class="clsHeadThree">Door handle and door lock - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020512" name="S10509740292008020700000">Fig. 71: Door Handle And Door Lock - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Door handle mount</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S02262582202008020700000">Door handle, removing and installing</a>.</li> </ul> <p>2 - Door handle</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S02262582202008020700000">Door handle, removing and installing</a>.</li> </ul> <p>3 - Door handle trim</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S37727371322008020700000">Door handle trim, removing and installing</a>.</li> </ul> <p>4 - Lock cylinder</p> <ul class="clsBULLET"> <li>Assembly overview --> <a class="clsHyperlink" href="#S01627590032008020700000">Lock cylinder - assembly overview</a>.</li> <li>Removing --> <a class="clsHyperlink" href="#S38374488302008020700000">Lock cylinder, removing and installing</a>.</li> </ul> <p>5 - Lock cylinder cover</p> <ul class="clsBULLET"> <li>To remove, remove lock cylinder and unclip cover.</li> </ul> <p>6 - Screw</p> <ul class="clsBULLET"> <li>20 Nm</li> </ul> <p>7 - Operating rod</p> <ul class="clsBULLET"> <li>Clip into door lock <a class="clsHyperlink" href="#S41411052262008040700000">Engaging operating rod in door lock</a></li> </ul> <p>8 - Door lock</p> <ul class="clsBULLET"> <li>Assembly overview up to model year 2005 --> <a class="clsHyperlink" href="#S03005592462008020700000">Door lock (up to model year 2005) - assembly overview</a>.</li> <li>Assembly overview from model year 2006 --> <a class="clsHyperlink" href="#S02709807822008020700000">Door lock (from model year 2006) - assembly overview</a>.</li> <li>Removing, up to model year 2005 --> <a class="clsHyperlink" href="#S03005592462008020700000">Door lock (up to model year 2005) - assembly overview</a>.</li> <li>Removing, from model year 2006 --> <a class="clsHyperlink" href="#S27074575082008020700000">Door lock (from model year 2006), removing and installing</a>.</li> </ul><a name="S01627590032008020700000"></a><h2 class="clsHeadThree">Lock cylinder - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020513" name="S40045341362008020700000">Fig. 72: Lock Cylinder, Lock Cylinder Cover Cap Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Cover cap</p> <ul class="clsBULLET"> <li>Pry out</li> </ul> <p>2 - Securing bracket</p> <ul class="clsBULLET"> <li>Engages in groove on lock cylinder.</li> </ul> <p>3 - Door handle</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S02262582202008020700000">Door handle, removing and installing</a>.</li> </ul> <p>4 - Lock cylinder</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S38374488302008020700000">Lock cylinder, removing and installing</a>.</li> </ul> <p>5 - Lock cylinder cover cap</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S19669326672008020700000">Lock cylinder cover cap, removing and installing</a>.</li> </ul><a name="S38374488302008020700000"></a><h2 class="clsHeadThree">Lock cylinder, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020513" name="S03491928962008020700000">Fig. 73: Lock Cylinder, Lock Cylinder Cover Cap Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Open drivers door and pry out cover cap - <span class="clsEmphBOLD">1</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove bolt - <span class="clsEmphBOLD">arrow</span> - counter-clockwise as far as stop.</li> </ul> <p>This moves the securing clip - <span class="clsEmphBOLD">2</span> - back and releases lock cylinder.</p> <ul class="clsDASH"> <li>Remove lock cylinder - <span class="clsEmphBOLD">4</span> - from door handle.</li> </ul> <p>Installation is reverse of removal.</p><a name="S19669326672008020700000"></a><h2 class="clsHeadThree">Lock cylinder cover cap, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020513" name="S33116173282008020700000">Fig. 74: Lock Cylinder, Lock Cylinder Cover Cap Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove lock cylinder - <span class="clsEmphBOLD">4</span> - --> <a class="clsHyperlink" href="#S38374488302008020700000">Lock cylinder, removing and installing</a>.</li> </ul> <ul class="clsDASH"> <li>Carefully loosen hooks from retainer and remove cover cap sideways toward rear from locking pins.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <ul class="clsDASH"> <li>Insert brace with square hole on pins on housing.</li> <li>Press cover cap onto housing until locking hooks engage.</li> </ul><a name="S02262582202008020700000"></a><h2 class="clsHeadThree">Door handle, removing and installing</h2> <p>Remove door trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020287" name="S15890588072008020700000">Fig. 75: Door Handle Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disengage operating rod - <span class="clsEmphBOLD">3</span> - on clip - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove lock cylinder --> <a class="clsHyperlink" href="#S01627590032008020700000">Lock cylinder - assembly overview</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020514" name="S08590038972008020700000">Fig. 76: Inserting Screwdriver Through Door Plate And Releasing Slider From Door Handle</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Insert screwdriver through door plate and release slider - <span class="clsEmphBOLD">2</span> - in - <span class="clsEmphBOLD">direction of arrow</span> - from door handle - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove door handle.</li> </ul><a name="S37727371322008020700000"></a><h2 class="clsHeadThree">Door handle trim, removing and installing</h2> <p>Remove door handle --> <a class="clsHyperlink" href="#S02262582202008020700000">Door handle, removing and installing</a>.</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020289" name="S15279631132008020700000">Fig. 77: Door Handle Trim Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull door handle - <span class="clsEmphBOLD">1</span> - up and slide retainer - <span class="clsEmphBOLD">3</span> - out lengthwise with a small screwdriver.</li> <li>Unlatch upper trim - <span class="clsEmphBOLD">2</span> - sideways and remove it downward from door handle.</li> </ul> <p>Installation is reverse of removal.</p><a name="S03005592462008020700000"></a><h2 class="clsHeadThree">Door lock (up to model year 2005) - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020290" name="S30143148772008020700000">Fig. 78: Door Lock (Up To Model Year 2005) Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Screw</p> <ul class="clsBULLET"> <li>M8</li> <li>20 Nm</li> </ul> <p>2 - Backing</p> <p>3 - Door lock</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S23815080072008020700000">Door lock (up to model year 2005), removing and installing</a>.</li> </ul> <p>4 - Release lever</p> <p>5 - Inside door release mechanism release</p><a name="S23815080072008020700000"></a><h2 class="clsHeadThree">Door lock (up to model year 2005), removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020290" name="S10318812882008020700000">Fig. 79: Door Lock (Up To Model Year 2005) Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove door trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove door lock cover cap.</li> <li>Remove window regulator rear brace --> <a class="clsHyperlink" href="#S27370049262008020700000">Window regulator - assembly overview</a>.</li> <li>Disconnect electrical harness connector at door lock.</li> </ul> <ul class="clsDASH"> <li>Unclip cable from inside door release mechanism - <span class="clsEmphBOLD">5</span> - on door lock, rotate it 90° and remove it from release lever - <span class="clsEmphBOLD">4</span> -.</li> <li>If the same door lock is installed again, disengage operating rod at door handle.</li> <li>If door lock is replaced, unclip operating rod from door lock at casing <a class="clsHyperlink" href="#S41411052262008040700000">Engaging operating rod in door lock</a>.</li> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - and remove door lock.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Installation is reverse of removal.</p><a name="S41411052262008040700000"></a><h2 class="clsHeadFour">Engaging operating rod in door lock</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020291" name="S22791368482008020700000">Fig. 80: Engaging Operating Rod In Door Lock</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>When installing a new door lock, clip operating rod - <span class="clsEmphBOLD">1</span> - into casing.</li> <li>Move slide - <span class="clsEmphBOLD">2</span> - of casing upward to engage operating rod.</li> <li>Pull securing pin - <span class="clsEmphBOLD">3</span> - out of door lock.</li> </ul> <p>Tightening torques --> <a class="clsHyperlink" href="#S03005592462008020700000">Door lock (up to model year 2005) - assembly overview</a>.</p><a name="S02709807822008020700000"></a><h2 class="clsHeadThree">Door lock (from model year 2006) - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020515" name="S13137022412008020700000">Fig. 81: Door Lock (From Model Year 2006) Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Screw</p> <ul class="clsBULLET"> <li>M8</li> <li>20 Nm</li> </ul> <p>2 - Backing</p> <p>3 - Door lock</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S27074575082008020700000">Door lock (from model year 2006), removing and installing</a>.</li> </ul> <p>4 - Clip</p> <p>5 - Operating rod</p> <p>6 - Release lever</p> <p>7 - Inside door release mechanism release</p><a name="S27074575082008020700000"></a><h2 class="clsHeadThree">Door lock (from model year 2006), removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020515" name="S41419049122008020700000">Fig. 82: Door Lock (From Model Year 2006) Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove door trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove door lock cover cap.</li> <li>Remove window regulator rear brace --> <a class="clsHyperlink" href="#S27370049262008020700000">Window regulator - assembly overview</a>.</li> <li>Disconnect electrical harness connector at door lock.</li> </ul> <ul class="clsDASH"> <li>Disengage operating rod to door handle - <span class="clsEmphBOLD">5</span> - at upper clip - <span class="clsEmphBOLD">4</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If door lock is replaced, operating rod on lock must be adjusted --> <a class="clsHyperlink" href="#S08293194052008020700000">Door lock operating rod (from model year 2006), adjusting</a>.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - and remove door lock - <span class="clsEmphBOLD">3</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020516" name="S32316372142008020700000">Fig. 83: Raising Locking Pin Slightly, Rotating Guide 90° And Removing It Sideways From Door Lock</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Raise locking pin - <span class="clsEmphBOLD">1</span> - slightly, rotate guide - <span class="clsEmphBOLD">2</span> - 90° and remove it sideways from door lock - <span class="clsEmphBOLD">3</span> -.</li> <li>Disengage door inside release mechanism cable at release lever.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Installation is reverse of removal.</p> <p>Tightening torques --> <a class="clsHyperlink" href="#S02709807822008020700000">Door lock (from model year 2006) - assembly overview</a>.</p><a name="S08293194052008020700000"></a><h2 class="clsHeadThree">Door lock operating rod (from model year 2006), adjusting</h2> <p>The door handle is adjusted correctly when it contacts handle molding and can be operated without noticeable play.</p> <ul class="clsBULLET"> <li>Door trim removed.</li> <li>Rear window regulator rail removed.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020517" name="S37546080002008020700000">Fig. 84: Door Lock Operating Rod (From Model Year 2006), Adjusting</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pry out clip - <span class="clsEmphBOLD">1</span> - on opening lever - <span class="clsEmphBOLD">2</span> -.</li> <li>Move operating rod - <span class="clsEmphBOLD">3</span> - and check adjustment.</li> </ul><a name="S40789925682008020700000"></a><h2 class="clsHeadTwo">Rear window regulator</h2><a name="S15550180072008020700000"></a><h2 class="clsHeadThree">Rear window regulator - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020518" name="S31307874732008020700000">Fig. 85: Rear Window Regulator - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Side panel</p> <p>2 - Retaining strip</p> <p>3 - Nuts</p> <ul class="clsBULLET"> <li>8 Nm</li> </ul> <p>4 - Side window</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S30047312062008020700000">Side windows - assembly overview</a>.</li> </ul> <p>5 - Window regulator</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S42117932892008020700000">Rear window regulator, removing and installing</a>.</li> </ul> <p>6 - Adjustment screw</p> <ul class="clsBULLET"> <li>3x</li> <li>20 Nm</li> <li>Side Window Installation Tool V.A.G 1739 is needed for adjusting.</li> <li>Angle of side window can be adjusted using these screws.</li> </ul> <p>7 - Nut</p> <ul class="clsBULLET"> <li>Union nut</li> <li>20 Nm</li> </ul> <p>8 - Screw</p> <ul class="clsBULLET"> <li>Qty. 4</li> <li>8 Nm</li> </ul><a name="S42117932892008020700000"></a><h2 class="clsHeadThree">Rear window regulator, removing and installing</h2> <ul class="clsDASH"> <li>Remove rear side trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020518" name="S37022557592008020700000">Fig. 86: Rear Window Regulator Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove window shaft strips --> <a class="clsHyperlink" href="#S14462019702008020700000">Window shaft strips</a>.</li> </ul> <ul class="clsDASH"> <li>Mark position of nuts - <span class="clsEmphBOLD">3</span> - , adjusting screws - <span class="clsEmphBOLD">6</span> - and bolts - <span class="clsEmphBOLD">8</span> -.</li> <li>Remove nuts - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove bolts - <span class="clsEmphBOLD">8</span> - and remove cover - <span class="clsEmphBOLD">2</span> -.</li> <li>Loosen Convertible Top Control Module J256 on right side of vehicle --> <a class="clsHyperlink" href="#S23783073242008020700000">Convertible Top Control Module J256 , removing</a>.</li> </ul> <ul class="clsDASH"> <li>Loosen nuts - <span class="clsEmphBOLD">7</span> - from adjusting screws - <span class="clsEmphBOLD">5</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The lower nuts - <span class="clsEmphBOLD">6</span> - can remain on the adjusting screws - <span class="clsEmphBOLD">5</span> - , the upper ones must be removed.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Disconnect window regulator motor connector.</li> <li>Remove window regulator - <span class="clsEmphBOLD">5</span> - from side panel - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p>Installation is reverse of removal.</p> <p>Tightening torques --> <a class="clsHyperlink" href="#S15550180072008020700000">Rear window regulator - assembly overview</a>.</p><a name="S30047312062008020700000"></a><h2 class="clsHeadThree">Side windows - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020519" name="S26455352652008020700000">Fig. 87: Side Window Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Angle bracket</p> <p>2 - Spacer discs</p> <ul class="clsBULLET"> <li>Note installation position <a class="clsHyperlink" href="#S12349951862008040700000">Spacer installation location</a>.</li> </ul> <p>3 - Side window</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S22365689822008020700000">Side window, removing and installing</a>.</li> <li>Adjusting --> <a class="clsHyperlink" href="#S39891246712008020700000">Side window, adjusting</a>.</li> </ul> <p>4 - Seal retaining strip</p> <ul class="clsBULLET"> <li>No replacement part.</li> </ul> <p>5 - Gasket</p> <ul class="clsBULLET"> <li>Installing.</li> </ul> <p>6 - Washers</p> <ul class="clsBULLET"> <li>Must engage on angle bracket retaining pins when pressing on.</li> </ul> <p>7 - Window regulator</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S15550180072008020700000">Rear window regulator - assembly overview</a>.</li> </ul> <p>8 - Nut</p> <ul class="clsBULLET"> <li>6 Nm</li> </ul> <p>9 - Window regulator motor</p> <ul class="clsBULLET"> <li>Can be removed and installed with window regulator in any position.</li> <li>When removing, cable tensioner must not be loosened from window regulator.</li> <li>Removing --> <a class="clsHyperlink" href="#S09734910382008020700000">Motor for window regulator, removing and installing</a>.</li> </ul> <p>10 - Screw</p> <ul class="clsBULLET"> <li>4.5 Nm</li> </ul><a name="S12349951862008040700000"></a><h2 class="clsHeadFour">Spacer installation location</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020520" name="S23784730862008020700000">Fig. 88: Spacer Installation Location</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ol class="clsARABICNUM"> <li>Angle bracket</li> <li>Spacer plate</li> <li>Side window</li> <li>Window regulator</li> <li>Spacer plate</li> <li>Nut</li> </ol><a name="S22365689822008020700000"></a><h2 class="clsHeadThree">Side window, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove rear window regulator --> <a class="clsHyperlink" href="#S42117932892008020700000">Rear window regulator, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020519" name="S26319352342008020700000">Fig. 89: Side Window Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Mark position of side window - <span class="clsEmphBOLD">3</span> - to window regulator - <span class="clsEmphBOLD">7</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove nuts - <span class="clsEmphBOLD">8</span> -.</li> <li>Remove side window - <span class="clsEmphBOLD">3</span> - together with angle bracket - <span class="clsEmphBOLD">1</span> - , spacers - <span class="clsEmphBOLD">2</span> - and washers - <span class="clsEmphBOLD">6</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020520" name="S17039283812008020700000">Fig. 90: Spacer Installation Location</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Place spacer - <span class="clsEmphBOLD">2</span> - as shown on angle bracket pins - <span class="clsEmphBOLD">1</span> - and insert pre-assembled side window - <span class="clsEmphBOLD">3</span> - in window regulator - <span class="clsEmphBOLD">4</span> -.</li> <li>Press window - <span class="clsEmphBOLD">5</span> - onto pins from rear side and tighten nut.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020521" name="S42771611352008020700000">Fig. 91: Coating New Side Window Seal With Lubricant & Inserting Upper Seal In Retaining Strip</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Coat new side window seal - <span class="clsEmphBOLD">2</span> - with lubricant (e.g. soap solution).</li> <li>Insert upper seal in retaining strip - <span class="clsEmphBOLD">1</span> - and pull it down.</li> </ul> <ul class="clsBULLET"> <li>Seal must be flush with retaining strip at top.</li> </ul> <p>Further installation is performed in the reverse order of removal.</p> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S30047312062008020700000">Side windows - assembly overview</a>.</p><a name="S09734910382008020700000"></a><h2 class="clsHeadThree">Motor for window regulator, removing and installing</h2> <ul class="clsDASH"> <li>Remove rear side trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020522" name="S42742062252008020700000">Fig. 92: Removing Bolts And Carefully Prying Motor Off Tensioner</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - and carefully pry motor - <span class="clsEmphBOLD">2</span> - off tensioner.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When removing, cable tensioner must not be loosened from window regulator.</li> </ul> </td> </tr> </table></span></p> <p>Installation is reverse of removal.</p> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S30047312062008020700000">Side windows - assembly overview</a>.</p><a name="S39891246712008020700000"></a><h2 class="clsHeadThree">Side window, adjusting</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020523" name="S07143093882008020700000">Fig. 93: Side Window Installation Tool V.A.G 1739</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Side Window Installation Tool V.A.G 1739</li> </ul> <p><span class="clsEmphBOLD">Distinctive features can be:</span> </p> <ul class="clsBULLET"> <li>Low window tension.</li> <li>Wind noise.</li> <li>Window rattles with convertible top open.</li> <li>Window runs poorly into roof frame seal.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020524" name="S01377146932008020700000">Fig. 94: Check Window To See If It Is Parallel</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Check window to see if it is parallel</span> </p> <ul class="clsBULLET"> <li>Close convertible top.</li> </ul> <ul class="clsDASH"> <li>Raise all windows.</li> <li>Close both doors.</li> <li>Using a steel ruler, measure gap dimension between door window and side window.</li> </ul> <ul class="clsBULLET"> <li>Gap must be parallel, dimension - <span class="clsEmphBOLD">a</span> - and dimension - <span class="clsEmphBOLD">b</span> - = 9-10 mm.</li> <li>Deviation from parallel: 0.5 mm.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020525" name="S18684731012008020700000">Fig. 95: Side Window Height And Parallelism, Adjusting</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Side window height and parallelism, adjusting</span> </p> <ul class="clsDASH"> <li>Open convertible top.</li> <li>Remove side panel trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove rear seat bench --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S17706875992008020700000">72 - SEAT - FRAMES</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S17455885962008020700000">72 - SEAT - FRAMES</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove speaker cover and speaker.</li> </ul> <ul class="clsDASH"> <li>Raise all windows.</li> <li>Loosen nuts - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Adjust parallelism or side window height to door window by moving side window.</li> <li>Tighten nuts.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020526" name="S02561307842008020700000">Fig. 96: Side Window Distance, Checking</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Side window distance, checking</span> </p> <ul class="clsDASH"> <li>Open convertible top.</li> <li>Raise side windows.</li> <li>Open both doors.</li> <li>Using a tape measure on inner edge of side windows - <span class="clsEmphBOLD">arrow</span> - , measure distance of side windows to each other.</li> </ul> <ul class="clsBULLET"> <li>Distance - <span class="clsEmphBOLD">a</span> - = 1169 -1171 mm.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Because this measurement cannot determine symmetry to both windows, the window that is still noticeable after all pre-adjustments is adjusted in case of a deviation from the dimension.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020527" name="S31098259762008020700000">Fig. 97: Side Window Distance, Adjusting</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Side window distance, adjusting</span> </p> <ul class="clsDASH"> <li>Remove side panel trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove rear seat bench --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S17706875992008020700000">72 - SEAT - FRAMES</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S17455885962008020700000">72 - SEAT - FRAMES</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove speaker cover and speaker.</li> <li>Loosen nut - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <ul class="clsDASH"> <li>Adjust window angle with Side Window Installation Tool V.A.G 1739 <a class="clsHyperlink" href="#S17409895982008040700000">Angle, adjusting</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020528" name="S21905149402008020700000">Fig. 98: Identifying Window Regulator Can Be Adjusted In Respective By Turning Adjusting Screw In/Out</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The window regulator - <span class="clsEmphBOLD">4</span> - can be adjusted in the respective - <span class="clsEmphBOLD">direction of arrow</span> - by turning adjusting screw - <span class="clsEmphBOLD">2</span> - in or out.</li> <li>Turning right: distance is increased.</li> <li>1 turn corresponds to approx. 2 mm.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Tighten nuts and bolts.</li> </ul> <p>Tightening torques --> <a class="clsHyperlink" href="#S30047312062008020700000">Side windows - assembly overview</a>.</p><a name="S07545716082008020700000"></a><h2 class="clsHeadTwo">Comfort system</h2><a name="S15533558782008020700000"></a><h2 class="clsHeadThree">Component locations</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020529" name="S40127965102008020700000">Fig. 99: Comfort System Component Locations</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Front Passengers Door Control Module J387</p> <ul class="clsBULLET"> <li>Installation location --> <a class="clsHyperlink" href="#S24936781032008040700000">Front Passengers Door Control Module J387</a>.</li> </ul> <p>2 - Radar Interior Monitoring Control Module 2 G305</p> <ul class="clsBULLET"> <li>Installation location --> <a class="clsHyperlink" href="#S14432518842008040700000">Radar Interior Monitoring Control Module 2 G305</a>.</li> </ul> <p>3 - Right Rear Window Regulator Motor V27</p> <ul class="clsBULLET"> <li>Installation location --> <a class="clsHyperlink" href="#S00773379792008040700000">Right Rear Window Regulator Motor V27</a>.</li> </ul> <p>4 - Alarm Horn H12</p> <ul class="clsBULLET"> <li>Installation location --> <a class="clsHyperlink" href="#S41970199792008040700000">Alarm Horn H12</a>.</li> </ul> <p>5 - Motor for fuel tank lid unlock V155</p> <ul class="clsBULLET"> <li>Installation location --> <a class="clsHyperlink" href="#S42791539752008040700000">Motor for fuel tank lid unlock V155</a>.</li> </ul> <p>6 - Motor for rear lid release V139</p> <ul class="clsBULLET"> <li>Installation location --> <a class="clsHyperlink" href="#S04482739322008040700000">Motor for rear lid release V139</a>.</li> </ul> <p>7 - Left Rear Window Regulator Motor V26</p> <ul class="clsBULLET"> <li>Installation location --> <a class="clsHyperlink" href="#S31785927672008040700000">Left Rear Window Regulator Motor V26</a>.</li> </ul> <p>8 - Radar Interior Monitoring Control Module 1 G303</p> <ul class="clsBULLET"> <li>Installation location --> <a class="clsHyperlink" href="#S31184809032008040700000">Radar Interior Monitoring Control Module 1 G303</a>.</li> </ul> <p>9 - Driver s Door Control Module J386</p> <ul class="clsBULLET"> <li>Installation location --> <a class="clsHyperlink" href="#S27707350122008040700000">Drivers Door Control Module J386</a>.</li> </ul> <p>10 - Central control module for comfort system J393</p> <ul class="clsBULLET"> <li>Installation location --> <a class="clsHyperlink" href="#S12445934192008040700000">Central control module for comfort system J393</a>.</li> </ul> <p>11 - Front hood switch F266</p> <ul class="clsBULLET"> <li>Installation location --> <a class="clsHyperlink" href="#S15326593592008040700000">Front hood switch F266</a>.</li> </ul><a name="S24936781032008040700000"></a><h2 class="clsHeadFour">Front Passengers Door Control Module J387</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020530" name="S17308485032008020700000">Fig. 100: Front Passengers Door Control Module J387</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Integrated in window regulator.</li> </ul><a name="S14432518842008040700000"></a><h2 class="clsHeadFour">Radar Interior Monitoring Control Module 2 G305</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020531" name="S38998878212008020700000">Fig. 101: Radar Interior Monitoring Control Module 2 G305</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Between front seats in center console below parking brake lever handle recess.</li> </ul><a name="S00773379792008040700000"></a><h2 class="clsHeadFour">Right Rear Window Regulator Motor V27</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020532" name="S12883832112008020700000">Fig. 102: Right Rear Window Regulator Motor V27</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Right rear behind side trim.</li> </ul><a name="S41970199792008040700000"></a><h2 class="clsHeadFour">Alarm Horn H12</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020533" name="S36424490042008020700000">Fig. 103: Alarm Horn H12</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>In convertible top compartment at right behind side trim.</li> </ul><a name="S42791539752008040700000"></a><h2 class="clsHeadFour">Motor for fuel tank lid unlock V155</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020534" name="S23431703252008020700000">Fig. 104: Motor For Fuel Tank Lid Unlock V155</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>In luggage compartment at right behind side trim.</li> </ul><a name="S04482739322008040700000"></a><h2 class="clsHeadFour">Motor for rear lid release V139</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020535" name="S29743064152008020700000">Fig. 105: Motor For Rear Lid Release V139</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>in luggage compartment on rear lid lock.</li> </ul><a name="S31785927672008040700000"></a><h2 class="clsHeadFour">Left Rear Window Regulator Motor V26</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020536" name="S33762500682008020700000">Fig. 106: Left Rear Window Regulator Motor V26</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Left rear behind side trim.</li> </ul><a name="S31184809032008040700000"></a><h2 class="clsHeadFour">Radar Interior Monitoring Control Module 1 G303</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020537" name="S26505788612008020700000">Fig. 107: Radar Interior Monitoring Control Module 1 G303</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Below rear seat bench.</li> </ul><a name="S27707350122008040700000"></a><h2 class="clsHeadFour">Drivers Door Control Module J386</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020538" name="S35901612802008020700000">Fig. 108: Drivers Door Control Module J386</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Integrated in window regulator.</li> </ul><a name="S12445934192008040700000"></a><h2 class="clsHeadFour">Central control module for comfort system J393</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020539" name="S32747870782008020700000">Fig. 109: Central Control Module For Comfort System J393</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>On left front sill.</li> </ul><a name="S15326593592008040700000"></a><h2 class="clsHeadFour">Front hood switch F266</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020540" name="S38523545782008020700000">Fig. 110: Front Hood Switch F266</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>In lock carrier.</li> </ul><a name="S26912409522008040700000"></a><h2 class="clsHeadFour">Fuel filler flap</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020541" name="S00572050732008020700000">Fig. 111: Fuel Filler Flap Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>5 - Tightening torque: 1.5 Nm</p><a name="S28677494612008020700000"></a><h2 class="clsHeadThree">Fuel Tank Lid Unlock Motor V155, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020542" name="S02218077272008020700000">Fig. 112: Fuel Tank Lid Unlock Motor V155 Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ol class="clsARABICNUM"> <li>Motor for fuel tank lid unlock V155</li> <li>Locking pin</li> <li>Fuel filler flap</li> </ol> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020543" name="S28858953452008020700000">Fig. 113: Loosening Bolts Using Socket Wrench T10010, Sliding Actuator Up And Removing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect electrical connector.</li> <li>Loosen bolts - <span class="clsEmphBOLD">arrows</span> - using Socket Wrench T10010 , slide actuator - <span class="clsEmphBOLD">1</span> - up and remove.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020541" name="S34985981412008020700000">Fig. 114: Fuel Filler Flap Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <ul class="clsDASH"> <li>Before installing actuator, emergency release - <span class="clsEmphBOLD">2</span> - must be slid over the locking pin.</li> <li>Locking pin of actuator must move cleanly into closed fuel filler flap - <span class="clsEmphBOLD">2</span> -.</li> <li>Clip in grommets - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>To remove fuel filler flap, remove bolts - <span class="clsEmphBOLD">5</span> -.</li> <li>Panel gap dimensions <a class="clsHyperlink" href="#S41034808482008040700000">Panel gap dimensions</a>.</li> </ul> </td> </tr> </table></span></p> <p>Tightening torques --> <a class="clsHyperlink" href="#S15533558782008020700000">Component locations</a>.</p><a name="S00114385602008020700000"></a><h2 class="clsHeadOne">61 - Convertible top</h2><a name="S08215229972008020700000"></a><h2 class="clsHeadTwo">Convertible top, servicing</h2><a name="S10977941592008020700000"></a><h2 class="clsHeadThree">Safety precautions</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Observe measures when disconnecting battery --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> </li> <li>27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET</li> </ul> .</td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>The convertible top hydraulic system loses pressure with ignition on 10 minutes after last use.<p>By pressing Convertible Top Operation Switch E137 briefly, the convertible top remains in respective position for another 10 minutes.</p> <p>Secure convertible top mechanism against unintentional folding up and down during all installation work as this can lead to personal injury or vehicle damage.</p> </td> </tr> </table></span></p><a name="S18067049312008020700000"></a><h2 class="clsHeadThree">Rivet connections, loosening</h2> <ul class="clsDASH"> <li>Cover areas that are difficult to reach to protect against shavings.</li> <li>Drill out rivet head.</li> <li>Carefully drive out rivet head using a chisel.</li> <li>Drive rest of rivet out with a punch.</li> </ul> <ul class="clsDASH"> <li>Remove shavings, e.g. with a workshop vacuum.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Drill shavings lead to damage of convertible top parts and vehicle paint.</li> </ul> </td> </tr> </table></span></p><a name="S25617576532008020700000"></a><h2 class="clsHeadThree">Convertible top - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020544" name="S24846198592008020700000">Fig. 115: Convertible Top - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Convertible top</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S26361979072008020700000">Convertible top, removing and installing</a>.</li> </ul> <p>2 - Front roof frame seal</p> <p>3 - Center roof frame seal</p> <p>4 - Bracket/rear roof frame seal</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S07337934352008020700000">Convertible top frame seals - assembly overview</a>.</li> </ul> <p>5 - Convertible top switch unit</p> <p>Consists of:</p> <ul class="clsBULLET"> <li>Convertible Top Closed Position Switch F202 and</li> <li>Convertible Top Open Position Switch F171</li> <li>Removing --> <a class="clsHyperlink" href="#S04690330222008020700000">Convertible top position switch (Convertible Top Open Position Switch F171/Convertible Top Closed Position Switch F202), removing</a>.</li> </ul> <p>6 - Bolts</p> <ul class="clsBULLET"> <li>21 Nm</li> </ul> <p>7 - Convertible top compartment cover</p> <p>8 - Main bracket</p> <p>9 - Bolts</p> <ul class="clsBULLET"> <li>36 Nm</li> </ul> <p>10 - Plastic washers</p> <p>11 - Main hydraulic cylinder retaining bracket</p> <p>12 - Nut</p> <ul class="clsBULLET"> <li>20 Nm</li> </ul><a name="S40475033052008040700000"></a><h2 class="clsHeadFour">Convertible top compartment cover</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020483" name="S26730424572008020700000">Fig. 116: Removing/Installing Bolts & Hinge</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>2 - 21 Nm</p> <p>3 - 21 Nm</p><a name="S26361979072008020700000"></a><h2 class="clsHeadThree">Convertible top, removing and installing</h2> <ul class="clsBULLET"> <li>The convertible top installation is described so that opening or removing the hydraulic system is not necessary.</li> <li>All assembly work is described for the right side of the vehicle and is performed the same or in a similar way on the left side.</li> <li>When installing, ensure convertible top moves easily when closing.</li> <li>When operating convertible top, ensure front and rear windows have lowered at least 50 mm.</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove rear side trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>For easier removal of convertible top, remove convertible top compartment cover.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020545" name="S13000619782008020700000">Fig. 117: Bringing Convertible Top Into Center Position</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Bring convertible top into center position.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020483" name="S29694873762008020700000">Fig. 118: Removing/Installing Bolts & Hinge</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Only remove bolts - <span class="clsEmphBOLD">2</span> - on hinge - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p>Bolt - <span class="clsEmphBOLD">3</span> - must not be removed. That way, no installation work arises when installing convertible top compartment cover.</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020546" name="S21551280682008020700000">Fig. 119: Removing Ball Sockets And Placing Cylinder In Convertible Top Compartment</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Loosen lift cylinder securing springs - <span class="clsEmphBOLD">1</span> - at top of convertible top compartment cover. Remove ball sockets - <span class="clsEmphBOLD">2</span> - and place cylinder in convertible top compartment.</li> <li>Raise convertible top compartment cover.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Protect vehicle from paint damage by using suitable protective covers and fabric reinforced adhesive tape.</td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020547" name="S17105352832008020700000">Fig. 120: Removing Hydraulic Lines And Cylinders From Convertible Top Frame</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Install bracket hydraulic cylinder - <span class="clsEmphBOLD">1</span> - on ball sockets - <span class="clsEmphBOLD">2</span> -.</li> <li>Unclip hydraulic lines from brackets - <span class="clsEmphBOLD">3</span> - (Qty. 6) and loosen cable ties - <span class="clsEmphBOLD">4</span> - (Qty. 2).</li> <li>Remove hydraulic lines and cylinders from convertible top frame and place them in convertible top compartment.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020548" name="S00226220752008020700000">Fig. 121: Disconnecting Connectors At Right In Vehicle</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect connectors - <span class="clsEmphBOLD">arrows</span> - at right in vehicle.</li> <li>Remove convertible top cable from guides and cable ties for body wall and convertible top frame.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>All cable ties that are loosened or cut off when removing convertible top frame should be re-installed in the same places during installation.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Right side of vehicle</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020549" name="S18798181042008020700000">Fig. 122: Removing Convertible Top Switch Unit Bolts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove convertible top switch unit bolts - <span class="clsEmphBOLD">1</span> -. The switch unit consists of Convertible Top Closed Position Switch F202 and Convertible Top Open Position Switch F171.</li> <li>Carefully remove convertible top switch unit from bolting point mounts.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The convertible top should be brought to the appropriate position to remove respective convertible top switch unit bolt.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Continuation for both sides of vehicle</span> </p> <ul class="clsDASH"> <li>Remove main hydraulic cylinder securing pins - <span class="clsEmphBOLD">2</span> -.</li> <li>Loosen nuts on main hydraulic cylinder bracket until they are removed from the center and can be stored in the vehicle.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020550" name="S21335135742008020700000">Fig. 123: Loosening Main Bracket Bolts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Loosen main bracket bolts - <span class="clsEmphBOLD">1</span> - , - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">3</span> - approx. 2 turns.</li> </ul> <ul class="clsBULLET"> <li>Two technicians must balance out the convertible top at the left and right.</li> </ul> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> </ul> <ul class="clsBULLET"> <li>Bolt - <span class="clsEmphBOLD">3</span> - remains as retainer in body wall.</li> </ul> <ul class="clsDASH"> <li>Raise convertible top approx. 20 cm and pull convertible top cable upward out of body.</li> <li>Raise convertible top toward rear over vehicle and out.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Installation is reverse of removal, noting the following:</p> <ul class="clsDASH"> <li>When inserting convertible top frame, ensure hydraulic lines and electrical wires are not damaged.</li> <li>When installing main hydraulic cylinder, ensure plastic washers are inserted in center of main hydraulic cylinder.</li> <li>Adjust door windows --> <a class="clsHyperlink" href="#S29234602252008020700000">Side windows, adjusting</a>.</li> <li>Adjust side window --> <a class="clsHyperlink" href="#S29234602252008020700000">Side windows, adjusting</a>.</li> </ul> <ul class="clsDASH"> <li>Perform function test.</li> <li>With convertible top closed, check whether front and rear windows run into seals when raised.</li> </ul><a name="S39426941022008020700000"></a><h2 class="clsHeadThree">Convertible top lock, removing and installing</h2> <ul class="clsBULLET"> <li>Front rail trim removed.</li> </ul> <ul class="clsDASH"> <li>Mark position of convertible top lock on front rail.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020551" name="S26099847602008020700000">Fig. 124: Removing Wire Bracket Retainer, Pressing Push Rod Off Ball Stud & Removing Bolts And Convertible Top Lock</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove wire bracket retainer and press push rod - <span class="clsEmphBOLD">1</span> - off ball stud.</li> <li>Remove bolts - <span class="clsEmphBOLD">2</span> - and remove convertible top lock.</li> </ul> <p>Installation is reverse of removal.</p> <p><span class="clsEmphBOLD">Tightening torque</span> --> <a class="clsHyperlink" href="#S26779293682008020700000">Attachments - assembly overview</a>.</p><a name="S23671616752008020700000"></a><h2 class="clsHeadThree">Convertible top locks, checking and adjusting</h2> <ul class="clsBULLET"> <li>Front rail trim and cowl panel trim removed.</li> <li>Close convertible top.</li> </ul> <ul class="clsDASH"> <li>Check position of convertible top lock and anchor plate to one another.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020552" name="S37580991592008020700000">Fig. 125: Convertible Top Locks, Checking And Adjusting</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Convertible top lock pins - 1 - must not contact anchor plate - 2 -.</span> </p> <ul class="clsDASH"> <li>If necessary, adjust position of anchor plate - <span class="clsEmphBOLD">2</span> -.</li> <li>Loosen wire bracket retainers and press both push rods - <span class="clsEmphBOLD">3</span> - off ball studs.</li> <li>Check whether convertible top locks have reached their end position by pressing firmly on ball studs - <span class="clsEmphBOLD">4</span> - in closing direction.</li> </ul> <p>The push rods - <span class="clsEmphBOLD">3</span> - must be able to be placed on the ball studs - <span class="clsEmphBOLD">4</span> - in this position.</p> <p><span class="clsEmphBOLD">Convertible top locks and linkages, adjusting</span> </p> <ul class="clsBULLET"> <li>Push rods - <span class="clsEmphBOLD">3</span> - removed from ball studs - <span class="clsEmphBOLD">4</span> - on both sides.</li> </ul> <ul class="clsDASH"> <li>Loosen Convertible Top Locking Motor V223 bolts approximately one turn.</li> <li>On right side of vehicle, place push rod - <span class="clsEmphBOLD">3</span> - on ball stud - <span class="clsEmphBOLD">4</span> -.</li> <li>Tighten Convertible Top Locking Motor V223 bolts.</li> <li>Loosen lock nut - <span class="clsEmphBOLD">5</span> - on left side of vehicle and adjust ball stud by screwing threads in or out.</li> </ul> <ul class="clsDASH"> <li>Adjust ball stud - <span class="clsEmphBOLD">3</span> - so that it can be placed on ball stud - <span class="clsEmphBOLD">4</span> -.</li> <li>Tighten lock nut in this position.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S26779293682008020700000">Attachments - assembly overview</a>.</p><a name="S29234602252008020700000"></a><h2 class="clsHeadThree">Side windows, adjusting</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020523" name="S05628700602008020700000">Fig. 126: Side Window Installation Tool V.A.G 1739</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Side Window Installation Tool V.A.G 1739</li> </ul> <ul class="clsDASH"> <li>Remove side panel trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove front door trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The adjustment steps are described on the rear windows as an example and can be done the same way on the door windows.</li> </ul> </td> </tr> </table></span></p><a name="S17409895982008040700000"></a><h2 class="clsHeadFour">Angle, adjusting</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020553" name="S23057864932008020700000">Fig. 127: Angle, Adjusting</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Using Side Window Installation Tool V.A.G 1739 , loosen lock nuts - <span class="clsEmphBOLD">1</span> - on adjusting collar screws.</li> <li>Adjust angle of inclination by turning hex socket - <span class="clsEmphBOLD">2</span> -.</li> <li>Tighten lock nut.</li> </ul><a name="S14910349052008040700000"></a><h2 class="clsHeadFour">Longitudinal angle and closing height, adjusting</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020554" name="S09462498612008020700000">Fig. 128: Longitudinal Angle And Closing Height, Adjusting</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Loosen bolts - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Slide side window into convertible top seal groove.</li> <li>Tighten screws.</li> </ul><a name="S09071399002008040700000"></a><h2 class="clsHeadFour">Adjustment, checking</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020555" name="S33264383852008020700000">Fig. 129: Adjustment, Checking</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>With convertible top closed, check whether front and rear windows run into seals when raised - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S15550180072008020700000">Rear window regulator - assembly overview</a>.</p><a name="S07337934352008020700000"></a><h2 class="clsHeadThree">Convertible top frame seals - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020556" name="S28477497662008020700000">Fig. 130: Convertible Top Frame Seals - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Front roof frame seal</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S10464931512008020700000">Front roof frame seal, removing and installing</a>.</li> </ul> <p>2 - Screw</p> <ul class="clsBULLET"> <li>5.2 Nm</li> </ul> <p>3 - Center roof frame seal</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S27883171032008020700000">Rear bracket/roof frame seal or center roof frame seal, removing and installing</a>.</li> </ul> <p>4 - Bracket/rear roof frame seal</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S27883171032008020700000">Rear bracket/roof frame seal or center roof frame seal, removing and installing</a>.</li> </ul> <p>5 - Front rail trim</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S30629876452008020700000">Front rail trim, removing and installing</a>.</li> </ul><a name="S10464931512008020700000"></a><h2 class="clsHeadThree">Front roof frame seal, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020557" name="S30232321462008020700000">Fig. 131: Front Roof Frame Seal Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove seal sideways out of seal carrier.</li> <li>Remove retaining strip with seal.</li> </ul> <p>Installation is reverse of removal.</p> <p>Tightening torque --> <a class="clsHyperlink" href="#S07337934352008020700000">Convertible top frame seals - assembly overview</a>.</p><a name="S27883171032008020700000"></a><h2 class="clsHeadThree">Rear bracket/roof frame seal or center roof frame seal, removing and installing</h2> <ul class="clsDASH"> <li>To remove, open convertible top until center roof frame seal and rear roof frame seat do not touch at rear edges.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020558" name="S34588290052008020700000">Fig. 132: Removing Seal From Retaining Track</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove seal from retaining track in - <span class="clsEmphBOLD">direction of arrow</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When installing, ensure seal is positioned exactly in sealing profile.</li> <li>Center roof frame seal, rear roof frame seal and bracket seal are removed in the same way.</li> </ul> </td> </tr> </table></span></p><a name="S30629876452008020700000"></a><h2 class="clsHeadThree">Front rail trim, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020557" name="S21263061262008020700000">Fig. 133: Front Rail Trim Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Carefully remove trim.</li> </ul> <p>Installation is reverse of removal.</p> <p>Tightening torque --> <a class="clsHyperlink" href="#S07337934352008020700000">Convertible top frame seals - assembly overview</a>.</p><a name="S00014563682008020700000"></a><h2 class="clsHeadThree">Convertible top - parts designations</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>These parts designations are used in the description for removal and installation of convertible top headliner, convertible top cover and convertible top upholstery.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020559" name="S23160700852008020700000">Fig. 134: Convertible Top - Parts Designations</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Rail "1"</p> <p>2 - Rail "2"</p> <p>3 - Rail "3"</p> <p>4 - Rail "4"</p> <p>5 - Rail "5"</p> <p>6 - Bracket</p> <p>7 - Center brace</p> <p>8 - Main bracket</p> <p>9 - Main guide</p> <p>10 - Roof guide "2"</p> <p>11 - Roof guide "1"</p> <p>12 - Front rail</p><a name="S38741795132008020700000"></a><h2 class="clsHeadThree">Convertible top headliner - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020560" name="S12365905082008020700000">Fig. 135: Convertible Top Headliner - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Convertible top headliner</p> <p>2 - Plastic profile</p> <p>3 - Plastic profile</p> <p>4 - Zip fastener</p> <p>5 - Rear window frame</p> <p>6 - Tab</p> <p>7 - Rivet</p> <p>8 - Plastic profile</p> <p>9 - Tensioning band 3</p> <p>10 - Strap</p> <p>11 - Tensioning band 2</p> <p>12 - Tensioning band 1</p> <p>13 - Tab</p> <p>14 - Screw</p> <p>15 - Securing profile</p><a name="S21254238112008020700000"></a><h2 class="clsHeadThree">Convertible top headliner, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020561" name="S31007264442008020700000">Fig. 136: Identifying Special Tools - Convertible Top Headliner, Removing And Installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <ul class="clsBULLET"> <li>Closing Pliers VAS 6138</li> <li>Staple Gun VAS 6148 with Replacement Staples F/VAS6148 VAS 6148/1</li> <li>Pop rivet pliers VAS 5072</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Convertible top, parts designations --> <a class="clsHyperlink" href="#S00014563682008020700000">Convertible top - parts designations</a></li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020545" name="S31744241902008020700000">Fig. 137: Bringing Convertible Top Into Center Position</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Bring convertible top into center position.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020557" name="S33988065232008020700000">Fig. 138: Removing Bolts & Retaining Strip With Seal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove seal sideways out of seal carrier.</li> <li>Remove retaining strip - <span class="clsEmphBOLD">1</span> - with seal.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020562" name="S38177553602008020700000">Fig. 139: Removing Bolt & Securing Profile From Rail</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolt - <span class="clsEmphBOLD">A</span> -.</li> <li>Remove securing profile - <span class="clsEmphBOLD">B</span> - from rail - <span class="clsEmphBOLD">C</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The tensioning cable and front strap on convertible top are fastened together with bolt - <span class="clsEmphBOLD">A</span> -.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020563" name="S05314345072008020700000">Fig. 140: Removing Rivet From Eyelet & Rubber Cable From Eyelet On Inner Side Of Roof Guide</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rivet - <span class="clsEmphBOLD">1</span> - from eyelet.</li> <li>Remove rubber cable - <span class="clsEmphBOLD">2</span> - from eyelet - <span class="clsEmphBOLD">3</span> - on inner side of roof guide "2".</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020564" name="S15577865082008020700000">Fig. 141: Disengaging Tensioning Cable From Spring And Pulling Through Eyelet On Rear End Of Roof Guide And Forward</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disengage tensioning cable from spring - <span class="clsEmphBOLD">arrow</span> - and pull through eyelet on rear end of roof guide and forward.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The spring is visible at the rear end of the roof guide "2" when the convertible top is brought into center position.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020565" name="S41605003292008020700000">Fig. 142: Identifying Cable Tie, Tensioning Cable & Rivet</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Loosen cable tie - <span class="clsEmphBOLD">1</span> -.</li> <li>Fold hose back and disengage tensioning cable - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove rivet - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove tensioning bands from sealing element bushings on convertible top frame.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020566" name="S19310724162008020700000">Fig. 143: Loosening Guide Bracket Upper Bolted Connection And Disengage Strap</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Loosen guide bracket upper bolted connection - <span class="clsEmphBOLD">1</span> - and disengage strap - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020567" name="S01417918712008020700000">Fig. 144: Removing Convertible Top Headliner Plastic Strips From Roof Rail</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove convertible top headliner plastic strips from roof rail "2" and "3".</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020568" name="S33715166092008020700000">Fig. 145: Clamping Replacement Staples VAS 6148/1 Onto Ends Of Zip Fasteners</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Clamp Replacement Staples VAS 6148/1 onto ends of zip fasteners - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Pull zip fasteners apart.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Ensure zip fastener is not damaged.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020569" name="S05720582282008020700000">Fig. 146: Drilling Convertible Top Headliner Tab Rivet On Bracket & Removing Convertible Top Headliner Securing Strip From Groove In Bracket</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Drill convertible top headliner tab rivet - <span class="clsEmphBOLD">1</span> - on bracket.</li> <li>Remove convertible top headliner securing strip - <span class="clsEmphBOLD">2</span> - from groove in bracket.</li> <li>Remove convertible top headliner from rear window guide frame. Ensure no clips remain in rear window guide frame.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Replace faulty clips.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020545" name="S26339620232008020700000">Fig. 147: Bringing Convertible Top Into Center Position</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Bring convertible top into center position.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020570" name="S12900281362008020700000">Fig. 148: Checking Whether Clips Are Located Completely In Convertible Top Headliner Frame</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Check whether clips - <span class="clsEmphBOLD">1</span> - are located completely in convertible top headliner frame.</li> <li>Press convertible top headliner frame into rear window frame with wide pliers.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020571" name="S20909570512008020700000">Fig. 149: Ensuring Center Markings Align</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>When closing zip fastener, ensure center markings - <span class="clsEmphBOLD">arrows</span> - align.</li> </ul> <p>The remaining convertible top headliner installation is done in reverse order.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Ensure all convertible top components are positioned and function properly.</li> <li>Perform function test.</li> </ul> </td> </tr> </table></span></p> <p>Tightening torques --> <a class="clsHyperlink" href="#S38741795132008020700000">Convertible top headliner - assembly overview</a> or --> <a class="clsHyperlink" href="#S26779293682008020700000">Attachments - assembly overview</a>.</p><a name="S02902403952008020700000"></a><h2 class="clsHeadThree">Convertible top cover - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020572" name="S04938122742008020700000">Fig. 150: Convertible Top Cover - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Convertible top cover</p> <p>2 - Zip fastener</p> <p>3 - Zip fastener</p> <p>4 - Zip fastener</p> <p>5 - Zip fastener</p> <p>6 - Rear window</p> <p>7 - Plastic profile</p> <p>8 - Rivet</p> <p>9 - Tensioning strap</p> <p>10 - Screw</p> <p>11 - Tab</p> <p>12 - Molding</p> <ul class="clsBULLET"> <li>3-part</li> </ul> <p>13 - Plastic profile</p><a name="S39063620412008020700000"></a><h2 class="clsHeadThree">Convertible top cover, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020561" name="S35824199392008020700000">Fig. 151: Identifying Special Tools - Convertible Top Cover, Removing And Installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <ul class="clsBULLET"> <li>Closing Pliers VAS 6138</li> <li>Staple Gun VAS 6148 with Replacement Staples F/VAS6148 VAS 6148/1</li> <li>Pop rivet pliers VAS 5072</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Convertible top, parts designations --> <a class="clsHyperlink" href="#S00014563682008020700000">Convertible top - parts designations</a></li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020545" name="S08608065222008020700000">Fig. 152: Bringing Convertible Top Into Center Position</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Bring convertible top into center position.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020557" name="S10295139642008020700000">Fig. 153: Removing Bolts For Seal Retaining Strip From Front Rail</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">arrows</span> - for seal retaining strip - <span class="clsEmphBOLD">1</span> - from front rail.</li> <li>Carefully remove front rail trim.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020573" name="S39902287622008020700000">Fig. 154: Removing Convertible Top Headliner Straps On Front Rail</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove convertible top headliner straps - <span class="clsEmphBOLD">1</span> - on front rail.</li> <li>Remove molding band - <span class="clsEmphBOLD">2</span> - and convertible top cover - <span class="clsEmphBOLD">3</span> - from front rail groove.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020574" name="S04797317412008020700000">Fig. 155: Removing Sealant On Front Corners Or Front Rail</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove sealant - <span class="clsEmphBOLD">arrow</span> - on front corners or front rail.</li> <li>Remove convertible top sideways from convertible top frame.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020575" name="S07693236722008020700000">Fig. 156: Removing Tensioning Strap On Roof Guide Between Rail And Rail</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove tensioning strap - <span class="clsEmphBOLD">1</span> - on roof guide between rail - <span class="clsEmphBOLD">3</span> - and rail - <span class="clsEmphBOLD">4</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When installing, ensure tensioning cable - <span class="clsEmphBOLD">2</span> - is not pinched.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020576" name="S39836628312008020700000">Fig. 157: Removing Tensioning Cable From Mounting Hole In Roof Guide</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove tensioning cable - <span class="clsEmphBOLD">1</span> - from mounting hole - <span class="clsEmphBOLD">2</span> - in roof guide - <span class="clsEmphBOLD">1</span> -.</li> <li>Pull tensioning cable back out of convertible top cover canvas pockets.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Use a suitable welding wire when pulling in tensioning cable.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Fold back convertible top cover.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020568" name="S42280139622008020700000">Fig. 158: Clamping Replacement Staples VAS 6148/1 Onto Ends Of Zip Fasteners</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Clamp Replacement Staples VAS 6148/1 onto ends of zip fasteners - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When installing, mark the convertible top cushion where the corresponding center line on the underside of the convertible top cover meets with the cushion. This will ensure exact centering of the top cover during installation</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Pull zip fasteners apart (Qty. 4).</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Ensure zip fastener is not damaged.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020577" name="S29104561772008020700000">Fig. 159: Folding Bracket In Vertical Position (Convertible Top In Center Position) And Removing Bolt</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Fold bracket in vertical position (convertible top in center position) and remove bolt - <span class="clsEmphBOLD">arrow B</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>To provide a better explanation, the adjoining illustration shows the convertible top frame without convertible top headliner, convertible top cover and convertible top upholstery to.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020578" name="S35414477682008020700000">Fig. 160: Removing Washer On Rear Window Cable Guide</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove washer on rear window cable guide and pull cable out of its guide - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020569" name="S09462808342008020700000">Fig. 161: Drilling Convertible Top Headliner Tab Rivet On Bracket & Removing Convertible Top Headliner Securing Strip From Groove In Bracket</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Drill convertible top headliner tab rivet - <span class="clsEmphBOLD">1</span> - on bracket.</li> <li>Remove convertible top headliner securing strip - <span class="clsEmphBOLD">2</span> - from groove in bracket.</li> <li>Remove convertible top headliner from rear window guide frame. Ensure no clips remain in rear window guide frame.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Replace faulty clips.</li> <li>The convertible top headliner is now separated from the convertible top cover (rear window frame).</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020579" name="S41157225632008020700000">Fig. 162: Removing Plastic Profile From Bracket Groove</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove plastic profile - <span class="clsEmphBOLD">1</span> - from bracket groove - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020580" name="S21206458722008020700000">Fig. 163: Cutting Cable Tie & Opening Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Cut cable tie - <span class="clsEmphBOLD">1</span> -.</li> <li>Open housing - <span class="clsEmphBOLD">2</span> - and disconnect rear window defroster electrical connectors.</li> <li>Remove convertible top frame on main guide downward.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Installation of the convertible top cover is the reverse of removal.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Ensure all convertible top components are positioned and function properly.</li> <li>Perform function test.</li> </ul> </td> </tr> </table></span></p><a name="S23181772482008020700000"></a><h2 class="clsHeadThree">Convertible top upholstery - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020581" name="S38048510792008020700000">Fig. 164: Convertible Top Upholstery - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Convertible top upholstery</p> <p>2 - Molding</p> <p>3 - Profile strip</p> <p>4 - Zip fastener</p> <ul class="clsBULLET"> <li>Outside</li> </ul> <p>5 - Round molding</p> <p>6 - Zip fastener</p> <ul class="clsBULLET"> <li>Outside</li> </ul> <p>7 - Round molding</p> <p>8 - Zip fastener</p> <ul class="clsBULLET"> <li>Outside</li> </ul> <p>9 - Round molding</p> <p>10 - Zip fastener</p> <ul class="clsBULLET"> <li>Outside</li> </ul> <p>11 - Zip fastener</p> <ul class="clsBULLET"> <li>Inner</li> </ul> <p>12 - Round molding</p> <p>13 - Round molding</p> <p>14 - Adhesive surface</p> <ul class="clsBULLET"> <li>Double-sided tape can be used several times.</li> <li>Use <span class="clsEmphITAL">Double-Sided Adhesive Tape 434 019 25</span> if damaged.</li> </ul><a name="S29113731462008020700000"></a><h2 class="clsHeadThree">Convertible top upholstery, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020545" name="S30805845052008020700000">Fig. 165: Bringing Convertible Top Into Center Position</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Convertible top, parts designations --> <a class="clsHyperlink" href="#S00014563682008020700000">Convertible top - parts designations</a></li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove convertible top headliner --> <a class="clsHyperlink" href="#S21254238112008020700000">Convertible top headliner, removing and installing</a>.</li> <li>Remove convertible top cover --> <a class="clsHyperlink" href="#S00014563682008020700000">Convertible top - parts designations</a>.</li> <li>Bring convertible top into center position.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020582" name="S19275133822008020700000">Fig. 166: Removing Molding Band And Convertible Top Upholstery From Front Rail Groove</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove molding band - <span class="clsEmphBOLD">1</span> - and remove convertible top upholstery from front rail groove - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020583" name="S34853419732008020700000">Fig. 167: Removing Convertible Top Upholstery From Adhesive Tape On Main Guide</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove convertible top upholstery from adhesive tape on main guide - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The double-sided tape can be reused if in good condition.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove bolt from back end of convertible top upholstery in bracket.</li> <li>Slide convertible top upholstery forward out of bracket upper groove - <span class="clsEmphBOLD">2</span> -.</li> <li>Pull convertible top upholstery to side and out of rails.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Installation of the convertible top upholstery is the reverse of removal.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Ensure all convertible top components are positioned and function properly.</li> <li>Perform function test.</li> </ul> </td> </tr> </table></span></p><a name="S19352679122008020700000"></a><h2 class="clsHeadThree">Inner headliner, servicing</h2> <p><span class="clsEmphBOLD">Inner headliner strap with hose B6C 003 05D</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020584" name="S16852439922008020700000">Fig. 168: Bringing Convertible Top Into Position</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Bring convertible top into position shown.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>The convertible top hydraulic system is depressurized after 10 minutes.<ul class="clsBULLET"> <li>Risk of injury from lowering convertible top.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>To prevent convertible top from lowering, press convertible top switch, secure top against lowering if necessary.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>For better accessibility, completely lower side windows.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020585" name="S29387540982008020700000">Fig. 169: Removing Cable Ties On Jacketed Pull-Spring</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove cable ties - <span class="clsEmphBOLD">arrow</span> - on jacketed pull-spring.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020586" name="S38718321872008020700000">Fig. 170: Checking Diverting Eyelet For Damage Or Deformation & Folding Sheathing Back And Disengage Headliner Cord At Pull-Spring</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Check diverting eyelet - <span class="clsEmphBOLD">1</span> - for damage or deformation.</li> <li>If necessary, replace both diverting eyes.</li> <li>Fold sheathing - <span class="clsEmphBOLD">2</span> - back and disengage headliner cord at pull-spring.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020587" name="S33365291972008020700000">Fig. 171: Identifying Rubber Hose, Sheathing & Over Pull-Spring</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Guide headliner cord through rubber hose - <span class="clsEmphBOLD">1</span> - and re-engage it at pull-spring - <span class="clsEmphBOLD">2</span> -.</li> <li>Slide sheathing - <span class="clsEmphBOLD">3</span> - over pull-spring - <span class="clsEmphBOLD">2</span> -.</li> <li>Guide a cable tie through slit - <span class="clsEmphBOLD">arrow</span> - present on sheathing - <span class="clsEmphBOLD">3</span> - and tighten it.</li> <li>Close convertible top until bracket is vertical (on stop) and convertible top compartment cover is closed.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Cover convertible top compartment cover and side panel to protect against paint damage.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020588" name="S40584708522008020700000">Fig. 172: Identifying Molding, Rivet & Sewn Seam</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove molding - <span class="clsEmphBOLD">1</span> - from bracket.</li> <li>Remove rivet - <span class="clsEmphBOLD">2</span> -.</li> <li>Separate sewn seam - <span class="clsEmphBOLD">3</span> - on torn off mounting strap and remove "old strap".</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020589" name="S12043114862008020700000">Fig. 173: Laying Mounting Strap From Repair Kit Flush On Convertible Top Headliner</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Lay mounting strap from repair kit flush on convertible top headliner - <span class="clsEmphBOLD">arrows</span> - and sew with a double seam.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Before sewing, ensure strap is positioned correctly on headliner to avoid a twisted seam.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020590" name="S10647950152008020700000">Fig. 174: Securing Strap To Convertible Top Frame With Accompanying Rivet</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Secure strap to convertible top frame with accompanying rivet - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Install inner headline molding on bracket.</li> <li>Perform function test.</li> </ul><a name="S10464024792008020700000"></a><h2 class="clsHeadThree">Convertible top emergency release</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If the convertible top cannot be operated because of implausible reasons, it may be in an undefined position (for the control module). Pull bracket up as far as stop and operate switch.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Convertible top compartment cover, unlocking and locking</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020591" name="S01204689962008020700000">Fig. 175: Convertible Top Emergency Release Key In Basic Position</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Convertible top emergency release key in basic position - <span class="clsEmphBOLD">arrow</span> -.</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020592" name="S03906584322008020700000">Fig. 176: Convertible Top Emergency Release Key In Work Position</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Convertible top emergency release key in work position - <span class="clsEmphBOLD">arrow</span> -.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Convertible top emergency release key is located at left under instrument panel fuse cover.</li> <li>The designation "NES" is used for the convertible top emergency release key in the following description.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020593" name="S36266774972008020700000">Fig. 177: Lowering Side Windows</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Lower side windows approx. 20 cm.</li> <li>Close luggage compartment cover.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020594" name="S11802825112008020700000">Fig. 178: Opening Drivers Door And Removing Fuse Carrier Cover On Instrument Panel</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Open drivers door and remove fuse carrier cover on instrument panel.</li> </ul> <ul class="clsBULLET"> <li>There is a groove on the lower edge of the fuse cover in which a screwdriver, for example, can be inserted - <span class="clsEmphBOLD">arrow</span> - in order to raise.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020595" name="S37564425602008020700000">Fig. 179: Removing "NES" From Bracket Over Fuse Carrier In Instrument Panel</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove "NES" from bracket over fuse carrier in instrument panel.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020596" name="S11348174842008020700000">Fig. 180: Removing Center Piece Of Rear Backrest By Pushing Small Tabs Town Slightly And Pulling</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove center piece of rear backrest by pushing small tabs town slightly and pulling.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020597" name="S21048255652008020700000">Fig. 181: Pressing Grip Holes Together And Folding Cover Up</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press grip holes together and fold cover up.</li> <li>Press ski sack down and remove if necessary.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020598" name="S19587189172008020700000">Fig. 182: Inserting "NES" In Opening At Top Center Of Ski Sack Tunnel</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Bring "NES" into basic position as follows:</p> <ul class="clsDASH"> <li>Turn red grip piece left as far as stop.</li> <li>Insert "NES" in opening at top center of ski sack tunnel.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020599" name="S18647263902008020700000">Fig. 183: Turning Entire "NES" Until Small Tabs On Key Head Engage In A Groove</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Turn entire "NES" until small tabs on key head engage in a groove.</li> <li>Turn entire "NES" <sup>1</sup> /<sub>4</sub> turn clockwise against stop in lock.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020600" name="S14325786512008020700000">Fig. 184: Turning Red Grip Clockwise (1.5 Turns) Until Both Grip Recesses On "NES" Audibly Engage</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Turn red grip clockwise (1.5 turns) until both grip recesses on the "NES" audibly engage.</li> </ul> <ul class="clsBULLET"> <li>The "NES" is secured in the lock system and can be operated.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020601" name="S04601790582008020700000">Fig. 185: Opening Convertible Top Compartment Cover By Turning "NES" Counter-Clockwise As Far As Stop</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Open convertible top compartment cover by turning "NES" counter-clockwise as far as stop.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020602" name="S07230840602008020700000">Fig. 186: Pulling Convertible Top Compartment Cover Out As Far As Stop</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull convertible top compartment cover out as far as stop.</li> </ul> <ul class="clsBULLET"> <li>The convertible top compartment cover engages in open position.</li> </ul> <ul class="clsDASH"> <li>Raise convertible top out of compartment by pulling roof edge up forcefully.</li> </ul> <p>Bring convertible top into center position manually as follows:</p> <ul class="clsDASH"> <li>Close convertible top until it stays half closed by itself. Slide roof edge forward as far as possible.</li> <li>Raise convertible top bracket until it stays in vertical position.</li> <li>Carefully press convertible top compartment cover shut.</li> <li>Turn entire "NES" clockwise as far as stop.</li> </ul> <ul class="clsBULLET"> <li>The convertible top compartment cover is locked.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020603" name="S26025107522008020700000">Fig. 187: Removing "NES"</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Remove "NES" as follows:</p> <ul class="clsDASH"> <li>Turn red grip piece counter-clockwise as far as stop.</li> <li>Turn entire "NES" <sup>1</sup> /<sub>4</sub> turn counter-clockwise and pull it down.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020604" name="S12364914082008020700000">Fig. 188: Convertible Top, Unlocking And Locking</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Convertible top, unlocking and locking</span> </p> <ul class="clsDASH"> <li>Press bracket onto convertible top compartment cover.</li> <li>Press convertible top at front of vehicle onto upper windshield frame.</li> </ul> <ul class="clsBULLET"> <li>The convertible top may spring out slightly.</li> </ul> <ul class="clsDASH"> <li>Remove cover in center of the front rail trim inside vehicle.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020605" name="S42445461162008020700000">Fig. 189: Bringing "NES" Into Basic Position</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Bring "NES" into basic position as follows:</p> <ul class="clsDASH"> <li>Turn red grip piece left as far as stop.</li> <li>Insert "NES" in opening in center of front rail trim.</li> <li>Turn entire "NES" until small tabs on key head engage in a groove.</li> <li>Turn entire "NES" <sup>1</sup> /<sub>4</sub> turn clockwise against stop in lock.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020606" name="S31479076512008020700000">Fig. 190: Turning Red Grip Clockwise (1.5 Turns) Until Both Grip Recesses On "NES" Audibly Engage</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Turn red grip clockwise (1.5 turns) until both grip recesses on the "NES" audibly engage.</li> </ul> <ul class="clsBULLET"> <li>The "NES" is secured in the lock system and can be operated.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020607" name="S25383483912008020700000">Fig. 191: Turning Entire "NES" Clockwise As Far As Stop</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Turn entire "NES" clockwise as far as stop.</li> <li>Pull convertible top down using "NES".</li> <li>Turn entire "NES" counter-clockwise as far as stop.</li> </ul> <ul class="clsBULLET"> <li>The convertible top is locked.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020608" name="S23774629262008020700000">Fig. 192: Removing "NES"</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Remove "NES" as follows:</p> <ul class="clsDASH"> <li>Turn red grip piece counter-clockwise as far as stop.</li> <li>Turn entire "NES" <sup>1</sup> /<sub>4</sub> turn counter-clockwise and pull it down.</li> <li>Re-install cover cap.</li> <li>Close side windows.</li> </ul><a name="S24154268802008020700000"></a><h2 class="clsHeadTwo">Convertible top frame</h2><a name="S17471039492008020700000"></a><h2 class="clsHeadThree">Safety precautions</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Observe measures when disconnecting battery --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> </li> <li>27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET</li> </ul> .</td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Secure convertible top mechanism against unintentional folding up and down during all installation work as this can lead to personal injury or vehicle damage.</td> </tr> </table></span></p><a name="S26779293682008020700000"></a><h2 class="clsHeadThree">Attachments - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020609" name="S26341190752008020700000">Fig. 193: Attachments - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Guide cable - rear window</p> <ul class="clsBULLET"> <li>Removing <a class="clsHyperlink" href="#S36541187922008020700000">Attachments, removing and installing</a> .</li> </ul> <p>2 - Bracket strap - rail "4"</p> <ul class="clsBULLET"> <li>Removing <a class="clsHyperlink" href="#S36541187922008020700000">Attachments, removing and installing</a>.</li> </ul> <p>3 - Bracket strap - rail "5"</p> <ul class="clsBULLET"> <li>Removing <a class="clsHyperlink" href="#S36541187922008020700000">Attachments, removing and installing</a>.</li> </ul> <p>4 - Rubber strap for rail "3" and "4"</p> <ul class="clsBULLET"> <li>Removing <a class="clsHyperlink" href="#S36541187922008020700000">Attachments, removing and installing</a> .</li> </ul> <p>5 - Center brace strap - rail "4"</p> <ul class="clsBULLET"> <li>Removing <a class="clsHyperlink" href="#S36541187922008020700000">Attachments, removing and installing</a> .</li> </ul> <p>6 - Convertible Top Locking Motor V223 bolts</p> <ul class="clsBULLET"> <li>10 Nm</li> </ul> <p>7 - Convertible Top Locking Motor V223 , (Convertible Top Lock Switch (open) F294 , Convertible Top Lock Switch (closed) F295)</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S30792614912008020700000">Convertible Top Locking Motor V223/Convertible Top Lock Switch (open) F294/Convertible Top Lock Switch (closed) F295 , removing and installing</a>.</li> </ul> <p>8 - Convertible top lock</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S39426941022008020700000">Convertible top lock, removing and installing</a>.</li> <li>Adjusting --> <a class="clsHyperlink" href="#S23671616752008020700000">Convertible top locks, checking and adjusting</a>.</li> </ul> <p>9 - Convertible top lock bolts</p> <ul class="clsBULLET"> <li>9 Nm</li> </ul> <p>10 - Nut</p> <ul class="clsBULLET"> <li>6 Nm</li> </ul> <p>11 - Cable eyelet- headliner</p> <ul class="clsBULLET"> <li>Removing <a class="clsHyperlink" href="#S36541187922008020700000">Attachments, removing and installing</a> .</li> </ul> <p>12 - Plastic profile</p> <ul class="clsBULLET"> <li>Only on first generation vehicles.</li> <li>Removing <a class="clsHyperlink" href="#S36541187922008020700000">Attachments, removing and installing</a>.</li> </ul> <p>13 - Screw</p> <ul class="clsBULLET"> <li>4 Nm</li> </ul> <p>14 - Tensioning wire - headliner</p> <ul class="clsBULLET"> <li>Removing <a class="clsHyperlink" href="#S36541187922008020700000">Attachments, removing and installing</a>.</li> </ul> <p>15 - Tensioning element - headliner</p> <ul class="clsBULLET"> <li>Removing <a class="clsHyperlink" href="#S36541187922008020700000">Attachments, removing and installing</a>.</li> </ul> <p>16 - Convertible top cover tensioning cable</p> <ul class="clsBULLET"> <li>Removing <a class="clsHyperlink" href="#S36541187922008020700000">Attachments, removing and installing</a> .</li> </ul> <p>17 - Cable spring - headliner (lengthwise)</p> <ul class="clsBULLET"> <li>Removing <a class="clsHyperlink" href="#S36541187922008020700000">Attachments, removing and installing</a> .</li> </ul> <p>18 - Cable spring - headliner (across)</p> <ul class="clsBULLET"> <li>Removing <a class="clsHyperlink" href="#S36541187922008020700000">Attachments, removing and installing</a>.</li> </ul> <p>19 - Cable eyelet- headliner</p> <ul class="clsBULLET"> <li>Removing <a class="clsHyperlink" href="#S36541187922008020700000">Attachments, removing and installing</a>.</li> </ul> <p>20 - Center brace spring - rail "5"</p> <ul class="clsBULLET"> <li>Removing <a class="clsHyperlink" href="#S36541187922008020700000">Attachments, removing and installing</a> .</li> </ul> <p>21 - Bracket insulation element</p> <ul class="clsBULLET"> <li>Removing <a class="clsHyperlink" href="#S36541187922008020700000">Attachments, removing and installing</a> .</li> </ul><a name="S36541187922008020700000"></a><h2 class="clsHeadThree">Attachments, removing and installing</h2> <ul class="clsDASH"> <li>Convertible top headliner, removing --> <a class="clsHyperlink" href="#S21254238112008020700000">Convertible top headliner, removing and installing</a>.</li> <li>Remove convertible top cover --> <a class="clsHyperlink" href="#S39063620412008020700000">Convertible top cover, removing and installing</a>.</li> <li>Remove convertible top upholstery --> <a class="clsHyperlink" href="#S29113731462008020700000">Convertible top upholstery, removing and installing</a>.</li> <li>Remove seals --> <a class="clsHyperlink" href="#S07337934352008020700000">Convertible top frame seals - assembly overview</a>.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>It is not always necessary to perform all preliminary work listed above to service individual convertible top frame attachments.</li> <li>In the instructions, the work on the convertible top frame is described without the convertible top headliner, convertible top cover, convertible top upholstery and seals.</li> <li>The description is based on the right side of the convertible top frame and can be applied to the left side the same way or in a similar way.</li> <li>The convertible top can be disassembled and pre-assembled in the vehicle when installed in vehicle.</li> <li>When working on the convertible top electrical system, disconnect vehicle battery ground strap.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove convertible top locks --> <a class="clsHyperlink" href="#S39426941022008020700000">Convertible top lock, removing and installing</a>.</li> <li>Remove convertible top latch <a class="clsHyperlink" href="#S30792614912008020700000">Convertible Top Locking Motor V223/Convertible Top Lock Switch (open) F294/Convertible Top Lock Switch (closed) F295 , removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020610" name="S16222131172008020700000">Fig. 194: Removing Bolts For Tensioning Wire And Tensioning Element On Main Guide Diverting Linkage</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li> Remove bolts for tensioning wire and tensioning element - <span class="clsEmphBOLD">arrows</span> - on main guide diverting linkage.</li> </ul> <ul class="clsBULLET"> <li>The tensioning wire and tensioning element are secured together at the threaded connection - <span class="clsEmphBOLD">arrow B</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>To install convertible top headliner, bolt - <span class="clsEmphBOLD">arrow B</span> - must be removed on some models in order to slide side strap on convertible top headliner over tensioning wire.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020577" name="S39251634532008020700000">Fig. 195: Folding Bracket In Vertical Position (Convertible Top In Center Position) And Removing Bolt</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Fold bracket in vertical position (convertible top in center position) and remove bolt - <span class="clsEmphBOLD">arrow B</span> -.</li> <li>Remove bolt - <span class="clsEmphBOLD">arrow A</span> - on rail - <span class="clsEmphBOLD">5</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020611" name="S11874263862008020700000">Fig. 196: Unclipping Tensioning Cable Sideways Out Of Guide On Main Guide</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Unclip tensioning cable - <span class="clsEmphBOLD">1</span> - sideways out of guide - <span class="clsEmphBOLD">2</span> - on main guide.</li> <li>Remove rivet - <span class="clsEmphBOLD">3</span> - and remove tensioning cable.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>On first generation vehicles, the tensioning cable - <span class="clsEmphBOLD">1</span> - is bonded into the guide - <span class="clsEmphBOLD">2</span> - with super glue.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020612" name="S09944477862008020700000">Fig. 197: Identifying Bolts, Tensioning Cable, Cable Guide & Convertible Top Frame Position Sensor G356</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolt - <span class="clsEmphBOLD">A</span> - for tensioning cable - <span class="clsEmphBOLD">1</span> - and cable guide - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove cable guide - <span class="clsEmphBOLD">2</span> - from linkage.</li> <li>Remove bolt - <span class="clsEmphBOLD">B</span> - and remove Convertible Top Frame Position Sensor G356 - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove wiring harness from its retainers on bracket.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020613" name="S36749534802008020700000">Fig. 198: Removing Band From Eyelet On Bracket & Bracket Insulating Element From Ball Head</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove band - <span class="clsEmphBOLD">2</span> - from eyelet on bracket.</li> <li>Remove bracket insulating element from ball head - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020614" name="S21330871182008020700000">Fig. 199: Removing Shared Band Rivet Connection For Bracket Rail "4" And Bracket Rail "5" On Bracket</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li> Remove shared band rivet connection for bracket rail "4" and bracket rail "5" on bracket - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Both bands must be re-riveted on shared mounting point in bracket - <span class="clsEmphBOLD">arrow</span> - during installation.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020615" name="S15018467902008020700000">Fig. 200: Removing Bolt For Center Brace Rail Spring</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolt - <span class="clsEmphBOLD">B</span> - for center brace rail spring "5" - <span class="clsEmphBOLD">A</span> -.</li> <li>On first generation vehicles, check protective glide foil - <span class="clsEmphBOLD">arrows</span> - on center bracket and on rail "5" for damage.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020616" name="S14349678952008020700000">Fig. 201: Identifying Bracket Strap, Cable Spring, Cable Eyelet & Center Brace Spring</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li> Remove rivet - <span class="clsEmphBOLD">arrow</span> - on rail "5".</li> </ul> <p>The following parts are secured at this rivet connection:</p> <ol class="clsARABICNUM"> <li>Bracket strap - rail 5</li> <li>Cable spring - headliner (across)</li> <li>Cable eyelet- headliner</li> <li>Center brace spring - rail 5</li> </ol> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020617" name="S33814830702008020700000">Fig. 202: Identifying Bolts, Rivets, Bands & Rubber Strap</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolt - <span class="clsEmphBOLD">A</span> - and slide rubber strap - <span class="clsEmphBOLD">1</span> - sideways from rail "3".</li> <li>Remove rivet - <span class="clsEmphBOLD">B</span> - on rail "4" and remove band - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove rivet - <span class="clsEmphBOLD">C</span> - from center brace and rivet - <span class="clsEmphBOLD">D</span> - from rail "4".</li> <li>Remove band - <span class="clsEmphBOLD">1</span> - and band - <span class="clsEmphBOLD">3</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020618" name="S21460628192008020700000">Fig. 203: Identifying Bolt & Plastic Profile</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolt - <span class="clsEmphBOLD">A</span> - on inside of roof guide "2" and remove eye.</li> <li> On first generation vehicles, remove plastic profile - <span class="clsEmphBOLD">B</span> - on bottom of roof guide "2".</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The plastic profile - <span class="clsEmphBOLD">B</span> - must be secured with suitable adhesive during installation.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020619" name="S22043356082008020700000">Fig. 204: Removing Bolt On "Lengthwise Headliner Cable" Eye</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Open convertible top until roof guide "2" and main guide do not touch at their rear edges.</li> <li>Remove bolt - <span class="clsEmphBOLD">arrow</span> - on "lengthwise headliner cable" eye.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>On some versions, the eyelet may be riveted to the main guide.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020620" name="S33916250892008020700000">Fig. 205: Removing Rivet On Inside Of Main Guide</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rivet - <span class="clsEmphBOLD">arrow</span> - on inside of main guide.</li> <li>Remove "lengthwise headliner cable" spring.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020621" name="S02644345542008020700000">Fig. 206: Unclipping Convertible Top Latch Wiring Harness From Its Guide Beginning At Front Rail To Cable Bracket On Main Guide</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Unclip convertible top latch wiring harness from its guide - <span class="clsEmphBOLD">arrow</span> - beginning at front rail to cable bracket on main guide.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020622" name="S01542821242008020700000">Fig. 207: Removing Rivet, Cable Bracket From Roof Guide, Bolt And Cable Channel From Diverting Linkage</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rivet - <span class="clsEmphBOLD">A</span> - and remove cable bracket - <span class="clsEmphBOLD">1</span> - from roof guide "2".</li> <li>Remove bolt - <span class="clsEmphBOLD">B</span> - and remove cable channel - <span class="clsEmphBOLD">2</span> - from diverting linkage on inside of main guide and from main guide.</li> <li>Remove wiring harness.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When installing, ensure there are sufficient wire loops between wiring bracket - <span class="clsEmphBOLD">1</span> - and cable channel - <span class="clsEmphBOLD">2</span> - so that wiring harness will not be rubbed or bent.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020623" name="S26112769452008020700000">Fig. 208: Checking Double-Sided Tape On Outside Of Main Guide For Damage</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Check double-sided tape on outside of main guide - <span class="clsEmphBOLD">arrows</span> - for damage.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The convertible top upholstery is secured to the main guide with the help of the adhesive tape.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove convertible top frame --> <a class="clsHyperlink" href="#S26361979072008020700000">Convertible top, removing and installing</a>.</li> </ul> <p>Installation is reverse of removal.</p><a name="S36894092112008020700000"></a><h2 class="clsHeadTwo">Convertible top hydraulic system</h2><a name="S20625478782008020700000"></a><h2 class="clsHeadThree">Hydraulic system, general information</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Observe measures when disconnecting battery --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> </li> <li>27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET</li> </ul> .</td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Secure convertible top mechanism against unintentional folding up and down during all installation work as this can lead to personal injury or vehicle damage.</td> </tr> </table></span></p> <p>The hydraulic system is self-bleeding and maintenance-free.</p> <p>When replacing the hydraulic cylinder or hoses, it is not necessary to top off hydraulic oil. There is sufficient hydraulic oil in the system so that the oil level does not go over or under the minimum markings.</p> <p>If work is done as a result of hydraulic oil loss, the oil level should be checked before operating and adjusted if necessary.</p> <p><span class="clsEmphBOLD">Vehicles through 04.2006</span> </p> <p>The hydraulic system is switched off when the ignition is switched off or 10 minutes after the convertible top switch is operated when the ignition is switched on.</p> <p>If the hydraulic pressure is maintained, the convertible top switch should be operated briefly with the ignition switched on.</p> <p><span class="clsEmphBOLD">Vehicles from 05.2006</span> </p> <p>When the ignition is switched off, the hydraulic system is switched off after 10 minutes.</p> <p>To depressurize the system before this (for manual convertible top operation), the convertible top switch must be operated for 3 seconds with "ignition off".</p> <p>If the hydraulic pressure is maintained, the convertible top switch should be operated briefly with the ignition switched on.</p><a name="S02012022422008020700000"></a><h2 class="clsHeadThree">Cleanliness rules</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Hydraulic oil damages paint. Immediately remove any hydraulic oil that has come in contact with painted surfaces.</td> </tr> </table></span></p> <ul class="clsBULLET"> <li>Clean connecting points and surrounding areas before loosening.</li> <li>Place removed parts on a clean surface and cover. Use foil and paper. Do not use cloths with lint!</li> <li>Carefully cover or seal opened components if the repair will not be done immediately.</li> <li>Only install clean parts: Only remove replacement parts from packaging right before installation.</li> </ul> <ul class="clsBULLET"> <li>Place collecting container or foil and cloths under connections to be opened so that hydraulic oil does not come into contact with painted surfaces.</li> <li>Seal open hydraulic lines with cover caps to prevent hydraulic oil from leaking out.</li> </ul><a name="S41249403412008020700000"></a><h2 class="clsHeadThree">Hydraulic system - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020624" name="S37745911082008020700000">Fig. 209: Hydraulic System - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Right bracket drive motor cylinder</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S03423298212008020700000">Hydraulic cylinder, removing and installing</a>.</li> </ul> <p>2 - Right main drive motor cylinder</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S03423298212008020700000">Hydraulic cylinder, removing and installing</a>.</li> </ul> <p>3 - Right convertible top compartment cover drive motor cylinder</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S03423298212008020700000">Hydraulic cylinder, removing and installing</a>.</li> </ul> <p>4 - Nut</p> <ul class="clsBULLET"> <li>3x</li> <li>10 Nm</li> </ul> <p>5 - Hydraulic pump with valve block</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S26313511952008020700000">Hydraulic unit (hydraulic pump), removing and installing</a>.</li> </ul> <p>6 - Hydraulic lines</p> <p>7 - Left convertible top compartment cover drive motor cylinder</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S03423298212008020700000">Hydraulic cylinder, removing and installing</a>.</li> </ul> <p>8 - Left bracket drive motor cylinder</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S03423298212008020700000">Hydraulic cylinder, removing and installing</a>.</li> </ul> <p>9 - Left main drive motor cylinder</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S03423298212008020700000">Hydraulic cylinder, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020625" name="S16311188192008020700000">Fig. 210: Hydraulic System, Filling And Bleeding</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Oil filler screw</span> </p> <p>Pfeil - 2 Nm</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020626" name="S36974974692008020700000">Fig. 211: Hydraulic Pump Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Hydraulic pump housing</span> </p> <p>Arrow - 6 Nm</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020627" name="S19942306782008020700000">Fig. 212: Solenoid Valves</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Solenoid valves</span> </p> <ol class="clsARABICNUM"> <li>6 Nm</li> <li>22 Nm</li> </ol> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020628" name="S39663654882008020700000">Fig. 213: Connecting Plate</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Connecting plate</span> </p> <p>Arrow - 10 Nm</p><a name="S10898968002008020700000"></a><h2 class="clsHeadThree">Hydraulic system, function overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020629" name="S08985637402008020700000">Fig. 214: Hydraulic System, Function Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Convertible top compartment cover cylinder</p> <p>2 - Main cylinder</p> <p>3 - Bracket cylinder</p> <p>4 - Check valve S1</p> <p>5 - Solenoid valve F3</p> <p>6 - Pressure regulation valve D2</p> <p>7 - ABS Hydraulic Pump</p> <p>8 - Two-way valve W2</p> <p>9 - Pressure regulation valve D1</p> <ul class="clsBULLET"> <li>On-board voltage in contact = flow</li> <li>Solenoid valve with no current = return open</li> </ul> <p>10 - Solenoid valve F2</p> <ul class="clsBULLET"> <li>On-board voltage in contact = flow</li> <li>Solenoid valve with no current = return open</li> </ul> <p>11 - Pump pressure</p> <p>12 - Return pressure</p> <p>13 - Line depressurized</p> <p>14 - Two-way valve W1</p> <p>15 - Solenoid valve F1</p> <ul class="clsBULLET"> <li>On-board voltage in contact = flow</li> <li>Solenoid valve with no current = return open</li> </ul><a name="S24518035072008040700000"></a><h2 class="clsHeadFour">Hydraulic function "open" , raise bracket</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020630" name="S40933855582008020700000">Fig. 215: Hydraulic Function "Open" , Raise Bracket</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Pump rotation direction: right</li> <li>Energized solenoid valve F2</li> <li>Energized solenoid valve F3</li> </ul> <p><span class="clsEmphBOLD">Convertible top compartment cover cylinder</span> </p> <p>The convertible top compartment cover cylinder rebound stages are charged with pressure via the energized solenoid valve F2. In this way, the convertible top compartment cover remains in closed position.</p> <p><span class="clsEmphBOLD">Main cylinder</span> </p> <p>Solenoid valves F2 and F3 are energized.</p> <p>In this way, the main cylinder pressure stage and rebound stage are charged with pressure.</p> <p>The pressure is evenly distributed to the cylinder rebound and pressure stages.</p> <p>Because the pressure stage has the larger piston surfaces in comparison to the rebound stage, different forces can be generated with the same pressure ratios. The force acts on the pressure stage, whereby the cylinder moves out to the end stop and remains there. The convertible top remains tilted forward.</p> <p><span class="clsEmphBOLD">Bracket cylinder</span> </p> <p>Both bracket cylinders are activated by solenoid valve F3 during the rebound stage and raise the bracket.</p> <p>Because it is activated simultaneously from both sides, the two-way valve W1 is permeable in the direction of the bracket cylinder rebound stage. Flow to the cylinder pressure stages is blocked by a check valve active on one side.</p> <p>Through this, the bracket cylinders are retracted and the bracket is raised. Hydraulic oil displaced in the pressure stages is transferred into the hydraulic reservoir.</p> <p>Component overview <a class="clsHyperlink" href="#S10898968002008020700000">Hydraulic system, function overview</a>.</p><a name="S23941571172008040700000"></a><h2 class="clsHeadFour">Hydraulic function "open" , convertible top compartment cover open</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020631" name="S08967242932008020700000">Fig. 216: Hydraulic Function "Open" , Convertible Top Compartment Cover Open</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Pump rotation direction: right</li> <li>Energized solenoid valve F1</li> <li>Energized solenoid valve F2</li> <li>Energized solenoid valve F3</li> </ul> <p><span class="clsEmphBOLD">Convertible top compartment cover cylinder</span> </p> <p>The convertible top compartment cover cylinders are charged with pressure from both sides simultaneously by the energized solenoid valves F1 and F2 and in this way are run out.</p> <p>The reason for this lies in the larger piston surface in the pressure stage and the different power ratios due to this resulting from the same large pressure charge.</p> <p>The convertible top compartment cover is raised.</p> <p><span class="clsEmphBOLD">Main cylinder</span> </p> <p>Solenoid valves F2 and F3 are energized.</p> <p>In this way, the main cylinder pressure stages and rebound stages are charged with pressure.</p> <p><span class="clsEmphBOLD">Bracket cylinder</span> </p> <p>The two-way valve S1 is charged with pressure from both sides simultaneously via the energized solenoid valves F2 and F3. In this way, it is interconnected and the hydraulic pressure is directed to the bracket cylinder rebound stages.</p> <p>Through this, the bracket cylinders remain retracted and the bracket is raised.</p> <p>Component overview <a class="clsHyperlink" href="#S10898968002008020700000">Hydraulic system, function overview</a>.</p><a name="S32310734212008040700000"></a><h2 class="clsHeadFour">Hydraulic function "open" , store bracket.</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020632" name="S12138583742008020700000">Fig. 217: Hydraulic Function "Open" , Store Bracket.</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Pump rotation direction: left</li> <li>Energized solenoid valve F1</li> <li>Energized solenoid valve F3</li> </ul> <p><span class="clsEmphBOLD">Convertible top compartment cover cylinder</span> </p> <p>The convertible top compartment cover cylinders are not activated.</p> <p>The check valve contained within comes into use through the energized solenoid valve F1. This prevents the cylinder from becoming depressurized in the pressure stage and the convertible top compartment cover from being closed.</p> <p><span class="clsEmphBOLD">Main cylinder</span> </p> <p>The hydraulic pressure is channeled directly to the main cylinder pressure stages via check valve S1.</p> <p>These remain run out and hold the convertible top in forward position.</p> <p>The hydraulic pressure cannot vent in the system through two-way valve S1 and energized solenoid valve F3.</p> <p><span class="clsEmphBOLD">Bracket cylinder</span> </p> <p>Both bracket cylinders are directly charged with pressure via the pressure stage.</p> <p>They are run out and the bracket is stored in the convertible top compartment.</p> <p>In the rebound stage, displaced hydraulic oil is directed in the system and discharged into the hydraulic oil reservoir via F2.</p> <p>Component overview <a class="clsHyperlink" href="#S10898968002008020700000">Hydraulic system, function overview</a>.</p><a name="S40318212882008040700000"></a><h2 class="clsHeadFour">Hydraulic function "open" , store convertible top</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020633" name="S00634997532008020700000">Fig. 218: Hydraulic Function "Open" , Store Convertible Top</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Pump rotation direction: right</li> <li>Energized solenoid valve F1</li> <li>Energized solenoid valve F2</li> </ul> <p><span class="clsEmphBOLD">Convertible top compartment cover cylinder</span> </p> <p>The convertible top compartment cover cylinders are charged with pressure simultaneously from both sides via energized solenoid valves F1 and F2.</p> <p>The cylinders remain run out and the convertible top compartment cover is raised.</p> <p><span class="clsEmphBOLD">Main cylinder</span> </p> <p>The hydraulic pressure is channeled directly to the main cylinder rebound stage via solenoid valve F2.</p> <p>These are retracted and store the convertible top in the convertible top compartment.</p> <p>The hydraulic oil displaced from the pressure stage is directed into the hydraulic oil reservoir via F3.</p> <p><span class="clsEmphBOLD">Bracket cylinder</span> </p> <p>Both bracket cylinders are not activated.</p> <p>Both bracket cylinders are partially retracted by the convertible top mechanics.</p> <p>Component overview <a class="clsHyperlink" href="#S10898968002008020700000">Hydraulic system, function overview</a>.</p><a name="S09713599892008040700000"></a><h2 class="clsHeadFour">Hydraulic function "open" , close convertible top compartment cover</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020634" name="S08636545972008020700000">Fig. 219: Hydraulic Function "Open" , Close Convertible Top Compartment Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Pump rotation direction: right</li> <li>Energized solenoid valve F2</li> </ul> <p><span class="clsEmphBOLD">Convertible top compartment cover cylinder</span> </p> <p>The convertible top compartment cover cylinders are charged with pressure at the rebound stage via the energized solenoid valve F2.</p> <p>They are retracted and in this way, the convertible top compartment cover is closed.</p> <p>The hydraulic oil escaping from the pressure stage is directed into the hydraulic oil reservoir via F1.</p> <p><span class="clsEmphBOLD">Main cylinder</span> </p> <p>The hydraulic pressure is channeled directly to the main cylinder rebound stage via solenoid valve F2.</p> <p>In that way, they remain retracted and leave the convertible top in the convertible top compartment.</p> <p><span class="clsEmphBOLD">Bracket cylinder</span> </p> <p>The bracket cylinders are not activated.</p> <p>They remain partially retracted.</p> <p>Component overview <a class="clsHyperlink" href="#S10898968002008020700000">Hydraulic system, function overview</a>.</p><a name="S05027751102008040700000"></a><h2 class="clsHeadFour">Hydraulic functions "close" , raise convertible top compartment cover</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020635" name="S28581389362008020700000">Fig. 220: Hydraulic Functions "Close" , Raise Convertible Top Compartment Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Pump rotation direction: right</li> <li>Energized solenoid valve F1</li> <li>Energized solenoid valve F2</li> </ul> <p><span class="clsEmphBOLD">Convertible top compartment cover cylinder</span> </p> <p>The convertible top compartment cover cylinders are charged with pressure from both sides simultaneously by the energized solenoid valves F1 and F2 and in this way are run out.</p> <p>The convertible top compartment cover is raised.</p> <p><span class="clsEmphBOLD">Main cylinder</span> </p> <p>The hydraulic pressure is directed to both main cylinders in the rebound stages via solenoid valve F2. Both main cylinders remain retracted.</p> <p><span class="clsEmphBOLD">Bracket cylinder</span> </p> <p>The bracket cylinders are not activated.</p> <p>They remain partially retracted.</p> <p>Component overview <a class="clsHyperlink" href="#S10898968002008020700000">Hydraulic system, function overview</a>.</p><a name="S02506267752008040700000"></a><h2 class="clsHeadFour">Hydraulic functions "close" , raise convertible top from convertible top compartment</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020636" name="S08994667582008020700000">Fig. 221: Hydraulic Functions "Close" , Raise Convertible Top From Convertible Top Compartment</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Pump rotation direction: right</li> <li>Energized solenoid valve F1</li> <li>Energized solenoid valve F3</li> </ul> <p><span class="clsEmphBOLD">Convertible top compartment cover cylinder</span> </p> <p>The convertible top compartment cover cylinders are not activated.</p> <p>The check valve contained within comes into use through the energized solenoid valve F1. This prevents the cylinder from running idle in the pressure stage and the convertible top compartment cover from being closed.</p> <p><span class="clsEmphBOLD">Main cylinder</span> </p> <p>The pressure stages for both main cylinders are directly charged with hydraulic pressure via the energized solenoid valve F3.</p> <p>The cylinders run out and the convertible top is raised.</p> <p><span class="clsEmphBOLD">Bracket cylinder</span> </p> <p>The bracket cylinders are not activated.</p> <p>Both bracket cylinders are partially run out by the convertible top mechanics.</p> <p>Component overview <a class="clsHyperlink" href="#S10898968002008020700000">Hydraulic system, function overview</a>.</p><a name="S27178908162008040700000"></a><h2 class="clsHeadFour">Hydraulic functions "close" , raise bracket</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020637" name="S07532164172008020700000">Fig. 222: Hydraulic Functions "Close" , Raise Bracket</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Pump rotation direction: right</li> <li>Energized solenoid valve F1</li> <li>Energized solenoid valve F2</li> <li>Energized solenoid valve F3</li> </ul> <p><span class="clsEmphBOLD">Convertible top compartment cover cylinder</span> </p> <p>The convertible top compartment cover cylinders remain charged with pressure from both sides simultaneously by the energized solenoid valves F1 and F2 and in this way remain run out.</p> <p>The convertible top compartment cover remains raised.</p> <p><span class="clsEmphBOLD">Main cylinder</span> </p> <p>Both pressure stages for the main cylinder are charged simultaneously by the energized solenoid valves F2 and F3.</p> <p>The cylinders remain run out and ensure the convertible top remains in forward position.</p> <p><span class="clsEmphBOLD">Bracket cylinder</span> </p> <p>The two-way valve S1 is charged with pressure from both sides simultaneously via the energized solenoid valves F2 and F3. In this way, it is interconnected and the hydraulic pressure is directed to the bracket cylinder rebound stage.</p> <p>The bracket cylinders are retracted and the bracket is raised.</p> <p>The hydraulic oil escaping from the pressure stage is directed into the hydraulic oil reservoir via W2.</p> <p>Component overview <a class="clsHyperlink" href="#S10898968002008020700000">Hydraulic system, function overview</a>.</p><a name="S03181314302008040700000"></a><h2 class="clsHeadFour">Hydraulic functions "close" , close convertible top compartment cover</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020638" name="S13920138032008020700000">Fig. 223: Hydraulic Functions "Close" , Close Convertible Top Compartment Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Pump rotation direction: right</li> <li>Energized solenoid valve F2</li> <li>Energized solenoid valve F3</li> </ul> <p><span class="clsEmphBOLD">Convertible top compartment cover cylinder</span> </p> <p>The convertible top compartment cover cylinders are charged with pressure at the rebound stage via the energized solenoid valve F2.</p> <p>They are retracted and in this way, the convertible top compartment cover is closed.</p> <p>The hydraulic oil displaced from the pressure stage is directed into the hydraulic oil reservoir via F1.</p> <p><span class="clsEmphBOLD">Main cylinder</span> </p> <p>Solenoid valves F2 and F3 are energized.</p> <p>In this way, the main cylinder pressure stage and rebound stage are charged with pressure.</p> <p>The cylinders remain run out and ensure the convertible top remains in forward position.</p> <p><span class="clsEmphBOLD">Bracket cylinder</span> </p> <p>The two-way valve W1 is charged with pressure simultaneously from both sides.</p> <p>In this way, it is interconnected and the hydraulic pressure is directed to the bracket cylinder rebound stages.</p> <p>The flow to the cylinder pressure stages is blocked by check valve S1 active on one side.</p> <p>Through this, the bracket cylinders remain retracted and the bracket is raised.</p> <p>Component overview <a class="clsHyperlink" href="#S10898968002008020700000">Hydraulic system, function overview</a>.</p><a name="S38722027832008040700000"></a><h2 class="clsHeadFour">Hydraulic functions "close" , store bracket</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020639" name="S40455938372008020700000">Fig. 224: Hydraulic Functions "Close" , Store Bracket</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Pump rotation direction: left</li> <li>Energized solenoid valve F3</li> </ul> <p><span class="clsEmphBOLD">Convertible top compartment cover cylinder</span> </p> <p>The convertible top compartment cover cylinders are not activated because solenoid valve F2 is not energized.</p> <p>They remain retracted and the convertible top compartment cover remains closed.</p> <p><span class="clsEmphBOLD">Main cylinder</span> </p> <p>The hydraulic pressure is channeled directly to the main cylinder pressure stage via check valve S1.</p> <p>These remain run out and hold the convertible top in forward position.</p> <p>The hydraulic pressure cannot vent in the system through two-way valve S1 and energized solenoid valve F3.</p> <p><span class="clsEmphBOLD">Bracket cylinder</span> </p> <p>Both bracket cylinders are charged with pressure in the pressure stage.</p> <p>They run out and the bracket is stored on the convertible top compartment cover. The hydraulic oil displaced from the rebound stages is directed in the system and channeled into the hydraulic oil reservoir via F2.</p> <p>Component overview <a class="clsHyperlink" href="#S10898968002008020700000">Hydraulic system, function overview</a>.</p><a name="S10968095202008020700000"></a><h2 class="clsHeadThree">Hydraulic system, filling and bleeding</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The electro-hydraulic convertible top operation involves a closed hydraulic system. Generally, filling is necessary after a loss of oil (accident, leaks, etc.).</li> <li>Due to the lift and displacement effect of the pistons in the hydraulic cylinders, the hydraulic system must be filled when the convertible top is stored in the compartment.</li> <li>The convertible top must be moved with electro-hydraulic operation.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Do not fill system above "MAX" marking as the pressure in the system can become so great that damage can result.</td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020625" name="S08513587902008020700000">Fig. 225: Hydraulic System, Filling And Bleeding</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Filling</span> </p> <ul class="clsDASH"> <li>Remove luggage compartment trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove oil filler plug - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Fill <span class="clsEmphITAL">Hydraulic Oil G 004 000</span> with a fill container until oil level is between "MIN" and "MAX" markings.</li> </ul> <p><span class="clsEmphBOLD">Bleeding</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Hydraulic system is self-bleeding. The system is bled after opening and closing the convertible top several times.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Start the engine.</li> <li>Close and open the convertible top 4 - 5 times with electro-hydraulic operation.</li> </ul> <ul class="clsBULLET"> <li>The convertible top must move smoothly and without jerking.</li> </ul> <ul class="clsDASH"> <li>Check oil level in oil reservoir - <span class="clsEmphBOLD">2</span> - when convertible top is stored in compartment.</li> </ul> <ul class="clsBULLET"> <li>Oil level must be between "MIN" and "MAX" markings.</li> </ul> <ul class="clsDASH"> <li>Top off hydraulic oil if necessary.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S41249403412008020700000">Hydraulic system - assembly overview</a>.</p><a name="S26313511952008020700000"></a><h2 class="clsHeadThree">Hydraulic unit (hydraulic pump), removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020640" name="S01468661442008020700000">Fig. 226: Hydraulic Unit (Hydraulic Pump)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove luggage compartment trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove bolts.</li> <li>Remove hydraulic lines from their guides.</li> <li>Remove electrical connectors.</li> </ul> <ul class="clsDASH"> <li>Raise hydraulic pump from its position and place it on a surface in the luggage compartment.</li> <li>Remove hydraulic lines --> <a class="clsHyperlink" href="#S41092926272008020700000">Hydraulic lines to connecting plate, removing and installing</a>.</li> </ul> <p>Installation is reverse of removal.</p> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S41249403412008020700000">Hydraulic system - assembly overview</a>.</p><a name="S31937321432008020700000"></a><h2 class="clsHeadThree">Hydraulic pump housing, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020626" name="S11449485712008020700000">Fig. 227: Hydraulic Pump Housing, Removing And Installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove hydraulic pump --> <a class="clsHyperlink" href="#S26313511952008020700000">Hydraulic unit (hydraulic pump), removing and installing</a>.</li> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Carefully remove pump housing.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S41249403412008020700000">Hydraulic system - assembly overview</a>.</p><a name="S16824769992008020700000"></a><h2 class="clsHeadThree">Pump wheel, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020641" name="S41554741692008020700000">Fig. 228: Checking Pump Wheel</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove hydraulic pump housing --> <a class="clsHyperlink" href="#S31937321432008020700000">Hydraulic pump housing, removing and installing</a>.</li> <li>Check pump wheel - <span class="clsEmphBOLD">arrow</span> - for damage.</li> <li>Remove pump wheel upward.</li> </ul><a name="S31320441542008020700000"></a><h2 class="clsHeadThree">Solenoid valve, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020642" name="S11844733222008020700000">Fig. 229: Solenoid Valve Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <p>Follow cleanliness rules --> <a class="clsHyperlink" href="#S02012022422008020700000">Cleanliness rules</a>.</p> <ul class="clsDASH"> <li>Remove hydraulic pump --> <a class="clsHyperlink" href="#S26313511952008020700000">Hydraulic unit (hydraulic pump), removing and installing</a>.</li> <li>Remove bolts - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove solenoid valve - <span class="clsEmphBOLD">2</span> - upward out of hydraulic pump - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Solenoid valves may only be installed in hydraulic pump in activated (energized) condition. Initiate output diagnostic test mode (DTM) and activate the affected solenoid valve for this.</td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020643" name="S27806659612008020700000">Fig. 230: Identifying Solenoid Valve, Electrical Harness Connector & Hydraulic Pump</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Connect electrical harness connector - <span class="clsEmphBOLD">1</span> - to solenoid valve - <span class="clsEmphBOLD">2</span> -.</li> <li>Initiate output diagnostic test mode and activate solenoid valve to be installed.</li> <li>Insert activated solenoid valve - <span class="clsEmphBOLD">2</span> - in hydraulic pump - <span class="clsEmphBOLD">3</span> -.</li> <li>Tighten bolts - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p>Tightening torques --> <a class="clsHyperlink" href="#S41249403412008020700000">Hydraulic system - assembly overview</a>.</p><a name="S20186302022008020700000"></a><h2 class="clsHeadThree">Hydraulic lines, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020644" name="S16682541072008020700000">Fig. 231: Removing Securing Plate From The Groove</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rear side trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Using pliers, remove securing plate - <span class="clsEmphBOLD">arrow</span> - from the groove.</li> <li>Remove hydraulic line from hydraulic cylinder.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Hydraulic line seal is pressed into hydraulic cylinder and cannot be replaced separately.</li> </ul> </td> </tr> </table></span></p><a name="S41092926272008020700000"></a><h2 class="clsHeadThree">Hydraulic lines to connecting plate, removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020645" name="S23096570122008020700000">Fig. 232: Hydraulic Line Connect Tool 3335</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hydraulic Line Connect Tool 3335</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020628" name="S17676567672008020700000">Fig. 233: Connecting Plate</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <p>Follow cleanliness rules --> <a class="clsHyperlink" href="#S02012022422008020700000">Cleanliness rules</a>.</p> <p>Hydraulic pump connection table <a class="clsHyperlink" href="#S36431510052008040700000">Hydraulic pump connection table</a>.</p> <ul class="clsDASH"> <li>Remove hydraulic pump --> <a class="clsHyperlink" href="#S26313511952008020700000">Hydraulic unit (hydraulic pump), removing and installing</a>.</li> <li>Remove center and side bulkhead trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020646" name="S25704553042008020700000">Fig. 234: Identifying Spring Washer</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Raise spring washer - <span class="clsEmphBOLD">1</span> - on hydraulic lines to be removed (supply and return) over collar on connecting piece with a small screwdriver and remove.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020647" name="S13276260612008020700000">Fig. 235: Identifying Hydraulic Line Connect Tool 3335 Sleeve, Spring Washer & Hydraulic Line Connect Tool 3335</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <ul class="clsDASH"> <li>Place hydraulic line with connecting piece through connecting plate.</li> <li>Place Hydraulic Line Connect Tool 3335 sleeve - <span class="clsEmphBOLD">1</span> - over connecting piece.</li> <li>Slide spring washer - <span class="clsEmphBOLD">2</span> - onto sleeve and press it on completely with Hydraulic Line Connect Tool 3335.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020648" name="S32308002502008020700000">Fig. 236: Springing Washer Must Slide Completely Over Collar On Connecting Piece & Coat Sealing Ring With Hydraulic Oil And Slide It Onto Connecting Piece</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Spring washer - <span class="clsEmphBOLD">2</span> - must slide completely over collar on connecting piece - <span class="clsEmphBOLD">1</span> -.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Coat sealing ring - <span class="clsEmphBOLD">3</span> - with hydraulic oil and slide it onto connecting piece.</li> </ul><a name="S36431510052008040700000"></a><h2 class="clsHeadFour">Hydraulic pump connection table</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020649" name="S33243022112008020700000">Fig. 237: Hydraulic Pump Connection Table</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Connections shown from hose side out.</p> <p>1 - Main drive motor hydraulic cylinder</p> <p>11 - Left piston rod side</p> <p>12 - Left piston side</p> <p>13 - Right piston rod side</p> <p>14 - Right piston side</p> <p>2 - Bracket drive motor hydraulic cylinder</p> <p>21 - Left piston rod side</p> <p>22 - Left piston side</p> <p>23 - Right piston rod side</p> <p>24 - Right piston side</p> <p>3 - Convertible top compartment cover hydraulic cylinder</p> <p>31 - Left piston rod side</p> <p>32 - Left piston side</p> <p>33 - Right piston rod side</p> <p>34 - Right piston side</p> <p>Tightening torques --> <a class="clsHyperlink" href="#S41249403412008020700000">Hydraulic system - assembly overview</a>.</p><a name="S03423298212008020700000"></a><h2 class="clsHeadThree">Hydraulic cylinder, removing and installing</h2> <p>Hydraulic lines, removing and installing --> <a class="clsHyperlink" href="#S20186302022008020700000">Hydraulic lines, removing and installing</a>.</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020547" name="S06601581242008020700000">Fig. 238: Removing Hydraulic Lines And Cylinders From Convertible Top Frame</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Bracket drive motor cylinder</span> </p> <ul class="clsDASH"> <li>Remove bracket hydraulic cylinder - <span class="clsEmphBOLD">1</span> - from ball sockets - <span class="clsEmphBOLD">2</span> -.</li> <li>Unclip hydraulic lines from brackets - <span class="clsEmphBOLD">3</span> - (Qty. 6) and loosen cable ties - <span class="clsEmphBOLD">4</span> - (Qty. 2).</li> <li>Remove hydraulic lines and cylinders from convertible top frame and place them in convertible top compartment.</li> </ul> <p><span class="clsEmphBOLD">Convertible top compartment cover cylinder</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The convertible top compartment cover cylinder is installed as described above.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020549" name="S18046482132008020700000">Fig. 239: Removing Convertible Top Switch Unit Bolts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Main drive cylinder</span> </p> <ul class="clsDASH"> <li>Remove convertible top switch unit bolts - <span class="clsEmphBOLD">1</span> -. The switch unit consists of Convertible Top Closed Position Switch F202 and Convertible Top Open Position Switch F171.</li> <li>Carefully remove convertible top switch unit from bolting point mounts.</li> <li>Remove main hydraulic cylinder securing pins - <span class="clsEmphBOLD">2</span> -.</li> <li>Loosen nuts on main hydraulic cylinder bracket until they are removed from the center and can be stored in the vehicle.</li> </ul> <p>Installation is reverse of removal.</p> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S41249403412008020700000">Hydraulic system - assembly overview</a>.</p><a name="S41635797812008020700000"></a><h2 class="clsHeadTwo">Convertible top compartment cover latch</h2><a name="S41892062252008020700000"></a><h2 class="clsHeadThree">Safety precautions</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Observe measures when disconnecting battery --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> </li> <li>27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET</li> </ul> .</td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Secure convertible top mechanism against unintentional folding up and down during all installation work as this can lead to personal injury or vehicle damage.</td> </tr> </table></span></p><a name="S02059849982008020700000"></a><h2 class="clsHeadThree">Convertible top compartment cover latch - assembly overview</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When working on the convertible top electrical system, disconnect vehicle battery ground strap.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020650" name="S21071047662008020700000">Fig. 240: Convertible Top Compartment Cover Latch - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Right tension plate</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S16471903072008020700000">Convertible top compartment cover, removing and installing</a>.</li> </ul> <p>2 - Screw</p> <ul class="clsBULLET"> <li>21 Nm</li> </ul> <p>3 - Locking washer</p> <p>4 - Screw</p> <ul class="clsBULLET"> <li>21 Nm</li> </ul> <p>5 - Securing clips</p> <p>6 - Lock bolt (motor/switch)</p> <ul class="clsBULLET"> <li>10 Nm</li> </ul> <p>7 - Left push rod</p> <ul class="clsBULLET"> <li>Preset.</li> </ul> <p>8 - Left convertible top compartment cover lock</p> <ul class="clsBULLET"> <li>The Left Convertible Top Compartment Cover Switch F290 is secured on the lock.</li> <li>Removing --> <a class="clsHyperlink" href="#S15646225942008020700000">Left and right convertible top compartment cover locks, removing and installing</a>.</li> </ul> <p>9 - Left tension plate</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S16471903072008020700000">Convertible top compartment cover, removing and installing</a>.</li> </ul> <p>10 - Convertible Top Compartment Cover Locking Motor V222 (Convertible Top Compartment Latch Switch (unlock) F293)</p> <ul class="clsBULLET"> <li>Removing <a class="clsHyperlink" href="#S24096584232008020700000">Convertible top compartment cover lock, removing and installing</a>.</li> <li>Adjusting --> <a class="clsHyperlink" href="#S41324420502008020700000">Convertible top compartment cover, adjusting drive motor</a>.</li> </ul> <p>11 - Right push rod</p> <ul class="clsBULLET"> <li>Preset</li> </ul> <p>12 - Right convertible top compartment cover lock</p> <ul class="clsBULLET"> <li>The Compartment Cover Locked Right Switch 1 F200 is secured on the lock.</li> <li>Removing <a class="clsHyperlink" href="#S15646225942008020700000">Left and right convertible top compartment cover locks, removing and installing</a>.</li> </ul><a name="S15646225942008020700000"></a><h2 class="clsHeadThree">Left and right convertible top compartment cover locks, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove rear seat bench and backrest --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S17706875992008020700000">72 - SEAT - FRAMES</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S17455885962008020700000">72 - SEAT - FRAMES</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Observe safety precautions when handling pyrotechnic belt tensioners --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S12872913122008020700000">69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S09284958162008020700000">69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove respective rear belt retractor --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S12872913122008020700000">69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S09284958162008020700000">69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Disconnect electrical connector behind belt retractor.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020545" name="S41884004332008020700000">Fig. 241: Bringing Convertible Top Into Center Position</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Bring convertible top into center position.</li> <li>Remove securing clips for front convertible top compartment well trim until compartment locks are accessible.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020651" name="S16798461792008020700000">Fig. 242: Identifying Locking Washer, Push Rod & Bolts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove locking washer - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove push rod - <span class="clsEmphBOLD">2</span> -.</li> <li>Mark exact position of bolts - <span class="clsEmphBOLD">3</span> - and remove.</li> <li>Remove convertible top compartment cover lock and lay it sideways,</li> </ul> <ul class="clsDASH"> <li>Disconnect switch unit electrical connector and remove switch and lock.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The connection is located behind the belt retractor.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Installation is reverse of removal, noting the following:</p> <ul class="clsDASH"> <li>Install bolts exactly at the markings made earlier. In this way, it is not necessary to adjust the locks.</li> <li>Ensure the convertible top compartment cover aligns with the side panel when closed.</li> <li>Check whether switch works with convertible top compartment cover closed.</li> </ul> <p>Tightening torques --> <a class="clsHyperlink" href="#S02059849982008020700000">Convertible top compartment cover latch - assembly overview</a>.</p><a name="S23706352202008020700000"></a><h2 class="clsHeadThree">Convertible top compartment cover, adjusting tension plates</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020652" name="S38188570772008020700000">Fig. 243: Convertible Top Compartment Cover, Adjusting Tension Plates</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Check whether convertible top compartment cover tension plates lowers into center of funnel for cover locks - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p>If necessary, loosen bolts - <span class="clsEmphBOLD">1</span> - and adjust tension plates to lock.</p> <p>Tightening torque --> <a class="clsHyperlink" href="#S02059849982008020700000">Convertible top compartment cover latch - assembly overview</a>.</p><a name="S24096584232008020700000"></a><h2 class="clsHeadThree">Convertible top compartment cover lock, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020653" name="S18221756102008020700000">Fig. 244: Convertible Top Compartment Cover Lock, Removing/Installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Bring convertible top into center position.</li> <li>Remove convertible top compartment well front trim.</li> <li>Mark position of Convertible Top Compartment Cover Locking Motor V222 before removal.</li> <li>Remove securing spring from ball socket and press push rod of ball stud (version 1) or remove securing clips and press push rods from guide pins (version 2).</li> </ul> <ul class="clsDASH"> <li>Disconnect electrical connector.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020654" name="S14458595262008020700000">Fig. 245: Identifying Screws</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Convertible Top Compartment Cover Locking Motor V222/Convertible Top Compartment Latch Switch (unlock) F293.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <ul class="clsDASH"> <li>Secure motor according to markings applied earlier and tighten bolts.</li> </ul> <p>Tightening torque --> <a class="clsHyperlink" href="#S02059849982008020700000">Convertible top compartment cover latch - assembly overview</a>.</p><a name="S41324420502008020700000"></a><h2 class="clsHeadThree">Convertible top compartment cover, adjusting drive motor</h2> <ul class="clsDASH"> <li>Ensure there is sufficient voltage supply for the vehicle battery.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020545" name="S21865353402008020700000">Fig. 246: Bringing Convertible Top Into Center Position</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Bring convertible top into center position.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>The convertible top hydraulic system is depressurized after 10 minutes.<ul class="clsBULLET"> <li>Risk of injury from lowering convertible top.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove securing clips for convertible top compartment well front trim until Convertible Top Compartment Cover Locking Motor V222 is accessible.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020654" name="S22352681912008020700000">Fig. 247: Identifying Screws</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Loosen bolts - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Bring convertible top compartment cover lock into "end position close" --> <a class="clsHyperlink" href="#S10464024792008020700000">Convertible top emergency release</a> with emergency key and hold it under tension.</li> <li>Tighten bolts in this position - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Bring convertible top compartment lock into "end position open" with emergency key.</li> </ul> <p>Tightening torque --> <a class="clsHyperlink" href="#S02059849982008020700000">Convertible top compartment cover latch - assembly overview</a>.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>With "motor in end position" let push rods attach to locks.</li> </ul> </td> </tr> </table></span></p><a name="S19381874182008020700000"></a><h2 class="clsHeadTwo">Convertible top operation electrical components</h2><a name="S09142966252008020700000"></a><h2 class="clsHeadThree">Safety precautions</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Observe measures when disconnecting battery --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> </li> <li>27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET</li> </ul> .</td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Secure convertible top mechanism against unintentional folding up and down during all installation work as this can lead to personal injury or vehicle damage.</td> </tr> </table></span></p><a name="S16763394462008020700000"></a><h2 class="clsHeadThree">Convertible top operation electrical components - assembly overview</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When working on the convertible top electrical system, disconnect vehicle battery ground strap.</li> <li>All cable ties that are loosened or cut off when removing convertible top should be re-installed in the same places during installation.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020655" name="S12981516552008020700000">Fig. 248: Convertible Top Operation Electrical Components - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Convertible top latch</p> <ul class="clsBULLET"> <li>Consists of:</li> <li>Convertible Top Locking Motor V223</li> <li>Convertible Top Lock Switch (open) F294</li> <li>Convertible Top Lock Switch (closed) F295</li> </ul> <ul class="clsBULLET"> <li>Tightening torque --> <a class="clsHyperlink" href="#S20584104112008040700000">Convertible Top Front Lock Switch F172</a></li> <li>Removing --> <a class="clsHyperlink" href="#S30792614912008020700000">Convertible Top Locking Motor V223/Convertible Top Lock Switch (open) F294/Convertible Top Lock Switch (closed) F295 , removing and installing</a>.</li> </ul> <p>2 - Convertible Top Control Module J256</p> <ul class="clsBULLET"> <li>Tightening torque --> <a class="clsHyperlink" href="#S02947390532008040700000">Convertible Top Control Module J256</a></li> <li>Removing --> <a class="clsHyperlink" href="#S23783073242008020700000">Convertible Top Control Module J256 , removing</a>.</li> </ul> <p>3 - Convertible top position switch</p> <ul class="clsBULLET"> <li>Consists of:</li> <li>Convertible Top Open Position Switch F171</li> <li>Convertible Top Closed Position Switch F202</li> <li>Removing --> <a class="clsHyperlink" href="#S04690330222008020700000">Convertible top position switch (Convertible Top Open Position Switch F171/Convertible Top Closed Position Switch F202), removing</a>.</li> </ul> <p>4 - Convertible Top Frame Position Sensor G356</p> <ul class="clsBULLET"> <li>Tightening torque --> <a class="clsHyperlink" href="#S05075854022008040700000">Convertible Top Frame Position Sensor G356</a>.</li> <li>Removing --> <a class="clsHyperlink" href="#S07413956522008020700000">Convertible Top Frame Position Sensor G356 , removing</a>.</li> </ul> <p>5 - Compartment Cover Open Position Switch F201</p> <ul class="clsBULLET"> <li>Tightening torque --> <a class="clsHyperlink" href="#S23338558502008040700000">Compartment Cover Open Position Switch F201</a>.</li> <li>Removing --> <a class="clsHyperlink" href="#S18448400522008020700000">Compartment Cover Open Position Switch F201 , removing</a>.</li> </ul> <p>6 - Convertible top operation hydraulic unit</p> <ul class="clsBULLET"> <li>Consists of:</li> <li>Convertible Top Hydraulic Pump V118</li> <li>Convertible Top Hydraulic Pump Relay J321</li> <li>Convertible Top Hydraulic Pump Relay 2 J588</li> </ul> <ul class="clsBULLET"> <li>Power Convertible Top Valve 1 N272</li> <li>Power Convertible Top Valve 2 N341</li> <li>Power Convertible Top Valve 3 N342</li> <li>Removing --> <a class="clsHyperlink" href="#S26313511952008020700000">Hydraulic unit (hydraulic pump), removing and installing</a>.</li> </ul> <p>7 - Convertible Top Compartment Enclosure Position Switch F292</p> <ul class="clsBULLET"> <li>Removing --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> </ul> <p>8 - Compartment Cover Locked Right Switch 1 F200</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S27131426382008020700000">Transmission Range (TR) Gear Monitoring Switch F290 and Compartment Cover Locked Right Switch 1 F200 , removing</a>.</li> </ul> <p>9 - Convertible top compartment cover lock</p> <ul class="clsBULLET"> <li>Consists of:</li> <li>Convertible Top Compartment Latch Switch (unlock) F293</li> <li>Convertible Top Compartment Cover Locking Motor V222</li> <li>Removing --> <a class="clsHyperlink" href="#S24096584232008020700000">Convertible top compartment cover lock, removing and installing</a>.</li> </ul> <p>10 - Left Convertible Top Compartment Cover Switch F290</p> <ul class="clsBULLET"> <li>Tightening torque --> <a class="clsHyperlink" href="#S02059849982008020700000">Convertible top compartment cover latch - assembly overview</a>.</li> <li>Removing --> <a class="clsHyperlink" href="#S27131426382008020700000">Transmission Range (TR) Gear Monitoring Switch F290 and Compartment Cover Locked Right Switch 1 F200 , removing</a>.</li> </ul> <p>11 - Convertible Top Front Lock Switch F172</p> <ul class="clsBULLET"> <li>Tightening torque --> <a class="clsHyperlink" href="#S20584104112008040700000">Convertible Top Front Lock Switch F172</a></li> <li>Removing --> <a class="clsHyperlink" href="#S10620906712008020700000">Convertible Top Front Lock Switch F172 , removing</a>.</li> </ul> <p>12 - Convertible Top Operation Switch E137</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S16705895802008020700000">Convertible Top Operation Switch E137 , removing</a>.</li> </ul><a name="S20584104112008040700000"></a><h2 class="clsHeadFour">Convertible Top Front Lock Switch F172</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020656" name="S28825506882008020700000">Fig. 249: Convertible Top Front Lock Switch F172</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>2 - 10 Nm</p><a name="S02947390532008040700000"></a><h2 class="clsHeadFour">Convertible Top Control Module J256</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020657" name="S27829633062008020700000">Fig. 250: Convertible Top Control Module J256</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Arrow - 2.5 Nm</p><a name="S05075854022008040700000"></a><h2 class="clsHeadFour">Convertible Top Frame Position Sensor G356</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020612" name="S17126498602008020700000">Fig. 251: Identifying Bolts, Tensioning Cable, Cable Guide & Convertible Top Frame Position Sensor G356</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>B - 1.5 Nm</p><a name="S23338558502008040700000"></a><h2 class="clsHeadFour">Compartment Cover Open Position Switch F201</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020658" name="S19811295282008020700000">Fig. 252: Compartment Cover Open Position Switch F201</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ol class="clsARABICNUM"> <li>1.5 Nm</li> </ol><a name="S30792614912008020700000"></a><h2 class="clsHeadThree">Convertible Top Locking Motor V223/Convertible Top Lock Switch (open) F294/Convertible Top Lock Switch (closed) F295 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020659" name="S04169284792008020700000">Fig. 253: Locating Convertible Top Locking Motor V223/Convertible Top Lock Switch (Open) F294/Convertible Top Lock Switch (Closed) F295</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Store convertible top in convertible top compartment.</li> </ul> <ul class="clsBULLET"> <li>The convertible top compartment cover remains open.</li> </ul> <ul class="clsDASH"> <li>Remove front roof frame seal bolts.</li> <li>Carefully remove front rail trim.</li> <li>Remove ball joint wire fastener and press push rods from convertible top lock ball studs.</li> <li>Disconnect electrical connector.</li> </ul> <ul class="clsDASH"> <li>Mark exact position of convertible top latch on rail 1.</li> <li>Remove convertible top latch bolts and remove latch.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <ul class="clsDASH"> <li>Ensure convertible top latch is installed in the position marked earlier.</li> </ul> <p>Further installation is performed in the reverse order of removal.</p> <p><span class="clsEmphBOLD">Tightening torques</span> --> <a class="clsHyperlink" href="#S26779293682008020700000">Attachments - assembly overview</a>.</p> <p>Adjust convertible top latch --> <a class="clsHyperlink" href="#S23671616752008020700000">Convertible top locks, checking and adjusting</a>.</p><a name="S04690330222008020700000"></a><h2 class="clsHeadThree">Convertible top position switch (Convertible Top Open Position Switch F171/Convertible Top Closed Position Switch F202), removing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020660" name="S15986796722008020700000">Fig. 254: Identifying Convertible Top Control Module J256</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rear side trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Disconnect electrical connector on Convertible Top Control Module J256.</li> <li>Remove convertible top cable from guides and cable ties for body wall and convertible top frame.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020549" name="S13738719282008020700000">Fig. 255: Removing Convertible Top Switch Unit Bolts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove switch bolts - <span class="clsEmphBOLD">1</span> -.</li> <li>Carefully remove convertible top position switch from bolting point mounts.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The convertible top switch unit described is located on the right main guide.</li> <li>The convertible top should be brought to the appropriate position to remove respective convertible top switch unit bolt.</li> </ul> </td> </tr> </table></span></p> <p>Tightening torque --> <a class="clsHyperlink" href="#S25617576532008020700000">Convertible top - assembly overview</a>.</p><a name="S07413956522008020700000"></a><h2 class="clsHeadThree">Convertible Top Frame Position Sensor G356 , removing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020661" name="S16138045042008020700000">Fig. 256: Identifying Convertible Top Frame Position Sensor G356</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Bring convertible top into center position.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020612" name="S40173920922008020700000">Fig. 257: Identifying Bolts, Tensioning Cable, Cable Guide & Convertible Top Frame Position Sensor G356</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connector on Convertible Top Frame Position Sensor G356 - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove bolt - <span class="clsEmphBOLD">B</span> - and carefully remove sensor - <span class="clsEmphBOLD">3</span> - from its mounting opening.</li> </ul> <p>Installation is reverse of removal.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When installing, ensure sensor slides over convertible top linkage synchronization pins.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> --> <a class="clsHyperlink" href="#S05075854022008040700000">Convertible Top Frame Position Sensor G356</a></p><a name="S18448400522008020700000"></a><h2 class="clsHeadThree">Compartment Cover Open Position Switch F201 , removing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020658" name="S09459243532008020700000">Fig. 258: Identifying Switch Bolts & Retainer</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Bring convertible top into center position.</li> <li>Remove right trim in convertible top compartment --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Disconnect electrical connector.</li> <li>Remove switch bolts - <span class="clsEmphBOLD">1</span> -.</li> </ul> <ul class="clsDASH"> <li>Carefully pry switch out of retainer - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p>Installation is reverse of removal.</p> <p><span class="clsEmphBOLD">Tightening torque</span> --> <a class="clsHyperlink" href="#S23338558502008040700000">Compartment Cover Open Position Switch F201</a>.</p><a name="S23783073242008020700000"></a><h2 class="clsHeadThree">Convertible Top Control Module J256 , removing</h2> <ul class="clsDASH"> <li>Remove rear side trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Disconnect electrical connectors.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020657" name="S42375150942008020700000">Fig. 259: Convertible Top Control Module J256</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove control module nuts - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p>Installation is reverse of removal.</p> <p><span class="clsEmphBOLD">Tightening torque</span> --> <a class="clsHyperlink" href="#S02059849982008020700000">Convertible top compartment cover latch - assembly overview</a>.</p><a name="S27131426382008020700000"></a><h2 class="clsHeadThree">Transmission Range (TR) Gear Monitoring Switch F290 and Compartment Cover Locked Right Switch 1 F200 , removing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020662" name="S37968997092008020700000">Fig. 260: Identifying Left Convertible Top Compartment Cover Switch F290</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>The Left Convertible Top Compartment Cover Switch F290 is installed in left convertible top compartment cover lock.</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020663" name="S35875671482008020700000">Fig. 261: Identifying Compartment Cover Locked Right Switch 1 F200</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>The Compartment Cover Locked Right Switch 1 F200 is installed in right convertible top compartment cover lock.</p> <ul class="clsDASH"> <li>Remove respective convertible top compartment cover lock --> <a class="clsHyperlink" href="#S15646225942008020700000">Left and right convertible top compartment cover locks, removing and installing</a>.</li> </ul><a name="S10620906712008020700000"></a><h2 class="clsHeadThree">Convertible Top Front Lock Switch F172 , removing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020664" name="S17636538222008020700000">Fig. 262: Opening Convertible Top</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Open convertible top.</li> <li>Remove upper roof frame trim on inside of windshield --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020656" name="S29995097882008020700000">Fig. 263: Disconnecting Electrical Connector, Removing Bolts & Switch</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connector - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove bolts - <span class="clsEmphBOLD">2</span> - and remove switch.</li> </ul> <p>Installation is reverse of removal.</p> <p><span class="clsEmphBOLD">Tightening torque</span> --> <a class="clsHyperlink" href="#S16763394462008020700000">Convertible top operation electrical components - assembly overview</a>.</p><a name="S16705895802008020700000"></a><h2 class="clsHeadThree">Convertible Top Operation Switch E137 , removing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020665" name="S19943065112008020700000">Fig. 264: Convertible Top Operation Switch E137</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully pry out button carrier unit on center console.</li> <li>Disconnect electrical connector.</li> <li>Slide convertible top latch button from carrier unit.</li> </ul><a name="S23588060132008020700000"></a><h2 class="clsHeadOne">63 - Bumpers</h2><a name="S34197285462008020700000"></a><h2 class="clsHeadTwo">Front bumper</h2><a name="S02424918622008020700000"></a><h2 class="clsHeadThree">Front bumper (up to model year 2005) - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020666" name="S32518515042008020700000">Fig. 265: Front Bumper (Up To Model Year 2005) - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Bumper cover</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S17178247732008020700000">Front bumper (up to model year 2005), removing and installing</a>.</li> <li>Adjustment to hood --> <a class="clsHyperlink" href="#S17973262872008020700000">Bumper cover (up to model year 2005), adjusting to hood</a>.</li> <li>Positioning license plate mounting holes <a class="clsHyperlink" href="#S24029405252008040700000">License plate securing holes, creating</a>.</li> <li>If a new part is installed, holes for license plate may only be drilled on places marked or the license plate may only be secured on the corresponding places.</li> </ul> <ul class="clsBULLET"> <li>Panel gap dimensions <a class="clsHyperlink" href="#S35004167672008040700000">Panel gap dimensions</a>.</li> </ul> <p>2 - Screw</p> <ul class="clsBULLET"> <li>6 Nm</li> </ul> <p>3 - Screw</p> <ul class="clsBULLET"> <li>3 Nm</li> </ul> <p>4 - Right support</p> <p>5 - Center support</p> <p>6 - Cross member</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S03056117122008020700000">Bumper crossmember (up to model year 2005), removing and installing</a>.</li> </ul> <p>7 - Left support</p> <p>8 - Guide piece</p> <ul class="clsBULLET"> <li>Removing and installing <a class="clsHyperlink" href="#S02269794052008040700000">Guide piece, removing and installing</a>.</li> </ul> <p>9 - Screw</p> <ul class="clsBULLET"> <li>1.5 Nm</li> </ul> <p>10 - Grommet</p> <ul class="clsBULLET"> <li>Qty. 2</li> <li>Insert bumper cover in fender before installing <a class="clsHyperlink" href="#S13365873442008040700000">Fender grommets, installing</a>.</li> </ul> <p>11 - Wheel housing liner</p><a name="S24029405252008040700000"></a><h2 class="clsHeadFour">License plate securing holes, creating</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020339" name="S35436899242008020700000">Fig. 266: License Plate Securing Holes, Creating</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Four punch marks are present in the bumper cover license plate field. They must be drilled out to secure a license plate (measurements 115 x 520 mm).</li> </ul> </td> </tr> </table></span></p> <p>If centering punch marks are not visible, proceed as follows:</p> <ul class="clsDASH"> <li>Determine vertical bisecting line from Audi emblem to center of grill on bumper.</li> <li>Determine horizontal bisecting line:</li> </ul> <ul class="clsBULLET"> <li>Dimension - <span class="clsEmphBOLD">a</span> - = Dimension - <span class="clsEmphBOLD">a</span> -.</li> </ul> <ul class="clsDASH"> <li>Determine mounting points for license plate symmetrically as follows:</li> </ul> <ul class="clsBULLET"> <li>Dimension - <span class="clsEmphBOLD">x</span> - = 139 mm</li> <li>Dimension - <span class="clsEmphBOLD">y</span> - = 62 mm</li> </ul><a name="S13365873442008040700000"></a><h2 class="clsHeadFour">Fender grommets, installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020667" name="S03943728392008020700000">Fig. 267: Fender Grommets, Installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Before installing bumper cover - <span class="clsEmphBOLD">1</span> - , grommets - <span class="clsEmphBOLD">3</span> - must slide onto threaded pins - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p>4 - Fender</p> <ul class="clsDASH"> <li>Tighten nut - <span class="clsEmphBOLD">5</span> - after installing.</li> </ul> <p>5 - Nut (6 Nm)</p><a name="S35004167672008040700000"></a><h2 class="clsHeadFour">Panel gap dimensions</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020668" name="S42751836012008020700000">Fig. 268: Panel Gap Dimensions</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Panel gap dimensions can be checked with Adjusting Gauge 3371.</li> <li>Dimension - <span class="clsEmphBOLD">A</span> - = 2 mm + 0.5 mm.</li> <li>Dimension - <span class="clsEmphBOLD">B</span> - = 0 mm ± 0.5 mm.</li> <li>Dimension - <span class="clsEmphBOLD">C</span> - = 0 mm ± 0.5 mm.</li> </ul> </td> </tr> </table></span></p><a name="S17178247732008020700000"></a><h2 class="clsHeadThree">Front bumper (up to model year 2005), removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020669" name="S19216411962008020700000">Fig. 269: Loosening Bolts Or Quick Release Fasteners</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Loosen bolts or quick release fasteners - <span class="clsEmphBOLD">3</span> -. The quick release fasteners behind the sound insulation - <span class="clsEmphBOLD">2</span> - remain installed.</li> <li>The quick release fasteners remain in the bumper cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020340" name="S14680714662008020700000">Fig. 270: Loosening Left/Right Wheelhousing Liners In Front Area</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Loosen left and right wheel housing liners in front area - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020341" name="S39873755032008020700000">Fig. 271: Pulling Back Wheelhousing Liner & Unclipping Bumper Rear Edge From Catch</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull back wheel housing liner - <span class="clsEmphBOLD">arrow A</span> -.</li> <li>Remove bolt - <span class="clsEmphBOLD">2</span> - and nuts - <span class="clsEmphBOLD">1</span> -.</li> <li>Unclip bumper rear edge from catch - <span class="clsEmphBOLD">arrow B</span> -.</li> <li>Repeat procedure on opposite side of the vehicle.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020477" name="S38379513572008020700000">Fig. 272: Radiator Grille, Removing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">1</span> -.</li> <li>Fold decorative grille - <span class="clsEmphBOLD">2</span> - forward slightly and pull up out of bumper.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020670" name="S26714820442008020700000">Fig. 273: Removing Bumper Cover Bolts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Unscrew bolts - <span class="clsEmphBOLD">8</span> -.</li> <li>Remove bolts - <span class="clsEmphBOLD">2</span> - , - <span class="clsEmphBOLD">3</span> - and - <span class="clsEmphBOLD">4</span> - as well as bolts - <span class="clsEmphBOLD">5</span> - , - <span class="clsEmphBOLD">6</span> - and - <span class="clsEmphBOLD">7</span> -.</li> <li>Remove side pieces - <span class="clsEmphBOLD">arrow</span> - sideways out of guide piece.</li> <li>Pull bumper cover forward slightly.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020344" name="S29518733902008020700000">Fig. 274: Identifying Hose To Headlight Cleaning System & Bumper Cover Connector(s)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>If installed, disconnect hose - <span class="clsEmphBOLD">1</span> - to headlight cleaning system and reserve washer fluid in a clean container for re-use.</li> <li>Disconnect connector(s) - <span class="clsEmphBOLD">2</span> - to bumper cover.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020667" name="S03344484322008020700000">Fig. 275: Checking To See If Threaded Pins On Bumper Side Walls And Grommets In Fenders Are Present</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Installation is reverse of removal, noting the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Before installing bumper cover - <span class="clsEmphBOLD">1</span> - , check to see if threaded pins - <span class="clsEmphBOLD">2</span> - on bumper side walls and grommets - <span class="clsEmphBOLD">3</span> - in fenders - <span class="clsEmphBOLD">4</span> - are present.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Tighten nut.</li> </ul> <p>5 - Nut (5 Nm)</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020344" name="S08976282492008020700000">Fig. 276: Identifying Hose To Headlight Cleaning System & Bumper Cover Connector(s)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Slide bumper cover onto lock carrier and if necessary, reconnect headlamp washer system hose - <span class="clsEmphBOLD">1</span> - and electrical connectors - <span class="clsEmphBOLD">2</span> -.</li> <li>Slide bumper cover into installation position. Ensure threaded pins in bumper side walls engage into holes at the fenders.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020345" name="S28464954222008020700000">Fig. 277: Pulling Back Wheelhousing Liner & Engaging Bumper Rear Edge Into Catch</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull back wheel housing liner - <span class="clsEmphBOLD">arrow A</span> -.</li> <li>Engage bumper rear edge into catch - <span class="clsEmphBOLD">arrow B</span> -.</li> <li>Tighten nuts - <span class="clsEmphBOLD">1</span> - and bolt - <span class="clsEmphBOLD">2</span> -.</li> <li>Repeat procedure on opposite side of the vehicle.</li> </ul> <p>1 - Nut (4 Nm)</p> <p>2 - Screw (1 Nm)</p><a name="S39330993452008020700000"></a><h2 class="clsHeadThree">Front bumper (from model year 2006) - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020671" name="S28339744982008020700000">Fig. 278: Front Bumper (From Model Year 2006) - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Screw</p> <ul class="clsBULLET"> <li>6 Nm</li> </ul> <p>2 - Screw</p> <ul class="clsBULLET"> <li>23 Nm</li> </ul> <p>3 - Bumper crossmember</p> <ul class="clsBULLET"> <li>Bumper cover removed.</li> <li>To remove, remove bolts - <span class="clsEmphBOLD">2</span> -.</li> <li>Disconnect harness connectors to signal horns and remove bumper crossmember from impact absorbers toward front.</li> </ul> <p>4 - Pop rivet</p> <p>5 - Signal horn</p> <ul class="clsBULLET"> <li>To remove, drill off rivet heads.</li> </ul> <p>6 - Support piece</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When turning adjustment screw, make sure mounting bracket raises.</li> <li>Before installing bumper cover, adjust support piece adjusting screw <a class="clsHyperlink" href="#S03956496692008040700000">Adjusting support piece</a>.</li> <li>Tighten adjustment screw to 2 Nm with a long Torx wrench - <span class="clsEmphBOLD">T30</span> - through holes in cover - <span class="clsEmphBOLD">arrows</span> -.</li> <li>To disassemble, drill off pop rivet heads.</li> </ul> </td> </tr> </table></span></p> <p>7 - Pop rivet</p> <p>8 - Signal horn</p> <p>9 - Brace for fender</p> <p>10 - Guide piece</p> <ul class="clsBULLET"> <li>Side piece of bumper cover must be clipped in between fender and guide piece <a class="clsHyperlink" href="#S30708974372008040700000">Removing guide piece</a>.</li> </ul> <p>11 - Screw</p> <ul class="clsBULLET"> <li>1 Nm</li> </ul> <p>12 - Screw</p> <ul class="clsBULLET"> <li>1 Nm</li> </ul> <p>13 - Bumper cover</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>While installing, the following sequence described for assembling/bolting must be observed for correct assembly.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Set cover onto vehicle and first clip the left and right side piece into guide parts - <span class="clsEmphBOLD">10</span> -.</li> <li>Tighten nuts on fender connection <a class="clsHyperlink" href="#S25295058092008040700000">Fender bolts</a>.</li> <li>Tighten bolts - <span class="clsEmphBOLD">12</span> - to wheelhousing liner.</li> <li>Loosely thread in bolts - <span class="clsEmphBOLD">1</span> -.</li> </ul> <ul class="clsBULLET"> <li>Close hood and check cover for projection and recess.</li> <li>If necessary, check position of cover and tighten bolts - <span class="clsEmphBOLD">12</span> -.</li> <li>Tighten bolt on support piece to 2 Nm <a class="clsHyperlink" href="#S03956496692008040700000">Adjusting support piece</a>.</li> <li>Bumper cover, removing and installing --> <a class="clsHyperlink" href="#S26424534892008020700000">Front bumper (from model year 2006), removing and installing</a>.</li> </ul> <ul class="clsBULLET"> <li>Crossmember, removing and installing --> <a class="clsHyperlink" href="#S10887213812008020700000">Bumper crossmember, removing from cover</a>.</li> </ul><a name="S25295058092008040700000"></a><h2 class="clsHeadFour">Fender bolts</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020325" name="S05918311942008020700000">Fig. 279: Fender Bolts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Make sure when installing that the clips - <span class="clsEmphBOLD">2</span> - are inserted onto threaded pins.</li> <li>Tighten nuts - <span class="clsEmphBOLD">4</span> - after inserting bumper cover - <span class="clsEmphBOLD">1</span> - in fender - <span class="clsEmphBOLD">3</span> -.</li> </ul> <p>4 - Nut (4 Nm)</p><a name="S03956496692008040700000"></a><h2 class="clsHeadFour">Adjusting support piece</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020326" name="S29878417822008020700000">Fig. 280: Adjusting Support Piece</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When turning adjustment screw - <span class="clsEmphBOLD">3</span> - , make sure mounting bracket - <span class="clsEmphBOLD">4</span> - raises.</li> <li>If mounting bracket does not raise, place a small drop (very small!) of locking compound D 000 600 A2 on the adjustment screw threads - <span class="clsEmphBOLD">3</span> - and allow locking compound to dry.</li> <li>Turn adjustment screw up to dimension - <span class="clsEmphBOLD">a</span> -.</li> <li>The mounting bracket raises when adjustment screw is turned due to the increased friction.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Before installing bumper cover - <span class="clsEmphBOLD">1</span> - , adjust adjusting screw - <span class="clsEmphBOLD">3</span> - on support piece - <span class="clsEmphBOLD">5</span> - to dimension - <span class="clsEmphBOLD">a</span> - = 21 mm +1 mm.</li> <li>Mounting bracket - <span class="clsEmphBOLD">4</span> - must be screwed on completely (left-hand thread) for this.</li> <li>Adjustment screw - <span class="clsEmphBOLD">3</span> - and mounting bracket - <span class="clsEmphBOLD">4</span> - belong to delivery casing for support piece and are not replacement parts.</li> <li>When installing bolt - <span class="clsEmphBOLD">3</span> - , mounting bracket - <span class="clsEmphBOLD">4</span> - unscrews and holds the carrier piece - <span class="clsEmphBOLD">2</span> - of bumper cover - <span class="clsEmphBOLD">1</span> - in the designated position.</li> </ul> <ul class="clsDASH"> <li>The support piece - <span class="clsEmphBOLD">5</span> - is secured to bumper cover - <span class="clsEmphBOLD">6</span> - with pop rivets.</li> </ul><a name="S16210437642008040700000"></a><h2 class="clsHeadFour">Clamping pins for noise insulation</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020327" name="S05472226392008020700000">Fig. 281: Clamping Pins For Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>When removing bumper cover - <span class="clsEmphBOLD">1</span> - , turn clamping pins - <span class="clsEmphBOLD">2</span> - 180° and remove from spring nut - <span class="clsEmphBOLD">4</span> - on sound insulation - <span class="clsEmphBOLD">3</span> -.</li> </ul><a name="S30708974372008040700000"></a><h2 class="clsHeadFour">Removing guide piece</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020328" name="S02485893332008020700000">Fig. 282: Removing Guide Piece</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Bumper cover removed</li> <li>Unscrew bolts - <span class="clsEmphBOLD">3</span> - and pull guide piece - <span class="clsEmphBOLD">2</span> - downward out of fender - <span class="clsEmphBOLD">1</span> -.</li> <li>When installing, bumper cover - <span class="clsEmphBOLD">4</span> - must engage cleanly in guide piece.</li> </ul><a name="S41032481122008040700000"></a><h2 class="clsHeadFour">Brace for wheelhousing liner</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020329" name="S11061190632008020700000">Fig. 283: Brace For Wheelhousing Liner</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>For mounting front wheelhousing liner - <span class="clsEmphBOLD">3</span> -.</li> <li>When installing brace - <span class="clsEmphBOLD">1</span> - , tighten bolt - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p>2 - Screw (10 Nm)</p><a name="S42166408972008020700000"></a><h2 class="clsHeadThree">Front bumper (RS4) - assembly overview</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Removal and installation is done the same as the standard bumper from model year 2006.</li> <li>Only differing steps are described.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020672" name="S42210942252008020700000">Fig. 284: Front Bumper (RS4) - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Screw</p> <ul class="clsBULLET"> <li>6 Nm</li> </ul> <p>2 - Bumper cover</p> <ul class="clsBULLET"> <li>Removal and installation as with standard production.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>While installing, the following sequence described for assembling/bolting must be observed for correct assembly.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Set cover onto vehicle and first clip the left and right side piece into guide parts - <span class="clsEmphBOLD">10</span> -.</li> <li>Tighten nuts on fender connection <a class="clsHyperlink" href="#S25295058092008040700000">Fender bolts</a>.</li> <li>Tighten bolts - <span class="clsEmphBOLD">12</span> - to wheelhousing liner.</li> <li>Loosely thread in bolts - <span class="clsEmphBOLD">1</span> -.</li> </ul> <ul class="clsBULLET"> <li>Close hood and check cover for projection and recess.</li> <li>If necessary, check position of cover and tighten bolts - <span class="clsEmphBOLD">4</span> -.</li> <li>Tighten bolt on support piece to 2 Nm <a class="clsHyperlink" href="#S03956496692008040700000">Adjusting support piece</a>.</li> <li>Bumper cover, removing and installing --> <a class="clsHyperlink" href="#S26424534892008020700000">Front bumper (from model year 2006), removing and installing</a>.</li> </ul> <ul class="clsBULLET"> <li>Crossmember, removing and installing --> <a class="clsHyperlink" href="#S10887213812008020700000">Bumper crossmember, removing from cover</a>.</li> </ul> <p>3 - Guide piece</p> <p>4 - Screw</p> <ul class="clsBULLET"> <li>1 Nm</li> </ul> <p>5 - Brace for fender</p> <p>6 - Bumper crossmember</p> <p>7 - Support piece</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When turning adjustment screw, make sure mounting bracket raises.</li> <li>Before installing bumper cover, adjust support piece adjusting screw <a class="clsHyperlink" href="#S03956496692008040700000">Adjusting support piece</a>.</li> <li>Tighten adjustment screw to 2 Nm with a long Torx wrench - <span class="clsEmphBOLD">T30</span> - through holes in cover - <span class="clsEmphBOLD">arrows</span> -.</li> <li>To disassemble, drill off pop rivet heads.</li> </ul> </td> </tr> </table></span></p> <p>8 - Front spoiler</p> <ul class="clsBULLET"> <li>Remove screws - <span class="clsEmphBOLD">10</span> -.</li> <li>Slide spoiler back slightly out of bumper cover guides.</li> <li>Remove spoiler downward.</li> </ul> <p>9 - Expanding rivet</p> <p>10 - Screw</p> <ul class="clsBULLET"> <li>2 Nm</li> </ul> <p>11 - Spring nut</p><a name="S30087272802008040700000"></a><h2 class="clsHeadFour">Air intake grille for S4</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020330" name="S23742803582008020700000">Fig. 285: Air Intake Grille For S4</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolt - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Press air intake grille - <span class="clsEmphBOLD">2</span> - on the inside of bumper cover - <span class="clsEmphBOLD">2</span> - as shown toward rear out of locking mechanism.</li> <li>Remove air intake grille forward from bumper cover.</li> </ul><a name="S26424534892008020700000"></a><h2 class="clsHeadThree">Front bumper (from model year 2006), removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020673" name="S15503901802008020700000">Fig. 286: Front Bumper (From Model Year 2006) Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - from top of bumper cover - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p>Only on RS4</p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - from top of bumper cover - <span class="clsEmphBOLD">2</span> -.</li> <li> Remove screw - <span class="clsEmphBOLD">4</span> - from inside of fender - <span class="clsEmphBOLD">3</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The bolt is only accessible after driving wheel housing liner back.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020674" name="S29829961062008020700000">Fig. 287: Identifying Spring Nut Placed On Bumper Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Spring nut - <span class="clsEmphBOLD">5</span> - placed on bumper cover.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017429" name="S38424411312008020700000">Fig. 288: Identifying Quick-Release Fasteners And Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts and quick release screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -. Rear noise insulation (quick release screws - <span class="clsEmphBOLD">3</span> -) remains installed.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>For the sake of a better illustration, the wheels are shown removed in the illustrations.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020340" name="S05405162672008020700000">Fig. 289: Loosening Left/Right Wheelhousing Liners In Front Area</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Loosen left and right wheel housing liners in front area - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020341" name="S37458371132008020700000">Fig. 290: Pulling Back Wheelhousing Liner & Unclipping Bumper Rear Edge From Catch</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull back wheel housing liner - <span class="clsEmphBOLD">arrow A</span> -.</li> <li>Remove bolt - <span class="clsEmphBOLD">2</span> - and nuts - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>On RS4 models, you must also loosen a screw on the inside of the fender. <a class="clsHyperlink" href="#S26424534892008020700000">Front bumper (from model year 2006), removing and installing</a>.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Unclip bumper rear edge from catch - <span class="clsEmphBOLD">arrow B</span> -.</li> <li>Repeat procedure on opposite side of the vehicle.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020326" name="S02640631762008020700000">Fig. 291: Adjusting Support Piece</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Loosen adjustment screw - <span class="clsEmphBOLD">3</span> - at support piece - <span class="clsEmphBOLD">5</span> -.</li> </ul> <p>The bracket - <span class="clsEmphBOLD">4</span> - retracts into the support piece - <span class="clsEmphBOLD">5</span> - and frees up the bumper cover - <span class="clsEmphBOLD">1</span> -.</p> <ul class="clsDASH"> <li>Pull bumper cover forward slightly.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020344" name="S11419573502008020700000">Fig. 292: Identifying Hose To Headlight Cleaning System & Bumper Cover Connector(s)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>If installed, disconnect hose - <span class="clsEmphBOLD">1</span> - to headlight cleaning system and reserve washer fluid in a clean container for re-use.</li> <li>Disconnect harness connector(s) - <span class="clsEmphBOLD">2</span> - to bumper.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Installation is reverse of removal, noting the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Before installing bumper, check to see if threaded pins at bumper rear edge as well as expanding clips and sleeves in the fenders are present.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020344" name="S41908111462008020700000">Fig. 293: Identifying Hose To Headlight Cleaning System & Bumper Cover Connector(s)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Slide bumper cover onto impact absorber and re-connect headlight cleaning system hose - <span class="clsEmphBOLD">1</span> - and electrical harness connectors - <span class="clsEmphBOLD">2</span> -.</li> <li>Slide bumper cover into installation position. Ensure threaded pins in bumper side walls engage into holes at the fenders.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020345" name="S22202388152008020700000">Fig. 294: Pulling Back Wheelhousing Liner & Engaging Bumper Rear Edge Into Catch</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull back wheel housing liner - <span class="clsEmphBOLD">arrow A</span> -.</li> <li>Engage bumper rear edge into catch - <span class="clsEmphBOLD">arrow B</span> -.</li> <li>Tighten nuts - <span class="clsEmphBOLD">1</span> - and bolt - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p>1 - Nut (4 Nm)</p> <p>2 - Screw (1 Nm)</p> <ul class="clsDASH"> <li>Repeat procedure on opposite side of the vehicle.</li> </ul> <p>Further installation is performed in the reverse order of removal.</p><a name="S05633294302008020700000"></a><h2 class="clsHeadThree">Radiator grille (from model year 2006) - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020331" name="S21697979912008020700000">Fig. 295: Radiator Grille (From Model Year 2006) - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Bumper cover</p> <p>2 - Radiator grille</p> <ul class="clsBULLET"> <li>Bumper cover removed.</li> </ul> <p>3 - Trim for radiator grille</p> <p>4 - License plate holder</p> <ul class="clsBULLET"> <li>Bumper cover not removed.</li> <li>To disassemble from rear side, unclip from radiator grille.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020332" name="S13748504372008020700000">Fig. 296: Removing Radiator Grille</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Removing radiator grille</span> </p> <ul class="clsBULLET"> <li>Bumper cover removed.</li> </ul> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">arrows</span> - around edge and pull radiator grille from bumper cover.</li> </ul> <p>Arrow - 1.5 Nm</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020333" name="S28659679362008020700000">Fig. 297: Removing Panel For Fog Lights</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Removing panel for fog lights</span> </p> <ul class="clsDASH"> <li>Disengage locking mechanisms - <span class="clsEmphBOLD">arrows</span> - and pull off panel toward vehicle interior.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020334" name="S31035001692008020700000">Fig. 298: Disengaging Fog Lights Locking Mechanisms</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Fog lights removed.</p> <ul class="clsDASH"> <li>Disengage locking mechanisms - <span class="clsEmphBOLD">arrows</span> - and pull off panel toward outside.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020335" name="S22921419552008020700000">Fig. 299: Disengaging Covers Locking Mechanisms</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Covers are divided into two parts.</p> <p>Disengage locking mechanisms - <span class="clsEmphBOLD">arrows</span> - and pull off cover toward outside.</p><a name="S17973262872008020700000"></a><h2 class="clsHeadThree">Bumper cover (up to model year 2005), adjusting to hood</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020670" name="S16587802812008020700000">Fig. 300: Removing Bumper Cover Bolts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Position bumper cover, clip in side flanks - <span class="clsEmphBOLD">arrow</span> - and secure with bolts - <span class="clsEmphBOLD">8</span> -.</li> <li>Loosely install bolt - <span class="clsEmphBOLD">3</span> -.</li> <li>Tighten bolts - <span class="clsEmphBOLD">2</span> - , - <span class="clsEmphBOLD">4</span> - , - <span class="clsEmphBOLD">5</span> - , - <span class="clsEmphBOLD">6</span> - and - <span class="clsEmphBOLD">7</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Note different torque values.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Close hood.</li> <li>Check projection and recess of bumper cover to hood.</li> <li>If OK, tighten all bolts to torque.</li> <li>If not OK, open hood.</li> </ul> <ul class="clsDASH"> <li>Loosen bolt(s) - <span class="clsEmphBOLD">2</span> - and/or - <span class="clsEmphBOLD">4</span> - , correct top of bumper cover accordingly and re-tighten bolt to torque.</li> <li>Tighten bolt - <span class="clsEmphBOLD">3</span> -.</li> </ul> <p>2 - Screw (6 Nm)</p> <p>3 - Screw (6 Nm)</p> <p>4 - Screw (6 Nm)</p> <p>5 - Screw (3 Nm)</p> <p>6 - Screw (3 Nm)</p> <p>7 - Screw (3 Nm)</p><a name="S03056117122008020700000"></a><h2 class="clsHeadThree">Bumper crossmember (up to model year 2005), removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020675" name="S01292745152008020700000">Fig. 301: Bumper Crossmember (Up To Model Year 2005) Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Bolts</p> <ul class="clsBULLET"> <li>3 Nm</li> </ul> <p>2 - Cross member</p> <ul class="clsBULLET"> <li>Mount on impact absorber --> <a class="clsHyperlink" href="#S31324226972008020700000">Bumper crossmember to impact absorber mount</a>.</li> <li>Bumper cover, removing --> <a class="clsHyperlink" href="#S17178247732008020700000">Front bumper (up to model year 2005), removing and installing</a>.</li> <li>Disconnect electrical connectors to signal horn.</li> </ul> <p>3 - Supports</p> <p>4 - Screw</p> <ul class="clsBULLET"> <li>26 Nm</li> </ul> <p>5 - Impact absorber</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S16451727132008020700000">Impact absorber, removing and installing</a>.</li> </ul> <p>6 - Pop rivet</p> <p>7 - Signal horn</p> <ul class="clsBULLET"> <li>To remove, drill out hollow rivet heads and drive out rivet shafts.</li> </ul> <p>8 - Guide piece</p> <ul class="clsBULLET"> <li>Removing and installing <a class="clsHyperlink" href="#S02269794052008040700000">Guide piece, removing and installing</a>.</li> </ul><a name="S02269794052008040700000"></a><h2 class="clsHeadFour">Guide piece, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020676" name="S28217068182008020700000">Fig. 302: Guide Piece Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>When installing guide piece - <span class="clsEmphBOLD">1</span> - , tighten bolts in the following sequence.</li> <li>Tighten bolt - <span class="clsEmphBOLD">2</span> - first.</li> <li>Then secure brace - <span class="clsEmphBOLD">4</span> - with bolt - <span class="clsEmphBOLD">3</span> -.</li> <li>Tighten bolt - <span class="clsEmphBOLD">5</span> - last.</li> </ul> <p>2 - Screw (4 Nm_</p> <p>3 - Screw (1 Nm)</p> <p>5 - Screw (6 Nm)</p><a name="S10887213812008020700000"></a><h2 class="clsHeadThree">Bumper crossmember, removing from cover</h2> <ul class="clsDASH"> <li>Bumper cover removed.</li> <li>Remove signal horn - <span class="clsEmphBOLD">4</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020348" name="S25291011112008020700000">Fig. 303: Crossmember, removing from cover and installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect hose - <span class="clsEmphBOLD">5</span> - of headlamp cleaning system on both sides (press release buttons).</li> <li>Unscrew bolts - <span class="clsEmphBOLD">3</span> - of right spray jet for headlamp cleaning system - spray jet remains installed.</li> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - (Qty. 5).</li> <li>Pry off retaining clips - <span class="clsEmphBOLD">2</span> - (Qty. 3).</li> </ul> <ul class="clsDASH"> <li>Swivel spray jet for headlamp cleaning system to the side and remove crossmember from bumper cover.</li> </ul><a name="S31324226972008020700000"></a><h2 class="clsHeadThree">Bumper crossmember to impact absorber mount</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Impact absorber is self-adjusting, meaning it can compensate bearing tolerances in height between crossmember and Impact absorber when installing the bolt.</li> <li>This holds and secures the crossmember automatically in the previously adjusted position when installing the bolt - <span class="clsEmphBOLD">1</span> -.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020346" name="S04378115352008020700000">Fig. 304: Bumper, Mounting To Shock Absorber Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Screw</p> <ul class="clsBULLET"> <li>23 Nm</li> </ul> <p>2 - Lower carrier bushing</p> <ul class="clsBULLET"> <li>Plastic part pressed into adjusting screw.</li> <li>No replacement part.</li> </ul> <p>3 - Lower adjusting screw</p> <ul class="clsBULLET"> <li>Before assembling bumper crossmember, install completely but do not tighten.</li> <li>Left-hand thread</li> <li>No replacement part.</li> </ul> <p>4 - Lower threaded bushing</p> <ul class="clsBULLET"> <li>Secured against falling out with securing pin.</li> <li>No replacement part.</li> </ul> <p>5 - Securing pin</p> <ul class="clsBULLET"> <li>No replacement part.</li> </ul> <p>6 - Impact absorber</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S16451727132008020700000">Impact absorber, removing and installing</a>.</li> </ul> <p>7 - Upper threaded bushing</p> <ul class="clsBULLET"> <li>Secured against falling out with securing pin.</li> <li>No replacement part.</li> </ul> <p>8 - Upper adjusting screw</p> <ul class="clsBULLET"> <li>Install completely before assembling bumper crossmember.</li> <li>Right-hand thread</li> <li>No replacement part.</li> </ul> <p>9 - Cover</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S02424918622008020700000">Front bumper (up to model year 2005) - assembly overview</a>.</li> </ul> <p>10 - Nut</p> <ul class="clsBULLET"> <li>Belongs to crossmember delivery casing.</li> </ul> <p>11 - Upper carrier bushing</p> <ul class="clsBULLET"> <li>Plastic part pressed into adjusting screw.</li> <li>No replacement part.</li> </ul> <p>12 - Cross member</p><a name="S16451727132008020700000"></a><h2 class="clsHeadThree">Impact absorber, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020350" name="S40395377052008020700000">Fig. 305: Impact Absorber Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Bumper crossmember removed.</li> </ul> <ul class="clsDASH"> <li>Unscrew bolts - <span class="clsEmphBOLD">2</span> -.</li> <li>Unscrew nut - <span class="clsEmphBOLD">3</span> - and pull impact absorber - <span class="clsEmphBOLD">1</span> - from longmember.</li> </ul> <p>2 - Screw (50 Nm)</p> <p>3 - Nut (4 Nm)</p><a name="S26871168502008020700000"></a><h2 class="clsHeadTwo">Rear bumper</h2><a name="S39391566632008020700000"></a><h2 class="clsHeadThree">Bumper cover, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020677" name="S35838828902008020700000">Fig. 306: Bumper Cover Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Guide piece</p> <ul class="clsBULLET"> <li>Removing and installing <a class="clsHyperlink" href="#S37543110512008040700000">Guide piece, removing and installing</a>.</li> </ul> <p>2 - Grommet</p> <ul class="clsBULLET"> <li>2 pieces per side.</li> <li>Must be inserted in fender before installing bumper cover <a class="clsHyperlink" href="#S32977553722008040700000">Side panel grommets, installing</a>.</li> </ul> <p>3 - Cross member</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S11422223192008020700000">Bumper crossmember, removing and installing</a>.</li> </ul> <p>4 - Bumper cover</p> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Removing:</span> </li> </ul> <ul class="clsDASH"> <li>Remove bolts in rear area of wheel housing liner.</li> <li>Drive back wheel housing liner and remove bolts from guide piece.</li> <li>Remove luggage compartment side trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove nuts from luggage compartment.</li> </ul> <ul class="clsDASH"> <li>Unclip bumper cover side flanks from guide piece.</li> <li>Pull bumper cover back slightly and if necessary, disconnect electrical connector (at left under tail light) to the parking assist system sensors.</li> <li>Remove bumper cover toward rear.</li> </ul> <ul class="clsBULLET"> <li>Panel gap dimensions <a class="clsHyperlink" href="#S26584122572008040700000">Panel gap dimensions</a></li> </ul> <p>5 - Screw</p> <ul class="clsBULLET"> <li>1.5 Nm</li> </ul> <p>6 - Wheel housing liner</p> <p>7 - Nut</p> <ul class="clsBULLET"> <li>4 Nm</li> </ul><a name="S32977553722008040700000"></a><h2 class="clsHeadFour">Side panel grommets, installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020667" name="S09828563582008020700000">Fig. 307: Checking To See If Threaded Pins On Bumper Side Walls And Grommets In Fenders Are Present</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Before installing bumper cover - <span class="clsEmphBOLD">1</span> - , check to see if threaded pins - <span class="clsEmphBOLD">2</span> - on bumper sides and grommets - <span class="clsEmphBOLD">3</span> - are present.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Before installing bumper cover - <span class="clsEmphBOLD">1</span> - , grommets - <span class="clsEmphBOLD">3</span> - must slide onto threaded pins - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p>4 - Side panel</p> <p>5 - Nut (6 Nm)</p> <ul class="clsDASH"> <li>Tighten nut - <span class="clsEmphBOLD">5</span> - after installing.</li> </ul><a name="S37543110512008040700000"></a><h2 class="clsHeadFour">Guide piece, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020678" name="S36959978992008020700000">Fig. 308: Guide Piece, Removing And Installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Bumper cover removed.</li> </ul> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">3</span> - and remove guide piece - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p>2 - Clip</p> <ul class="clsDASH"> <li>When installing, tighten bolts - <span class="clsEmphBOLD">3</span> - in - <span class="clsEmphBOLD">a</span> - , - <span class="clsEmphBOLD">b</span> - and - <span class="clsEmphBOLD">c</span> - sequence.</li> </ul> <p>a, b, c - Screw (1.5 Nm)</p><a name="S26584122572008040700000"></a><h2 class="clsHeadFour">Panel gap dimensions</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020679" name="S18376140402008020700000">Fig. 309: Panel Gap Dimensions</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Panel gap dimensions can be checked with Adjusting Gauge 3371.</li> <li>Dimension - <span class="clsEmphBOLD">A</span> - = 2 mm + 0.5 mm.</li> <li>Dimension - <span class="clsEmphBOLD">B</span> - = 0 mm ± 0.6 mm.</li> <li>Dimension - <span class="clsEmphBOLD">C</span> - = 0 mm ± 0.6 mm.</li> </ul> </td> </tr> </table></span></p><a name="S11422223192008020700000"></a><h2 class="clsHeadThree">Bumper crossmember, removing and installing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Bumper cover removed.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020680" name="S31671936312008020700000">Fig. 310: Bumper Crossmember Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Screw</p> <ul class="clsBULLET"> <li>18 Nm</li> <li>Qty. 4</li> </ul> <p>2 - Grommets</p> <p>3 - Support piece</p> <p>4 - Screw</p> <ul class="clsBULLET"> <li>1.5 Nm</li> </ul> <p>5 - Cross member</p> <p>6 - Nut</p> <ul class="clsBULLET"> <li>20 Nm</li> <li>Qty. 2</li> </ul> <p>7 - Screw</p> <ul class="clsBULLET"> <li>20 Nm</li> <li>Qty. 2</li> </ul> <p>8 - Impact absorber</p><a name="S21766745152008020700000"></a><h2 class="clsHeadOne">64 - Glass, Windows</h2><a name="S40916623592008020700000"></a><h2 class="clsHeadTwo">Flush-bonded windows</h2><a name="S31809393582008020700000"></a><h2 class="clsHeadThree">Flush-bonded windows, removing and installing - general information</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020368" name="S05647101682008020700000">Fig. 311: Identifying Special Tools - Flush-Bonded Windows, Removing And Installing - General Information</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <ul class="clsBULLET"> <li>Suction lifter V.A.G 1344</li> <li>Electric Cutter V.A.G 1561 A with V.A.G 1561/10 and V.A.G 1561/11</li> <li>Cartridge gun V.A.G 1628</li> <li>Window Removing Kit V.A.G 1755 or Cutting Tools for Glass V.A.G 1351</li> </ul> <ul class="clsBULLET"> <li>Cutting tool kit V.A.G 1474 A</li> <li>Cartridge heater V.A.G 1939</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020369" name="S19043327512008020700000">Fig. 312: Spooling Tool V.A.G 1654 A</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Spooling tool V.A.G 1654 A</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003668" name="S02829877342008020700000">Fig. 313: Double Cartridge Gun VAS 5237</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Double cartridge gun VAS 5237</li> <li><span class="clsEmphITAL">Cutting cord 357 853 999</span> </li> </ul><a name="S25741300862008020700000"></a><h2 class="clsHeadThree">Windows, repairing with Talon Repair Resin VAS 1993/2</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00009309" name="S20910251112008020700000">Fig. 314: Windshield Repair Set VAS 1993</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <ul class="clsBULLET"> <li>Window repair kit VAS 1993 or VAS 6092</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Windshields damaged with stone chips can be repaired with Talon Repair Resin VAS 1993/2.</li> <li>These damaged areas must not exceed a certain dimension or lie within the drivers field of sight.</li> <li>For further details on use, refer to Users Manual enclosed with each kit.</li> </ul> </td> </tr> </table></span></p><a name="S05575302222008020700000"></a><h2 class="clsHeadThree">Materials</h2> <p><span class="clsArticleTable"><a name="S055753022220080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal"> <ul class="clsBULLET"> <li><span class="clsEmphITAL">Set 2C- window adhesive DA 004 600 A2</span> * See note</li> </ul> </td> </tr> <tr> <td align="" class="clsCellNormal"> <ul class="clsBULLET"> <li><span class="clsEmphITAL">1K window adhesive DH 009 100 03</span> * See note</li> </ul> </td> </tr> <tr> <td align="" class="clsCellNormal"> <ul class="clsBULLET"> <li><span class="clsEmphITAL">Glass and paint primer D 009 200 02</span> </li> </ul> </td> </tr> <tr> <td align="" class="clsCellNormal"> <ul class="clsBULLET"> <li><span class="clsEmphITAL">Cleaning solution D 009 401 04</span> </li> </ul> </td> </tr> <tr> <td align="" class="clsCellNormal"> <ul class="clsBULLET"> <li><span class="clsEmphITAL">Applicator D 009 500 25</span> </li> </ul> </td> </tr> <tr> <td align="" class="clsCellNormal"> <ul class="clsBULLET"> <li><span class="clsEmphITAL">Adhesive remover D 002 000 10</span> </li> </ul> </td> </tr> <tr> <td align="" class="clsCellNormal"> <ul class="clsBULLET"> <li><span class="clsEmphITAL">Cutting cord 357 853 999</span> </li> </ul> </td> </tr> <tr> <td align="" class="clsCellNormal"> <ul class="clsBULLET"> <li><span class="clsEmphITAL">Cutting cord 357 845 955</span> </li> </ul> </td> </tr> </tbody> </table></span></p> <p>* Observe minimum curing time --> <a class="clsHyperlink" href="#S17744966812008020700000">Minimum curing times</a>.</p> <p>* Double cartridge pistol VAS 5237 must be used to process this material.</p> <p>* Heat according to manufacturers instructions using cartridge heater V.A.G 1939 A.</p> <p>*Small cartridge (110 ml) for sealing and/or when a 400 ml double cartridge is not sufficient.</p><a name="S17744966812008020700000"></a><h2 class="clsHeadThree">Minimum curing times</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>For safety reasons, use only electrically non-conductive 2C-adhesive when installing windshield using the materials listed below.</li> <li>Vehicle is only safe for operation after minimum curing time has elapsed and only then may it be used.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsArticleTable"><a name="S177449668120080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1" width="159px"> <col span="1" id="COL2" width="158px"> <col span="1" id="COL3" width="159px"> <col span="1" id="COL4" width="158px"> </colgroup> <thead> <tr class="clsTblHead"> <th valign="TOP" align="LEFT" class="clsCellNormal">Window type</th> <th valign="TOP" align="CENTER" class="clsCellNormal">Vehicle</th> <th valign="TOP" align="CENTER" class="clsCellNormal">Adhesive sealing material</th> <th valign="TOP" align="CENTER" class="clsCellNormal">Curing time in hours</th> </tr> </thead> <tbody> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Windshield</td> <td valign="TOP" align="CENTER" class="clsCellNormal">With airbag</td> <td valign="TOP" align="CENTER" class="clsCellNormal">DA 004 600 A2</td> <td valign="TOP" align="CENTER" class="clsCellNormal">3</td> </tr> </tbody> </table></span></p><a name="S06146081902008020700000"></a><h2 class="clsHeadThree">Cleaning when soiled by adhesive sealing material</h2> <p><span class="clsEmphITAL">Adhesive removal solution D 002 000 10</span> is the recommended cleaning solution. Observe safety precautions when processing.</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>When cleaning from vehicle interior out, the window just installed must not be pressed outward.</td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Paint surfaces</span> </p> <ul class="clsDASH"> <li>First, clean paint surfaces with a dry cloth. Remove further material using <span class="clsEmphITAL">adhesive removal solution D 002 000 10</span> .</li> </ul> <p><span class="clsEmphBOLD">Plastic trim</span> </p> <ul class="clsDASH"> <li>Allow adhesive sealing material to harden (about 1 hour) and then peel off.</li> </ul><a name="S37882819132008020700000"></a><h2 class="clsHeadTwo">Windshield</h2><a name="S29128878842008020700000"></a><h2 class="clsHeadThree">Trim, removing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020681" name="S28084626902008020700000">Fig. 315: A-Pillar And Roof Frame Trim, Removing Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Right A-pillar trim</p> <ul class="clsBULLET"> <li>Remove A-pillar trim.</li> <li>Remove door seal in A-pillar area.</li> <li>Bore out side hollow rivet heads <a class="clsHyperlink" href="#S37220745782008040700000">A-pillar trim, removing</a> (Qty. 3), drive rivet shafts out and remove trim.</li> </ul> <p>2 - Roof frame trim</p> <ul class="clsBULLET"> <li>Remove roof frame trim.</li> <li>Remove left and right A-pillar trim.</li> </ul> <p>3 - Nut</p> <ul class="clsBULLET"> <li>6.5 Nm</li> </ul> <p>4 - Pop rivet</p> <p>5 - Retaining clamp</p> <p>6 - Left A-pillar trim</p> <ul class="clsBULLET"> <li>Removal is same as right trim.</li> </ul> <p>7 - Nut</p> <ul class="clsBULLET"> <li>6.5 Nm</li> </ul> <p>8 - Retaining clamp</p> <ul class="clsBULLET"> <li>Movable</li> </ul> <p>9 - Retaining clamp</p> <ul class="clsBULLET"> <li>Fixed</li> </ul> <p>10 - Retaining clamp</p> <ul class="clsBULLET"> <li>Movable</li> </ul><a name="S37220745782008040700000"></a><h2 class="clsHeadFour">A-pillar trim, removing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020682" name="S41021929992008020700000">Fig. 316: A-Pillar Trim, Removing Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove door seal in A-pillar area and remove A-pillar trim.</li> <li>Remove nut - <span class="clsEmphBOLD">6</span> -.</li> <li>Drill rivet heads off hollow rivets - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">7</span> - and knock rivet shafts through.</li> <li>Remove trim - <span class="clsEmphBOLD">1</span> -.</li> </ul> <ul class="clsDASH"> <li>Upper and lower retaining clips - <span class="clsEmphBOLD">3</span> - must move to balance out tolerances.</li> <li>Retaining clip - <span class="clsEmphBOLD">5</span> - is fixed. It is secured to A-pillar with hollow rivets - <span class="clsEmphBOLD">4</span> -.</li> </ul><a name="S15537009132008020700000"></a><h2 class="clsHeadThree">Windshield - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020683" name="S16777797642008020700000">Fig. 317: Windshield - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Windshield</p> <ul class="clsBULLET"> <li>Removing --> <a class="clsHyperlink" href="#S01215954182008020700000">Windshield, removing</a>.</li> <li>Installing --> <a class="clsHyperlink" href="#S15166392522008020700000">Preparing for window installation</a>.</li> <li>Align distance - <span class="clsEmphBOLD">d</span> - at sides.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Stickers on windshield (e.g. for airbag) must be replaced in same position on new windshield.</li> </ul> </td> </tr> </table></span></p> <p>2 - Upper spacer buffer</p> <ul class="clsBULLET"> <li>Qty. 3, self-adhesive.</li> <li>Attach in regular intervals to retaining strip.</li> <li>Attach 1 in center of vehicle on window flange at a distance of 430 mm to left and right.</li> </ul> <p>3 - Adhesive sealing material</p> <ul class="clsBULLET"> <li>Observe curing times --> <a class="clsHyperlink" href="#S17744966812008020700000">Minimum curing times</a>.</li> <li>Note varying spacing dimensions to window edge.</li> <li>Distances from upper and side window edge, dimension - <span class="clsEmphBOLD">a</span> - = 16 mm and dimension - <span class="clsEmphBOLD">b</span> - = 12 mm.</li> <li>The distance on the lower window edge is measured from the outer side of the clip outward.</li> </ul> <ul class="clsBULLET"> <li>The distance to the lower window edge does not run in parallel distance to window edge.</li> <li>Distances <a class="clsHyperlink" href="#S04784395512008020700000">Windshield, installing</a>.</li> <li>Bead cross section.</li> <li>Bead width = 8 mm + +2 mm.</li> </ul> <ul class="clsBULLET"> <li>Bead height = 13.5 mm + +1.5 mm.</li> </ul> <p>4 - Lower spacer buffer</p> <ul class="clsBULLET"> <li>Qty. 2, self-adhesive.</li> <li>Attach in corners on lower window edge.</li> </ul> <p>5 - Window adjuster</p> <ul class="clsBULLET"> <li>Slide sideways on lower window edge as far as stop.</li> </ul> <p>6 - Plenum chamber cover</p> <ul class="clsBULLET"> <li>Pull protective piping from retaining strip before installing plenum chamber cover <a class="clsHyperlink" href="#S14984557642008040700000">Removing protective piping for grip channel</a>.</li> <li>Press into fastening strip only after window adhesive curing time has elapsed.</li> </ul><a name="S14984557642008040700000"></a><h2 class="clsHeadFour">Removing protective piping for grip channel</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020684" name="S03659725312008020700000">Fig. 318: Removing Protective Piping For Grip Channel</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull off protective piping from grip channel only after installing window.</li> <li>Before installing plenum chamber cover, protective piping - <span class="clsEmphBOLD">1</span> - must be pulled out of grip channel - <span class="clsEmphBOLD">2</span> - of windshield - <span class="clsEmphBOLD">3</span> -.</li> </ul><a name="S31919695412008020700000"></a><h2 class="clsHeadThree">Rain sensor, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020685" name="S09619736352008020700000">Fig. 319: Rain Sensor Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Removing rain sensor</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If the sensor foil is damaged when removing rain sensor, this must be replaced before re-installing.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Rearview mirror removed --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> </li> <li>Remove clamps - <span class="clsEmphBOLD">3</span> - from mirror base retaining plate - <span class="clsEmphBOLD">1</span> -.</li> <li>Disconnect electrical connector to rain sensor.</li> <li>Remove rain sensor from mirror base.</li> </ul> <ul class="clsDASH"> <li>A sensor foil remains adhered to the windshield.</li> <li>If the same windshield is reinstalled, remove this completely from the windshield.</li> <li>Clean the surface with cleaning solution D 009 401 04.</li> </ul> <p><span class="clsEmphBOLD">Installing rain sensor</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If the same rain sensor is reinstalled, proceed as described.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020686" name="S28891146792008020700000">Fig. 320: Removing Rest Of The Sensor Foil From Rain Sensor</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove the rest of the sensor foil from the rain sensor, if necessary.</li> <li>Also clean the surface with cleaning solution D 009 401 04.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Sensor surface must be completely free of foil remnants.</td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020687" name="S33786454722008020700000">Fig. 321: Removing Silicone Paper From Sensor Foil</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove silicone paper from sensor foil.</li> <li>The transparent protective film remains on the sensor foil as an installation aid.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020688" name="S41202064102008020700000">Fig. 322: Placing Sensor Foil On Rain Sensor With Help Of Transparent Protective Foil</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Place sensor foil on rain sensor with help of transparent protective foil.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020689" name="S30536053742008020700000">Fig. 323: Pressing Sensor Foil Onto Rain Sensor Without Bubbles</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press sensor foil as shown in - <span class="clsEmphBOLD">direction of arrow</span> - onto rain sensor without bubbles.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020690" name="S17671301312008020700000">Fig. 324: Removing Transparent Protective Foil From Sensor Foil</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Then remove transparent protective foil from sensor foil.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020691" name="S39605836022008020700000">Fig. 325: Spraying Entire Surface Of Sensor Foil With Cleaning Solution D 009 401 04 And Inserting Sensor In Mirror Base</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Spray entire surface of sensor foil with cleaning solution D 009 401 04 and insert sensor in mirror base.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Rain sensor must be free of inclusions and bubbles on the windshield to function properly.</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Press sensor retaining clamps on mirror base.</li> </ul> <p><span class="clsEmphBOLD">Replacing rain sensor</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>To remove sensor, proceed as described above.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>If necessary, completely remove foil remnants from windshield.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020690" name="S25702111612008020700000">Fig. 326: Cleaning Sensor Contact Surface On Windshield With Cleaning Solution D 009 401 04</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Clean sensor contact surface on windshield with cleaning solution D 009 401 04.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020691" name="S25400753882008020700000">Fig. 327: Spraying Entire Surface Of Sensor Foil With Cleaning Solution D 009 401 04 And Inserting Sensor In Mirror Base</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Peel off protective foil from rain sensor.</li> <li>Spray entire surface of sensor foil with cleaning solution D 009 401 04 and insert sensor in mirror base.</li> <li>Press sensor onto windshield without bubbles and place retaining clamps on mirror base.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Rain sensor must be free of inclusions and bubbles on the windshield to function properly.</td> </tr> </table></span></p><a name="S01215954182008020700000"></a><h2 class="clsHeadThree">Windshield, removing</h2> <p>Necessary tools and materials --> <a class="clsHyperlink" href="#S31809393582008020700000">Flush-bonded windows, removing and installing - general information</a>.</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>When removing a window, always wear protective eyewear and leather gloves.</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove windshield wiper arms --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278929_S20032899222008020700000">92 WINDSHIELD WIPER WASHER SYSTEM</a> </li> <li>92 WINDSHIELD WIPER & WASHER SYSTEM for ELECTRICAL EQUIPMENT, CABRIOLET</li> </ul> .</li> <li>Remove cowl panel trim.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020371" name="S13377878492008020700000">Fig. 328: Piercing Hole In Adhesive Sealing Material From Inside Of Vehicle Using Awl V.A.G 1755 Or Awl V.A.G 1351 At Bottom-Left Of Windshield</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove left, middle and right sun visors --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove rearview mirror --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove trim from upper A-pillars and top of windshield --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Pierce awl from Window Removing Kit V.A.G 1755 or Cutting Tools For Glass V.A.G 1351 through adhesive bead from inside to outside in lower left corner of windshield.</li> </ul> <ul class="clsDASH"> <li>Pull cutting cord through adhesive sealing material into inside of vehicle using awl.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020372" name="S30061654522008020700000">Fig. 329: Laying Cutting Cord Underneath And All Around Inside Of Windshield</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Lay cutting cord underneath and all around inside of windshield.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020373" name="S05265243102008020700000">Fig. 330: Securing End Of Cutting Cord At Bolt For Securing Window Wiper Frame</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Secure end of cutting cord at bolt - <span class="clsEmphBOLD">arrow</span> - for securing window wiper frame.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020372" name="S40756096412008020700000">Fig. 331: Laying Cutting Cord Underneath And All Around Inside Of Windshield</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Slide Cover for Audi A4 Dash Panel V.A.G 1474/13 between windshield and instrument panel.</li> <li>Secure beginning of cutting cord in winding device and cut out first area of adhesive (up to about center of windshield).</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020374" name="S00153179792008020700000">Fig. 332: Moving Spooling Tool And Continue Cutting</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Move spooling tool, as shown in illustration, and continue cutting.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020375" name="S13140070232008020700000">Fig. 333: Moving Spooling Tool And Attaching Relay Pulley</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Move spooling tool, as shown in illustration, and attach relay pulley.</li> </ul> <ul class="clsBULLET"> <li>Route cord as shown.</li> </ul> <ul class="clsDASH"> <li>Cut window free until cutting cord is no longer fed through idler pulley.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020376" name="S25263056022008020700000">Fig. 334: Removing Relay Pulley And Continue To Cut Adhesive</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove idler pulley and continue cutting window free.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020377" name="S34335939692008020700000">Fig. 335: Moving Spooling Tool And Attaching Relay Pulley In Upper Corner Of Window</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Move spooling tool, as shown in illustration, and attach relay pulley at upper part of window.</li> </ul> <ul class="clsBULLET"> <li>Route cord as shown.</li> </ul> <ul class="clsDASH"> <li>Cut window free until cutting cord is no longer fed through idler pulley.</li> <li>Remove idler pulley and continue cutting window free.</li> <li>Repeat these steps in top left and bottom left corners of windshield.</li> <li>Completely cut window free.</li> </ul> <ul class="clsDASH"> <li>Cut through any adhesive beads that were not completely cut through using Electric Cutter V.A.G 1561 A and appropriate cutting blade.</li> <li>Remove window with two double suction cups.</li> </ul><a name="S15166392522008020700000"></a><h2 class="clsHeadThree">Preparing for window installation</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If windshield flange was damaged during removal, paint structure should be repaired and if necessary, corrosion repair measures should be taken.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">For undamaged removed windshield</span> </p> <ul class="clsDASH"> <li>When reusing an undamaged window, smoothly cut back residual adhesive sealing material on window and flange using Electric Cutter V.A.G 1561 A and Cutting Blade, Bent at Right Angle V.A.G 1561/10 ; do not remove completely.</li> <li>Residual material acts as a base for the new adhesive sealing material.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Keep adhesive surface free of dirt and grease.</li> <li>Only cut back adhesive surface shortly before installation.</li> <li>Do not prime or use a cleaning solution on the adhesive surface.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">With new window</span> </p> <ul class="clsDASH"> <li>Clean window in adhesive area with <span class="clsEmphITAL">Cleaning Solution D 009 401 04</span> and prime with <span class="clsEmphITAL">Glass/Paint Primer D 009 200 02</span> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00016551" name="S42637657732008020700000">Fig. 336: Applying Primer</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Applying primer</span> </p> <ul class="clsDASH"> <li>Apply primer - <span class="clsEmphBOLD">2</span> - along circumference evenly and in one motion using applicator - <span class="clsEmphBOLD">1</span> -.</li> <li>Begin applying with saturated felt. Drying time approx. 10 minutes</li> </ul> <ul class="clsBULLET"> <li>Primer width dimension: Dimension a - <span class="clsEmphBOLD">a</span> - = approx. 20 mm</li> </ul> <ul class="clsDASH"> <li>Apply primer in center of adhesive bead.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material!</td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00016552" name="S02788741842008020700000">Fig. 337: Dimensions For Adhesive Application</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Dimensions for adhesive application</span> </p> <ol class="clsARABICNUM"> <li>Adhesive sealing material</li> <li>Primer</li> <li>Window</li> </ol> <ul class="clsBULLET"> <li>Bead width - <span class="clsEmphBOLD">a</span> - = 8 ± 2 mm.</li> <li>Bead height - <span class="clsEmphBOLD">b</span> - = 12 + 3 mm.</li> </ul><a name="S04784395512008020700000"></a><h2 class="clsHeadThree">Windshield, installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020378" name="S15392602752008020700000">Fig. 338: Positioning Complete Surface Of Nozzle Onto Window</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>After preparatory work has been performed, apply the adhesive.</li> <li>Position complete surface of nozzle - <span class="clsEmphBOLD">2</span> - onto window.</li> <li>- <span class="clsEmphBOLD">Arrow</span> - indicates direction of application</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Cross-section thickness of adhesive bead - <span class="clsEmphBOLD">1</span> - is determined by dimension of opening in nozzle tip and rate of application.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020379" name="S27488991932008020700000">Fig. 339: Applying Adhesive Sealing Material All Around</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Apply adhesive sealing material all around, as shown in illustration.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020692" name="S36219017942008020700000">Fig. 340: Varying Spacing Dimensions To Window Edge</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li> Note varying spacing dimensions to window edge:</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Maintain specified distances of adhesive bead to window edges, otherwise there may be leaks.</td> </tr> </table></span></p> <ul class="clsDASH"> <li>In the lower corners, adhesive bead must be applied in even curves at 12 mm distance to side window edge and 25 mm to lower window edge.</li> <li>On the lower window edge, the adhesive bead must increase from dimension - <span class="clsEmphBOLD">a</span> - = 25 mm over dimension - <span class="clsEmphBOLD">f</span> - = 30 mm to dimension - <span class="clsEmphBOLD">g</span> - = 36 mm.</li> </ul> <ul class="clsBULLET"> <li>Dimension - <span class="clsEmphBOLD">a</span> - = 16 mm.</li> <li>Dimension - <span class="clsEmphBOLD">b</span> - = 12 mm.</li> <li>Dimension - <span class="clsEmphBOLD">c</span> - = 92 mm.</li> <li>Dimension - <span class="clsEmphBOLD">d</span> - = 63 mm</li> </ul> <ul class="clsBULLET"> <li>Dimension - <span class="clsEmphBOLD">e</span> - = 25 mm</li> <li>Dimension - <span class="clsEmphBOLD">f</span> - = 30 mm.</li> <li>Dimension - <span class="clsEmphBOLD">g</span> - = 36 mm.</li> </ul> <ul class="clsDASH"> <li>Using two suction lifters, install windshield in windshield opening.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Window must be installed within 15 minutes, otherwise bonding properties of adhesive will be impaired.</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Center window along sides.</li> <li>The window must not touch the cover trim retaining clips.</li> <li>Slide window up to upper spacer buffer stop.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020381" name="S35008362862008020700000">Fig. 341: Affixing Stickers On Windshield In Same Position On New Windshield</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>"Caution- Safety information" sticker.</p> <ul class="clsDASH"> <li>Attach stickers on windshield (e.g. for airbag) in same position on new windshield.</li> </ul> <ul class="clsBULLET"> <li>Determine dimensions - <span class="clsEmphBOLD">a</span> - and - <span class="clsEmphBOLD">b</span> - from removed window.</li> </ul><a name="S31920768832008020700000"></a><h2 class="clsHeadOne">66 - Exterior equipment</h2><a name="S41861412052008020700000"></a><h2 class="clsHeadTwo">A-pillar and roof frame trim, removing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020681" name="S11973183552008020700000">Fig. 342: A-Pillar And Roof Frame Trim, Removing Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Right A-pillar trim</p> <ul class="clsBULLET"> <li>Remove A-pillar trim.</li> <li>Remove door seal in A-pillar area.</li> <li>Bore out side hollow rivet heads <a class="clsHyperlink" href="#S25346446312008040700000">A-pillar trim, removing</a> (Qty. 3), drive rivet shafts out and remove trim.</li> </ul> <p>2 - Roof frame trim</p> <ul class="clsBULLET"> <li>Remove roof frame trim.</li> <li>Before removal, removing left and right A-pillar trim.</li> </ul> <p>3 - Nut</p> <ul class="clsBULLET"> <li>6.5 Nm</li> </ul> <p>4 - Pop rivet</p> <p>5 - Retaining clamp</p> <p>6 - Left A-pillar trim</p> <ul class="clsBULLET"> <li>Removal is same as right trim.</li> </ul> <p>7 - Nut</p> <ul class="clsBULLET"> <li>6.5 Nm</li> </ul> <p>8 - Retaining clamp</p> <ul class="clsBULLET"> <li>Movable</li> </ul> <p>9 - Retaining clamp</p> <ul class="clsBULLET"> <li>Fixed</li> </ul> <p>10 - Retaining clamp</p> <ul class="clsBULLET"> <li>Movable</li> </ul> <p>11 - Pop rivet</p><a name="S25346446312008040700000"></a><h2 class="clsHeadThree">A-pillar trim, removing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020682" name="S05653230162008020700000">Fig. 343: A-Pillar Trim, Removing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove door seal in A-pillar area and remove A-pillar trim.</li> <li>Remove nut - <span class="clsEmphBOLD">6</span> -.</li> <li>Drill rivet heads off hollow rivets - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">7</span> - and knock rivet shafts through.</li> <li>Remove trim - <span class="clsEmphBOLD">1</span> -.</li> </ul> <ul class="clsDASH"> <li>Upper and lower retaining clips - <span class="clsEmphBOLD">3</span> - must move to balance out tolerances.</li> <li>Retaining clip - <span class="clsEmphBOLD">5</span> - is fixed. It is secured to A-pillar with hollow rivets.</li> </ul> <p>4 - Pop rivet</p><a name="S31898295702008020700000"></a><h2 class="clsHeadTwo">Protective moldings</h2><a name="S21189672692008020700000"></a><h2 class="clsHeadThree">Replacing side protective moldings</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Protective moldings cannot be removed without destroying them.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020693" name="S20071448872008020700000">Fig. 344: Replacing Side Protective Moldings</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>To remove, warm protective strips - <span class="clsEmphBOLD">1</span> - , - <span class="clsEmphBOLD">2</span> - or - <span class="clsEmphBOLD">3</span> - with a hot air gun and remove.</li> </ul> <ul class="clsBULLET"> <li>Adhesion surface must be free of dust and grease.</li> </ul> <ul class="clsDASH"> <li>Clean outer panel with mineral spirits, treat with silicone remover and rub dry.</li> </ul> <ul class="clsBULLET"> <li>Protective moldings must be attached only at room temperature.</li> <li>For this purpose, bring vehicle and protective moldings to room temperature at least 2 hours before processing.</li> <li>Protective moldings must be adhered within 90 minutes after protective foil has been removed.</li> </ul> <ul class="clsDASH"> <li>Pull protective foil - <span class="clsEmphBOLD">4</span> - from double-sided adhesive tape - <span class="clsEmphBOLD">5</span> - shortly before installation.</li> <li>Apply protective molding to be adhered at front and adhere working toward rear.</li> <li>Heat protective molding to approx. 40°C using heat gun and forcefully press on or roll on.</li> </ul> <ul class="clsBULLET"> <li>After adhering strip, leave vehicle 4 hours in room temperature.</li> </ul><a name="S14462019702008020700000"></a><h2 class="clsHeadThree">Window shaft strips</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020694" name="S08456249722008020700000">Fig. 345: Window Shaft Strips, Replacing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Window shaft strips, replacing</span> </p> <ul class="clsDASH"> <li>Completely lower window.</li> <li>Remove window shaft strip trim - <span class="clsEmphBOLD">1</span> - or - <span class="clsEmphBOLD">2</span> - --> <a class="clsHyperlink" href="#S12515667672008020700000">Window shaft strips, removing and installing</a>.</li> <li>To remove, pull window shaft strip - <span class="clsEmphBOLD">3</span> - upward from door or shaft strip - <span class="clsEmphBOLD">4</span> - from side panel.</li> <li>When installing on door, first slide shaft strip under exterior mirror, then press onto door edge in stages by hand.</li> </ul><a name="S28533450312008020700000"></a><h2 class="clsHeadThree">Trim cover for side member, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020429" name="S24791008492008020700000">Fig. 346: Trim Cover For Side Member Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Front trim cover</p> <ul class="clsBULLET"> <li>Remove trim cover sideways.</li> </ul> <p>2 - Rear sill cover</p> <ul class="clsBULLET"> <li>Removal as for front trim cover.</li> </ul> <p>3 - Screw</p> <ul class="clsBULLET"> <li>1 Nm</li> </ul> <p>4 - Clip</p><a name="S05183780062008020700000"></a><h2 class="clsHeadTwo">Outer door sill panel trim</h2><a name="S34703868522008020700000"></a><h2 class="clsHeadThree">Outer door sill panel trim, replacing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Outer door sill panel trim cannot be removed without destroying it.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020695" name="S05084327322008020700000">Fig. 347: Outer Door Sill Panel Trim, Replacing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Unclip sill panel trim - <span class="clsEmphBOLD">1</span> - from sill panel cover - <span class="clsEmphBOLD">2</span> -.</li> <li>Heat door sill molding using a hot air gun and carefully pull upward and off.</li> <li>Clean adhesion surface with mineral spirits, treat with silicone remover and rub dry.</li> </ul> <ul class="clsBULLET"> <li>Door sill moldings must be attached only at room temperature.</li> <li>For this purpose, bring vehicle and door sill moldings to room temperature at least 2 hours before processing.</li> <li>Sill moldings must be adhered within 90 minutes after protective foil has been removed.</li> </ul> <ul class="clsDASH"> <li>Heat adhesion surface to approx. 40° C using a hot air gun.</li> <li>Pull protective foil from double-sided adhesive tape shortly before installation.</li> <li>Clip in door sill molding and press on.</li> </ul> <ul class="clsBULLET"> <li>After adhering strip, leave vehicle 4 hours in room temperature.</li> </ul><a name="S15820106522008020700000"></a><h2 class="clsHeadTwo">Sill panel cover - assembly overview</h2><a name="S37161946022008020700000"></a><h2 class="clsHeadThree">Sill panel cover - assembly overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020696" name="S14493984092008020700000">Fig. 348: Sill Panel Cover - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Front cover cap</p> <p>2 - Sill panel cover</p> <ul class="clsBULLET"> <li>When installing, first center trim in front clip, then slightly secure with fitting bolts.</li> <li>Engage front end cap in bracket <a class="clsHyperlink" href="#S24412295902008040700000">Cover cap, installing</a>.</li> <li>Tighten all bolts to specified torque.</li> </ul> <p>3 - Fitting screw</p> <ul class="clsBULLET"> <li>1.5 Nm</li> </ul> <p>4 - Front clip</p> <ul class="clsBULLET"> <li>With sill panel cover centering device</li> </ul> <p>5 - Rear clip</p><a name="S24412295902008040700000"></a><h2 class="clsHeadFour">Cover cap, installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020697" name="S37396819022008020700000">Fig. 349: Cover Cap, Installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>To install, first engage cover cap - <span class="clsEmphBOLD">1</span> - in bracket - <span class="clsEmphBOLD">3</span> - and tighten bolts - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p>2 - Screw (1.3 Nm)</p><a name="S05173962192008020700000"></a><h2 class="clsHeadTwo">Rear wheel spoiler, removing and installing</h2><a name="S25207720152008020700000"></a><h2 class="clsHeadThree">Rear wheel spoiler, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020698" name="S39288384202008020700000">Fig. 350: Rear Wheel Spoiler Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Rear wheel spoiler</p> <ul class="clsBULLET"> <li>When installing, rear wheel spoiler must be slide under wheel housing liner or under underbody trim as shown.</li> </ul> <p>2 - Screw</p> <ul class="clsBULLET"> <li>3 Nm</li> </ul> <p>3 - Underbody trim</p> <p>4 - Rear wheel housing liner</p><a name="S28294577252008020700000"></a><h2 class="clsHeadTwo">Exterior rearview mirror</h2><a name="S16700749992008020700000"></a><h2 class="clsHeadThree">Rearview mirror - assembly overview</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003655" name="S14883861682008020700000">Fig. 351: Identifying Pry Lever 80-200</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Pry lever 80-200</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020699" name="S29644590062008020700000">Fig. 352: Rearview Mirror - Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Mirror glass</p> <ul class="clsBULLET"> <li>Use Pry Lever 80-200 to unclip.</li> <li>Protect mirror housing against damage using textile tape above and below.</li> <li>Press mirror lens first downward, then upward.</li> <li>To install mirror lens into guide pins and friction finger, insert into friction spring and press on.</li> </ul> <ul class="clsBULLET"> <li>Apply pressure only on center of glass, wear protective gloves while doing so.</li> </ul> <p>2 - Mirror heating connector</p> <p>3 - Mirror adjusting unit</p> <p>4 - Adjusting motor</p> <ul class="clsBULLET"> <li>Removal --> <a class="clsHyperlink" href="#S30951832132008020700000">Mirror adjusting motor, removing and installing</a>.</li> </ul> <p>5 - Mirror housing</p> <ul class="clsBULLET"> <li>May be removed from door without removing entire exterior rearview mirror --> <a class="clsHyperlink" href="#S42103640892008020700000">Mirror housing, removing and installing</a>.</li> </ul> <p>6 - Electrical connection</p> <ul class="clsBULLET"> <li>Clip into mirror glass on rear side.</li> </ul><a name="S13120415952008020700000"></a><h2 class="clsHeadThree">Side mirror, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020700" name="S22248002742008020700000">Fig. 353: Side Mirror Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Screw</p> <ul class="clsBULLET"> <li>8 Nm</li> </ul> <p>2 - Front door</p> <p>3 - Exterior rearview mirror</p> <ul class="clsBULLET"> <li>Before removing, remove door trim --> <ul class="clsBULLET"> <li><a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> </li> <li><a class="clsExtHyperlink" id="A00278923_S41505270512008020700000">70 - INTERIOR TRIM</a> for BODY INTERIOR - CABRIOLET</li> </ul> .</li> <li>Remove door seal in bolt area.</li> </ul> <ul class="clsDASH"> <li>Mark position of bolts.</li> </ul> <p>4 - Screw</p> <ul class="clsBULLET"> <li>8 Nm</li> </ul><a name="S08216680102008020700000"></a><h2 class="clsHeadThree">Mirror lens, installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020441" name="S15827869112008020700000">Fig. 354: Mirror Lens, Installing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Install mirror lens - <span class="clsEmphBOLD">3</span> - with locking tabs onto mirror lens base - <span class="clsEmphBOLD">2</span> - in - <span class="clsEmphBOLD">direction of arrow</span> -.</li> <li>Friction finger must be inserted into friction spring - <span class="clsEmphBOLD">arrow</span> - of housing - <span class="clsEmphBOLD">1</span> - while doing so.</li> <li>Apply pressure only on center of glass, wear protective gloves while doing so.</li> </ul><a name="S30951832132008020700000"></a><h2 class="clsHeadThree">Mirror adjusting motor, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020442" name="S41864283672008020700000">Fig. 355: Mirror Adjusting Motor Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Mirror lens removed.</li> </ul> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">arrows</span> - from mirror adjusting unit.</li> <li>Remove motor - <span class="clsEmphBOLD">2</span> - from mirror adjusting unit and disconnect electrical harness connector.</li> </ul> <p>Arrow - Screw (1 Nm)</p><a name="S42103640892008020700000"></a><h2 class="clsHeadThree">Mirror housing, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020443" name="S31513528422008020700000">Fig. 356: Mirror Housing Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Mirror housing</p> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Removing:</span> </li> </ul> <ul class="clsDASH"> <li>Remove bolts from cover trim and remove downward.</li> <li>Release housing from locking tabs on mirror adjusting unit and remove it upward.</li> </ul> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Installing:</span> </li> </ul> <ul class="clsDASH"> <li>Position mirror housing onto mirror adjusting unit from above.</li> <li>While doing so, locking tabs - <span class="clsEmphBOLD">arrows</span> - in mirror adjusting unit must engage above and below <a class="clsHyperlink" href="#S03743625412008040700000">Lower mirror locking tab</a>.</li> </ul> <p>2 - Mirror adjusting unit</p> <p>3 - Lower cover</p> <p>4 - Bolts</p> <ul class="clsBULLET"> <li>1 Nm</li> </ul><a name="S03743625412008040700000"></a><h2 class="clsHeadFour">Lower mirror locking tab</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020444" name="S05942899102008020700000">Fig. 357: Lower Mirror Locking Tab</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>When installing, locking tab - <span class="clsEmphBOLD">arrow A</span> - of mirror adjusting unit - <span class="clsEmphBOLD">2</span> - must be inserted into mirror housing catches - <span class="clsEmphBOLD">1</span> - in - <span class="clsEmphBOLD">direction of arrow</span> -.</li> </ul><a name="S06870432052008020700000"></a><h2 class="clsHeadTwo">Wheel housing liner</h2><a name="S26809231732008020700000"></a><h2 class="clsHeadThree">Front wheel housing liner, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020701" name="S11316758802008020700000">Fig. 358: Front Wheel Housing Liner Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Fender</p> <p>2 - Screw</p> <ul class="clsBULLET"> <li>2.3 Nm</li> </ul> <p>3 - Front wheel housing liner</p> <ul class="clsBULLET"> <li>Remove front wheel before disassembly.</li> <li>Disengage wheel housing liner from fender and pull downward and out.</li> </ul> <p>4 - Spreader nut</p> <p>5 - Sill panel cover</p> <p>6 - Quick release screw</p><a name="S08993381272008020700000"></a><h2 class="clsHeadThree">Rear wheel housing liner, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020454" name="S14039086092008020700000">Fig. 359: Rear Wheel Housing Liner Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Rear wheel housing liner</p> <ul class="clsBULLET"> <li>Remove rear wheel before disassembly.</li> <li>Remove wheelhousing liner downward.</li> </ul> <p>2 - Screw</p> <ul class="clsBULLET"> <li>1.5 Nm</li> </ul> <p>3 - Screw</p> <ul class="clsBULLET"> <li>Inserted only on the right side of vehicle.</li> </ul> <p>4 - Spreader nut</p><a name="S38490466422008020700000"></a><h2 class="clsHeadTwo">Ornamental parts</h2><a name="S22349100252008020700000"></a><h2 class="clsHeadThree">Rear lid lettering</h2> <p><span class="clsEmphBOLD">Dimensional data for front-wheel drive vehicles</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Outer edges of rear lid and lines extending from lower rear lights are used as reference edges.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020702" name="S31327110362008020700000">Fig. 360: Rear Lid Lettering (Dimensional Data For Front-Wheel Drive Vehicles)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Name plate</p> <ul class="clsBULLET"> <li>Installation:</li> </ul> <ul class="clsDASH"> <li>Warm vehicle and type designation to room temperature.</li> <li>Bonding surfaces must be dry and free from dust and grease.</li> <li>Clean outer panel with mineral spirits, treat with silicone remover and rub dry.</li> <li>Pull off backing paper and press on characters, maintaining pressure for approx. 3 seconds.</li> </ul> <ul class="clsBULLET"> <li>- <span class="clsEmphBOLD">a</span> - = 30 mm.</li> <li>- <span class="clsEmphBOLD">b</span> - = 28 mm.</li> <li>- <span class="clsEmphBOLD">c</span> - = 36 mm.</li> <li>- <span class="clsEmphBOLD">d</span> - = 28 mm.</li> </ul> <ul class="clsBULLET"> <li>- <span class="clsEmphBOLD">e</span> - = 152 mm.</li> </ul> <p><span class="clsEmphBOLD">Dimensional data for All Wheel Drive (AWD) vehicles</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Outer edges of rear lid and lines extending from lower rear lights are used as reference edges.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020703" name="S18034005842008020700000">Fig. 361: Rear Lid Lettering (Dimensional Data For All Wheel Drive (AWD) Vehicles)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Name plate</p> <ul class="clsBULLET"> <li>Installation:</li> </ul> <ul class="clsDASH"> <li>Warm vehicle and type designation to room temperature.</li> <li>Bonding surfaces must be dry and free from dust and grease.</li> <li>Clean outer panel with mineral spirits, treat with silicone remover and rub dry.</li> <li>Pull off backing paper and press on characters, maintaining pressure for approx. 3 seconds.</li> </ul> <ul class="clsBULLET"> <li>- <span class="clsEmphBOLD">a</span> - = 30 mm.</li> <li>- <span class="clsEmphBOLD">b</span> - = 28 mm.</li> <li>- <span class="clsEmphBOLD">c</span> - = 4 mm.</li> <li>- <span class="clsEmphBOLD">d</span> - = 36 mm.</li> </ul> <ul class="clsBULLET"> <li>- <span class="clsEmphBOLD">e</span> - = 13 mm.</li> <li>- <span class="clsEmphBOLD">f</span> - = 53 mm.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Dimensions - <span class="clsEmphBOLD">g</span> - and - <span class="clsEmphBOLD">h</span> - only apply to RS4</li> <li>- <span class="clsEmphBOLD">g</span> - = 68 mm.</li> <li>- <span class="clsEmphBOLD">h</span> - = 18 mm.</li> </ul> </td> </tr> </table></span></p><a name="S12515667672008020700000"></a><h2 class="clsHeadThree">Window shaft strips, removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00002640" name="S13836281142008020700000">Fig. 362: Identifying Trim Removal Wedge 3409</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Trim removal wedge 3409</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020704" name="S03633775252008020700000">Fig. 363: Using Trim Removal Wedge 3409 To Press Upper Edge Of Rubber Strip Down Until It Slides Over Upper Edge Of Window Shaft Strip</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Using Trim Removal Wedge 3409 - <span class="clsEmphBOLD">1</span> - , press upper edge of rubber strip - <span class="clsEmphBOLD">2</span> - down until it slides over upper edge of window shaft strip - <span class="clsEmphBOLD">3</span> -.</li> <li>Pull Trim Removal Wedge 3409 along strip - <span class="clsEmphBOLD">arrow</span> - in this position.</li> <li>Remove strip.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Only use <span class="clsEmphITAL">Cleaning Solution D 009 401 04</span> as an installation aid.</li> <li>If other lubricants are used, the trim may fall off due to vibrations.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Engage at top and lightly press down - rail slides over rubber</li> <li>Engage top of trim - <span class="clsEmphBOLD">3</span> -.</li> <li>With flat hand, press trim down until rubber - <span class="clsEmphBOLD">5</span> - slides over lower edge - <span class="clsEmphBOLD">4</span> -.</li> <li>Pull with hand in this position over complete trim.</li> </ul> </body> </html>

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BODY EXTERIOR - CABRIOLET
  • HEADINGS
    • 00 - General, Technical Data
      • Wiring, routing and securing
      • Contact corrosion
        • Contact corrosion
    • 50 - Body - Front
      • Body, front
        • Lock carrier with attachments - assembly overview
        • Lock carrier with attachments, removing and installing
        • Lock carrier service position
        • Cowl panel trim, removing and installing
        • Engine compartment covers
        • Front fender - assembly overview
          • Bracket for fender
          • Fender insulation
          • Left fender seal
          • Right fender seal
          • Remove and install end plate
        • Noise insulation panel - assembly overview
    • 55 - Hood, Lids
      • Hood
        • Hood, removing, installing and adjusting (up to model year 2005)
          • Buffer stop for height adjustment
        • Hood, removing, installing and adjusting (from model year 2006)
          • Gas-filled strut, removing and installing
          • Removing and installing lower part of hood lock
        • Gas-filled strut, removing and installing
          • Gas-filled strut, venting
        • Radiator grille, removing
        • Catch hook, removing and installing
        • Lower portion of hood lock, removing and installing
        • Front hood seal (up to model year 2005) - assembly overview
        • Front hood seal (from model year 2006) - assembly overview
        • Front hood trim, removing
        • Hood cable, removing and installing
      • Convertible top compartment cover
        • Convertible top compartment cover, removing and installing
          • Cover side hinge, removing
          • Hinge, removing
          • Convertible top compartment cover insulation, removing and installing
          • Tension plate, removing
          • Hold-down fastener, removing and installing
          • Convertible top compartment cover seal
        • Cover for convertible top compartment cover, removing and installing
      • Rear lid
        • Rear lid, removing and installing and adjusting
          • Striker, removing and installing
          • Rear lid, adjusting
          • Panel gap dimensions
        • Rear lid lock and handle mechanism, removing and installing
        • Gas-filled strut, removing and installing
          • Gas-filled strut, venting
        • Rear lid hinge, removing and installing
        • Rear lid seal, installing
        • Stop buffer, adjusting
      • Fuel filler flap
        • Fuel filler flap, removing and installing
          • Insert filler neck cup drain hose into guide piece
    • 57 - Front doors, Central locking system
      • Front door
        • Door, removing and installing
        • Window regulator - assembly overview
        • Window regulator, removing and installing
        • Side impact absorber, removing and installing
        • Window regulator, basic setting
          • Window tension, checking
          • Window tension, adjusting (rear lifting unit)
          • Adjusting (front lifting unit)
          • Shaft dimension, checking and adjusting (rear lifting unit)
        • Motor for window regulator, removing and installing
        • Door window - assembly overview
        • Door window, removing and installing
        • Door window, adjusting
        • Door hinge - assembly overview
          • Bottom door hinge
          • Upper door hinge
        • Front door, adjusting
          • Panel gap dimensions
        • Door handle and door lock - assembly overview
        • Lock cylinder - assembly overview
        • Lock cylinder, removing and installing
        • Lock cylinder cover cap, removing and installing
        • Door handle, removing and installing
        • Door handle trim, removing and installing
        • Door lock (up to model year 2005) - assembly overview
        • Door lock (up to model year 2005), removing and installing
          • Engaging operating rod in door lock
        • Door lock (from model year 2006) - assembly overview
        • Door lock (from model year 2006), removing and installing
        • Door lock operating rod (from model year 2006), adjusting
      • Rear window regulator
        • Rear window regulator - assembly overview
        • Rear window regulator, removing and installing
        • Side windows - assembly overview
          • Spacer installation location
        • Side window, removing and installing
        • Motor for window regulator, removing and installing
        • Side window, adjusting
      • Comfort system
        • Component locations
          • Front Passengers Door Control Module J387
          • Radar Interior Monitoring Control Module 2 G305
          • Right Rear Window Regulator Motor V27
          • Alarm Horn H12
          • Motor for fuel tank lid unlock V155
          • Motor for rear lid release V139
          • Left Rear Window Regulator Motor V26
          • Radar Interior Monitoring Control Module 1 G303
          • Drivers Door Control Module J386
          • Central control module for comfort system J393
          • Front hood switch F266
          • Fuel filler flap
        • Fuel Tank Lid Unlock Motor V155, removing and installing
    • 61 - Convertible top
      • Convertible top, servicing
        • Safety precautions
        • Rivet connections, loosening
        • Convertible top - assembly overview
          • Convertible top compartment cover
        • Convertible top, removing and installing
        • Convertible top lock, removing and installing
        • Convertible top locks, checking and adjusting
        • Side windows, adjusting
          • Angle, adjusting
          • Longitudinal angle and closing height, adjusting
          • Adjustment, checking
        • Convertible top frame seals - assembly overview
        • Front roof frame seal, removing and installing
        • Rear bracket/roof frame seal or center roof frame seal, removing and installing
        • Front rail trim, removing and installing
        • Convertible top - parts designations
        • Convertible top headliner - assembly overview
        • Convertible top headliner, removing and installing
        • Convertible top cover - assembly overview
        • Convertible top cover, removing and installing
        • Convertible top upholstery - assembly overview
        • Convertible top upholstery, removing and installing
        • Inner headliner, servicing
        • Convertible top emergency release
      • Convertible top frame
        • Safety precautions
        • Attachments - assembly overview
        • Attachments, removing and installing
      • Convertible top hydraulic system
        • Hydraulic system, general information
        • Cleanliness rules
        • Hydraulic system - assembly overview
        • Hydraulic system, function overview
          • Hydraulic function "open" , raise bracket
          • Hydraulic function "open" , convertible top compartment cover open
          • Hydraulic function "open" , store bracket.
          • Hydraulic function "open" , store convertible top
          • Hydraulic function "open" , close convertible top compartment cover
          • Hydraulic functions "close" , raise convertible top compartment cover
          • Hydraulic functions "close" , raise convertible top from convertible top compartment
          • Hydraulic functions "close" , raise bracket
          • Hydraulic functions "close" , close convertible top compartment cover
          • Hydraulic functions "close" , store bracket
        • Hydraulic system, filling and bleeding
        • Hydraulic unit (hydraulic pump), removing and installing
        • Hydraulic pump housing, removing and installing
        • Pump wheel, removing and installing
        • Solenoid valve, removing and installing
        • Hydraulic lines, removing and installing
        • Hydraulic lines to connecting plate, removing and installing
          • Hydraulic pump connection table
        • Hydraulic cylinder, removing and installing
      • Convertible top compartment cover latch
        • Safety precautions
        • Convertible top compartment cover latch - assembly overview
        • Left and right convertible top compartment cover locks, removing and installing
        • Convertible top compartment cover, adjusting tension plates
        • Convertible top compartment cover lock, removing and installing
        • Convertible top compartment cover, adjusting drive motor
      • Convertible top operation electrical components
        • Safety precautions
        • Convertible top operation electrical components - assembly overview
          • Convertible Top Front Lock Switch F172
          • Convertible Top Control Module J256
          • Convertible Top Frame Position Sensor G356
          • Compartment Cover Open Position Switch F201
        • Convertible Top Locking Motor V223/Convertible Top Lock Switch (open) F294/Convertible Top Lock Switch (closed) F295 , removing and installing
        • Convertible top position switch (Convertible Top Open Position Switch F171/Convertible Top Closed Position Switch F202), removing
        • Convertible Top Frame Position Sensor G356 , removing
        • Compartment Cover Open Position Switch F201 , removing
        • Convertible Top Control Module J256 , removing
        • Transmission Range (TR) Gear Monitoring Switch F290 and Compartment Cover Locked Right Switch 1 F200 , removing
        • Convertible Top Front Lock Switch F172 , removing
        • Convertible Top Operation Switch E137 , removing
    • 63 - Bumpers
      • Front bumper
        • Front bumper (up to model year 2005) - assembly overview
          • License plate securing holes, creating
          • Fender grommets, installing
          • Panel gap dimensions
        • Front bumper (up to model year 2005), removing and installing
        • Front bumper (from model year 2006) - assembly overview
          • Fender bolts
          • Adjusting support piece
          • Clamping pins for noise insulation
          • Removing guide piece
          • Brace for wheelhousing liner
        • Front bumper (RS4) - assembly overview
          • Air intake grille for S4
        • Front bumper (from model year 2006), removing and installing
        • Radiator grille (from model year 2006) - assembly overview
        • Bumper cover (up to model year 2005), adjusting to hood
        • Bumper crossmember (up to model year 2005), removing and installing
          • Guide piece, removing and installing
        • Bumper crossmember, removing from cover
        • Bumper crossmember to impact absorber mount
        • Impact absorber, removing and installing
      • Rear bumper
        • Bumper cover, removing and installing
          • Side panel grommets, installing
          • Guide piece, removing and installing
          • Panel gap dimensions
        • Bumper crossmember, removing and installing
    • 64 - Glass, Windows
      • Flush-bonded windows
        • Flush-bonded windows, removing and installing - general information
        • Windows, repairing with Talon Repair Resin VAS 1993/2
        • Materials
        • Minimum curing times
        • Cleaning when soiled by adhesive sealing material
      • Windshield
        • Trim, removing
          • A-pillar trim, removing
        • Windshield - assembly overview
          • Removing protective piping for grip channel
        • Rain sensor, removing and installing
        • Windshield, removing
        • Preparing for window installation
        • Windshield, installing
    • 66 - Exterior equipment
      • A-pillar and roof frame trim, removing
        • A-pillar trim, removing
      • Protective moldings
        • Replacing side protective moldings
        • Window shaft strips
        • Trim cover for side member, removing and installing
      • Outer door sill panel trim
        • Outer door sill panel trim, replacing
      • Sill panel cover - assembly overview
        • Sill panel cover - assembly overview
          • Cover cap, installing
      • Rear wheel spoiler, removing and installing
        • Rear wheel spoiler, removing and installing
      • Exterior rearview mirror
        • Rearview mirror - assembly overview
        • Side mirror, removing and installing
        • Mirror lens, installing
        • Mirror adjusting motor, removing and installing
        • Mirror housing, removing and installing
          • Lower mirror locking tab
      • Wheel housing liner
        • Front wheel housing liner, removing and installing
        • Rear wheel housing liner, removing and installing
      • Ornamental parts
        • Rear lid lettering
        • Window shaft strips, removing and installing
  • FIGURES
    • Fig. 1: Lock Carrier With Attachments - Assembly Overview
    • Fig. 2: Lock Carrier With Attachments Remove/Install Components
    • Fig. 3: Removing Coolant Hose Connecting Flange Retainer On Top Of Cooler And Connecting Flange
    • Fig. 4: Removing Coolant Hose Connecting Flange Retainer On Bottom Of Cooler And Connecting Flange
    • Fig. 5: Disconnecting Hydraulic Oil Cooler
    • Fig. 6: Disconnecting Hoses For Charge Air Cooler
    • Fig. 7: Support Tool 3369
    • Fig. 8: Lock Carrier Overview
    • Fig. 9: Install Support Tool 3369 At Left/Right
    • Fig. 10: Securing Lock Carrier At Left/Right With Bolts
    • Fig. 11: Cowl Panel Trim Remove/Install Components
    • Fig. 12: Engine Compartment Covers
    • Fig. 13: Front Fender - Assembly Overview
    • Fig. 14: Bracket For Fender
    • Fig. 15: Fender Insulation
    • Fig. 16: Left Fender Seal
    • Fig. 17: Right Fender Seal
    • Fig. 18: Remove And Install End Plate
    • Fig. 19: Noise Insulation Panel - Assembly Overview
    • Fig. 20: Hood Remove/Install/Adjusting Components (Up To Model Year 2005)
    • Fig. 21: Buffer Stop For Height Adjustment
    • Fig. 22: Hood Remove/Install/Adjusting Components (From Model Year 2006)
    • Fig. 23: Gas-Filled Strut, Removing/Installing
    • Fig. 24: Removing/Installing Lower Part Of Hood Lock
    • Fig. 25: Gas-Filled Strut, Removing/Installing
    • Fig. 26: Gas-Filled Strut, Venting
    • Fig. 27: Radiator Grille, Removing
    • Fig. 28: Catch Hook, Removing/Installing
    • Fig. 29: Lower Portion Of Hood Lock, Removing/Installing
    • Fig. 30: Front Hood Seal (Up To Model Year 2005) - Assembly Overview
    • Fig. 31: Front Hood Seal (From Model Year 2006) - Assembly Overview
    • Fig. 32: Front Hood Trim, Removing
    • Fig. 33: Hood Cable Remove/Install Components
    • Fig. 34: Convertible Top Compartment Cover Remove/Install Components
    • Fig. 35: Cover Side Hinge, Removing
    • Fig. 36: Removing/Installing Bolts & Hinge
    • Fig. 37: Convertible Top Compartment Cover Insulation Remove/Install Components
    • Fig. 38: Tension Plate, Removing
    • Fig. 39: Hold-Down Fastener Remove/Install Components
    • Fig. 40: Convertible Top Compartment Cover Seal
    • Fig. 41: Cover For Convertible Top Compartment Cover Remove/Install Components
    • Fig. 42: Rear Lid Remove/Install/Adjusting Components
    • Fig. 43: Striker Remove/Install Components
    • Fig. 44: Rear Lid Remove/Install Components
    • Fig. 45: Panel Gap Dimensions
    • Fig. 46: Rear Lid Lock And Handle Mechanism Remove/Install Components
    • Fig. 47: Gas-Filled Strut Remove/Install Components
    • Fig. 48: Gas-Filled Strut, Venting
    • Fig. 49: Rear Lid Hinge Remove/Install Components
    • Fig. 50: Rear Lid Seal, Installing
    • Fig. 51: Stop Buffer, Adjusting
    • Fig. 52: Fuel Filler Flap Remove/Install Components
    • Fig. 53: Insert Filler Neck Cup Drain Hose Into Guide Piece
    • Fig. 54: Door Remove/Install Components
    • Fig. 55: Window Regulator - Assembly Overview
    • Fig. 56: Window Regulator, Removing And Installing
    • Fig. 57: Side Impact Absorber, Removing And Installing
    • Fig. 58: Window Tension, Checking
    • Fig. 59: Window Tension, Adjusting (Rear Lifting Unit)
    • Fig. 60: Adjusting (Front Lifting Unit)
    • Fig. 61: Shaft Dimension, Checking And Adjusting (Rear Lifting Unit)
    • Fig. 62: Removing Bolts And Motor
    • Fig. 63: Door Window - Assembly Overview
    • Fig. 64: Door Window Remove/Install Components
    • Fig. 65: Window Immersion Depth, Determining
    • Fig. 66: Identifying Convertible Top Fabric & Applying Marking To Making Tape At Front And Back Directly Below Roof Frame Seal
    • Fig. 67: Window Immersion Depth, Adjusting
    • Fig. 68: Door Hinge - Assembly Overview (Bottom Door Hinge)
    • Fig. 69: Door Hinge - Assembly Overview (Upper Door Hinge)
    • Fig. 70: Panel Gap Dimensions
    • Fig. 71: Door Handle And Door Lock - Assembly Overview
    • Fig. 72: Lock Cylinder, Lock Cylinder Cover Cap Remove/Install Components
    • Fig. 73: Lock Cylinder, Lock Cylinder Cover Cap Remove/Install Components
    • Fig. 74: Lock Cylinder, Lock Cylinder Cover Cap Remove/Install Components
    • Fig. 75: Door Handle Remove/Install Components
    • Fig. 76: Inserting Screwdriver Through Door Plate And Releasing Slider From Door Handle
    • Fig. 77: Door Handle Trim Remove/Install Components
    • Fig. 78: Door Lock (Up To Model Year 2005) Remove/Install Components
    • Fig. 79: Door Lock (Up To Model Year 2005) Remove/Install Components
    • Fig. 80: Engaging Operating Rod In Door Lock
    • Fig. 81: Door Lock (From Model Year 2006) Remove/Install Components
    • Fig. 82: Door Lock (From Model Year 2006) Remove/Install Components
    • Fig. 83: Raising Locking Pin Slightly, Rotating Guide 90° And Removing It Sideways From Door Lock
    • Fig. 84: Door Lock Operating Rod (From Model Year 2006), Adjusting
    • Fig. 85: Rear Window Regulator - Assembly Overview
    • Fig. 86: Rear Window Regulator Remove/Install Components
    • Fig. 87: Side Window Remove/Install Components
    • Fig. 88: Spacer Installation Location
    • Fig. 89: Side Window Remove/Install Components
    • Fig. 90: Spacer Installation Location
    • Fig. 91: Coating New Side Window Seal With Lubricant & Inserting Upper Seal In Retaining Strip
    • Fig. 92: Removing Bolts And Carefully Prying Motor Off Tensioner
    • Fig. 93: Side Window Installation Tool V.A.G 1739
    • Fig. 94: Check Window To See If It Is Parallel
    • Fig. 95: Side Window Height And Parallelism, Adjusting
    • Fig. 96: Side Window Distance, Checking
    • Fig. 97: Side Window Distance, Adjusting
    • Fig. 98: Identifying Window Regulator Can Be Adjusted In Respective By Turning Adjusting Screw In/Out
    • Fig. 99: Comfort System Component Locations
    • Fig. 100: Front Passengers Door Control Module J387
    • Fig. 101: Radar Interior Monitoring Control Module 2 G305
    • Fig. 102: Right Rear Window Regulator Motor V27
    • Fig. 103: Alarm Horn H12
    • Fig. 104: Motor For Fuel Tank Lid Unlock V155
    • Fig. 105: Motor For Rear Lid Release V139
    • Fig. 106: Left Rear Window Regulator Motor V26
    • Fig. 107: Radar Interior Monitoring Control Module 1 G303
    • Fig. 108: Drivers Door Control Module J386
    • Fig. 109: Central Control Module For Comfort System J393
    • Fig. 110: Front Hood Switch F266
    • Fig. 111: Fuel Filler Flap Remove/Install Components
    • Fig. 112: Fuel Tank Lid Unlock Motor V155 Remove/Install Components
    • Fig. 113: Loosening Bolts Using Socket Wrench T10010, Sliding Actuator Up And Removing
    • Fig. 114: Fuel Filler Flap Remove/Install Components
    • Fig. 115: Convertible Top - Assembly Overview
    • Fig. 116: Removing/Installing Bolts & Hinge
    • Fig. 117: Bringing Convertible Top Into Center Position
    • Fig. 118: Removing/Installing Bolts & Hinge
    • Fig. 119: Removing Ball Sockets And Placing Cylinder In Convertible Top Compartment
    • Fig. 120: Removing Hydraulic Lines And Cylinders From Convertible Top Frame
    • Fig. 121: Disconnecting Connectors At Right In Vehicle
    • Fig. 122: Removing Convertible Top Switch Unit Bolts
    • Fig. 123: Loosening Main Bracket Bolts
    • Fig. 124: Removing Wire Bracket Retainer, Pressing Push Rod Off Ball Stud & Removing Bolts And Convertible Top Lock
    • Fig. 125: Convertible Top Locks, Checking And Adjusting
    • Fig. 126: Side Window Installation Tool V.A.G 1739
    • Fig. 127: Angle, Adjusting
    • Fig. 128: Longitudinal Angle And Closing Height, Adjusting
    • Fig. 129: Adjustment, Checking
    • Fig. 130: Convertible Top Frame Seals - Assembly Overview
    • Fig. 131: Front Roof Frame Seal Remove/Install Components
    • Fig. 132: Removing Seal From Retaining Track
    • Fig. 133: Front Rail Trim Remove/Install Components
    • Fig. 134: Convertible Top - Parts Designations
    • Fig. 135: Convertible Top Headliner - Assembly Overview
    • Fig. 136: Identifying Special Tools - Convertible Top Headliner, Removing And Installing
    • Fig. 137: Bringing Convertible Top Into Center Position
    • Fig. 138: Removing Bolts & Retaining Strip With Seal
    • Fig. 139: Removing Bolt & Securing Profile From Rail
    • Fig. 140: Removing Rivet From Eyelet & Rubber Cable From Eyelet On Inner Side Of Roof Guide
    • Fig. 141: Disengaging Tensioning Cable From Spring And Pulling Through Eyelet On Rear End Of Roof Guide And Forward
    • Fig. 142: Identifying Cable Tie, Tensioning Cable & Rivet
    • Fig. 143: Loosening Guide Bracket Upper Bolted Connection And Disengage Strap
    • Fig. 144: Removing Convertible Top Headliner Plastic Strips From Roof Rail
    • Fig. 145: Clamping Replacement Staples VAS 6148/1 Onto Ends Of Zip Fasteners
    • Fig. 146: Drilling Convertible Top Headliner Tab Rivet On Bracket & Removing Convertible Top Headliner Securing Strip From Groove In Bracket
    • Fig. 147: Bringing Convertible Top Into Center Position
    • Fig. 148: Checking Whether Clips Are Located Completely In Convertible Top Headliner Frame
    • Fig. 149: Ensuring Center Markings Align
    • Fig. 150: Convertible Top Cover - Assembly Overview
    • Fig. 151: Identifying Special Tools - Convertible Top Cover, Removing And Installing
    • Fig. 152: Bringing Convertible Top Into Center Position
    • Fig. 153: Removing Bolts For Seal Retaining Strip From Front Rail
    • Fig. 154: Removing Convertible Top Headliner Straps On Front Rail
    • Fig. 155: Removing Sealant On Front Corners Or Front Rail
    • Fig. 156: Removing Tensioning Strap On Roof Guide Between Rail And Rail
    • Fig. 157: Removing Tensioning Cable From Mounting Hole In Roof Guide
    • Fig. 158: Clamping Replacement Staples VAS 6148/1 Onto Ends Of Zip Fasteners
    • Fig. 159: Folding Bracket In Vertical Position (Convertible Top In Center Position) And Removing Bolt
    • Fig. 160: Removing Washer On Rear Window Cable Guide
    • Fig. 161: Drilling Convertible Top Headliner Tab Rivet On Bracket & Removing Convertible Top Headliner Securing Strip From Groove In Bracket
    • Fig. 162: Removing Plastic Profile From Bracket Groove
    • Fig. 163: Cutting Cable Tie & Opening Housing
    • Fig. 164: Convertible Top Upholstery - Assembly Overview
    • Fig. 165: Bringing Convertible Top Into Center Position
    • Fig. 166: Removing Molding Band And Convertible Top Upholstery From Front Rail Groove
    • Fig. 167: Removing Convertible Top Upholstery From Adhesive Tape On Main Guide
    • Fig. 168: Bringing Convertible Top Into Position
    • Fig. 169: Removing Cable Ties On Jacketed Pull-Spring
    • Fig. 170: Checking Diverting Eyelet For Damage Or Deformation & Folding Sheathing Back And Disengage Headliner Cord At Pull-Spring
    • Fig. 171: Identifying Rubber Hose, Sheathing & Over Pull-Spring
    • Fig. 172: Identifying Molding, Rivet & Sewn Seam
    • Fig. 173: Laying Mounting Strap From Repair Kit Flush On Convertible Top Headliner
    • Fig. 174: Securing Strap To Convertible Top Frame With Accompanying Rivet
    • Fig. 175: Convertible Top Emergency Release Key In Basic Position
    • Fig. 176: Convertible Top Emergency Release Key In Work Position
    • Fig. 177: Lowering Side Windows
    • Fig. 178: Opening Drivers Door And Removing Fuse Carrier Cover On Instrument Panel
    • Fig. 179: Removing "NES" From Bracket Over Fuse Carrier In Instrument Panel
    • Fig. 180: Removing Center Piece Of Rear Backrest By Pushing Small Tabs Town Slightly And Pulling
    • Fig. 181: Pressing Grip Holes Together And Folding Cover Up
    • Fig. 182: Inserting "NES" In Opening At Top Center Of Ski Sack Tunnel
    • Fig. 183: Turning Entire "NES" Until Small Tabs On Key Head Engage In A Groove
    • Fig. 184: Turning Red Grip Clockwise (1.5 Turns) Until Both Grip Recesses On "NES" Audibly Engage
    • Fig. 185: Opening Convertible Top Compartment Cover By Turning "NES" Counter-Clockwise As Far As Stop
    • Fig. 186: Pulling Convertible Top Compartment Cover Out As Far As Stop
    • Fig. 187: Removing "NES"
    • Fig. 188: Convertible Top, Unlocking And Locking
    • Fig. 189: Bringing "NES" Into Basic Position
    • Fig. 190: Turning Red Grip Clockwise (1.5 Turns) Until Both Grip Recesses On "NES" Audibly Engage
    • Fig. 191: Turning Entire "NES" Clockwise As Far As Stop
    • Fig. 192: Removing "NES"
    • Fig. 193: Attachments - Assembly Overview
    • Fig. 194: Removing Bolts For Tensioning Wire And Tensioning Element On Main Guide Diverting Linkage
    • Fig. 195: Folding Bracket In Vertical Position (Convertible Top In Center Position) And Removing Bolt
    • Fig. 196: Unclipping Tensioning Cable Sideways Out Of Guide On Main Guide
    • Fig. 197: Identifying Bolts, Tensioning Cable, Cable Guide & Convertible Top Frame Position Sensor G356
    • Fig. 198: Removing Band From Eyelet On Bracket & Bracket Insulating Element From Ball Head
    • Fig. 199: Removing Shared Band Rivet Connection For Bracket Rail "4" And Bracket Rail "5" On Bracket
    • Fig. 200: Removing Bolt For Center Brace Rail Spring
    • Fig. 201: Identifying Bracket Strap, Cable Spring, Cable Eyelet & Center Brace Spring
    • Fig. 202: Identifying Bolts, Rivets, Bands & Rubber Strap
    • Fig. 203: Identifying Bolt & Plastic Profile
    • Fig. 204: Removing Bolt On "Lengthwise Headliner Cable" Eye
    • Fig. 205: Removing Rivet On Inside Of Main Guide
    • Fig. 206: Unclipping Convertible Top Latch Wiring Harness From Its Guide Beginning At Front Rail To Cable Bracket On Main Guide
    • Fig. 207: Removing Rivet, Cable Bracket From Roof Guide, Bolt And Cable Channel From Diverting Linkage
    • Fig. 208: Checking Double-Sided Tape On Outside Of Main Guide For Damage
    • Fig. 209: Hydraulic System - Assembly Overview
    • Fig. 210: Hydraulic System, Filling And Bleeding
    • Fig. 211: Hydraulic Pump Housing
    • Fig. 212: Solenoid Valves
    • Fig. 213: Connecting Plate
    • Fig. 214: Hydraulic System, Function Overview
    • Fig. 215: Hydraulic Function "Open" , Raise Bracket
    • Fig. 216: Hydraulic Function "Open" , Convertible Top Compartment Cover Open
    • Fig. 217: Hydraulic Function "Open" , Store Bracket.
    • Fig. 218: Hydraulic Function "Open" , Store Convertible Top
    • Fig. 219: Hydraulic Function "Open" , Close Convertible Top Compartment Cover
    • Fig. 220: Hydraulic Functions "Close" , Raise Convertible Top Compartment Cover
    • Fig. 221: Hydraulic Functions "Close" , Raise Convertible Top From Convertible Top Compartment
    • Fig. 222: Hydraulic Functions "Close" , Raise Bracket
    • Fig. 223: Hydraulic Functions "Close" , Close Convertible Top Compartment Cover
    • Fig. 224: Hydraulic Functions "Close" , Store Bracket
    • Fig. 225: Hydraulic System, Filling And Bleeding
    • Fig. 226: Hydraulic Unit (Hydraulic Pump)
    • Fig. 227: Hydraulic Pump Housing, Removing And Installing
    • Fig. 228: Checking Pump Wheel
    • Fig. 229: Solenoid Valve Remove/Install Components
    • Fig. 230: Identifying Solenoid Valve, Electrical Harness Connector & Hydraulic Pump
    • Fig. 231: Removing Securing Plate From The Groove
    • Fig. 232: Hydraulic Line Connect Tool 3335
    • Fig. 233: Connecting Plate
    • Fig. 234: Identifying Spring Washer
    • Fig. 235: Identifying Hydraulic Line Connect Tool 3335 Sleeve, Spring Washer & Hydraulic Line Connect Tool 3335
    • Fig. 236: Springing Washer Must Slide Completely Over Collar On Connecting Piece & Coat Sealing Ring With Hydraulic Oil And Slide It Onto Connecting Piece
    • Fig. 237: Hydraulic Pump Connection Table
    • Fig. 238: Removing Hydraulic Lines And Cylinders From Convertible Top Frame
    • Fig. 239: Removing Convertible Top Switch Unit Bolts
    • Fig. 240: Convertible Top Compartment Cover Latch - Assembly Overview
    • Fig. 241: Bringing Convertible Top Into Center Position
    • Fig. 242: Identifying Locking Washer, Push Rod & Bolts
    • Fig. 243: Convertible Top Compartment Cover, Adjusting Tension Plates
    • Fig. 244: Convertible Top Compartment Cover Lock, Removing/Installing
    • Fig. 245: Identifying Screws
    • Fig. 246: Bringing Convertible Top Into Center Position
    • Fig. 247: Identifying Screws
    • Fig. 248: Convertible Top Operation Electrical Components - Assembly Overview
    • Fig. 249: Convertible Top Front Lock Switch F172
    • Fig. 250: Convertible Top Control Module J256
    • Fig. 251: Identifying Bolts, Tensioning Cable, Cable Guide & Convertible Top Frame Position Sensor G356
    • Fig. 252: Compartment Cover Open Position Switch F201
    • Fig. 253: Locating Convertible Top Locking Motor V223/Convertible Top Lock Switch (Open) F294/Convertible Top Lock Switch (Closed) F295
    • Fig. 254: Identifying Convertible Top Control Module J256
    • Fig. 255: Removing Convertible Top Switch Unit Bolts
    • Fig. 256: Identifying Convertible Top Frame Position Sensor G356
    • Fig. 257: Identifying Bolts, Tensioning Cable, Cable Guide & Convertible Top Frame Position Sensor G356
    • Fig. 258: Identifying Switch Bolts & Retainer
    • Fig. 259: Convertible Top Control Module J256
    • Fig. 260: Identifying Left Convertible Top Compartment Cover Switch F290
    • Fig. 261: Identifying Compartment Cover Locked Right Switch 1 F200
    • Fig. 262: Opening Convertible Top
    • Fig. 263: Disconnecting Electrical Connector, Removing Bolts & Switch
    • Fig. 264: Convertible Top Operation Switch E137
    • Fig. 265: Front Bumper (Up To Model Year 2005) - Assembly Overview
    • Fig. 266: License Plate Securing Holes, Creating
    • Fig. 267: Fender Grommets, Installing
    • Fig. 268: Panel Gap Dimensions
    • Fig. 269: Loosening Bolts Or Quick Release Fasteners
    • Fig. 270: Loosening Left/Right Wheelhousing Liners In Front Area
    • Fig. 271: Pulling Back Wheelhousing Liner & Unclipping Bumper Rear Edge From Catch
    • Fig. 272: Radiator Grille, Removing
    • Fig. 273: Removing Bumper Cover Bolts
    • Fig. 274: Identifying Hose To Headlight Cleaning System & Bumper Cover Connector(s)
    • Fig. 275: Checking To See If Threaded Pins On Bumper Side Walls And Grommets In Fenders Are Present
    • Fig. 276: Identifying Hose To Headlight Cleaning System & Bumper Cover Connector(s)
    • Fig. 277: Pulling Back Wheelhousing Liner & Engaging Bumper Rear Edge Into Catch
    • Fig. 278: Front Bumper (From Model Year 2006) - Assembly Overview
    • Fig. 279: Fender Bolts
    • Fig. 280: Adjusting Support Piece
    • Fig. 281: Clamping Pins For Noise Insulation
    • Fig. 282: Removing Guide Piece
    • Fig. 283: Brace For Wheelhousing Liner
    • Fig. 284: Front Bumper (RS4) - Assembly Overview
    • Fig. 285: Air Intake Grille For S4
    • Fig. 286: Front Bumper (From Model Year 2006) Remove/Install Components
    • Fig. 287: Identifying Spring Nut Placed On Bumper Cover
    • Fig. 288: Identifying Quick-Release Fasteners And Noise Insulation
    • Fig. 289: Loosening Left/Right Wheelhousing Liners In Front Area
    • Fig. 290: Pulling Back Wheelhousing Liner & Unclipping Bumper Rear Edge From Catch
    • Fig. 291: Adjusting Support Piece
    • Fig. 292: Identifying Hose To Headlight Cleaning System & Bumper Cover Connector(s)
    • Fig. 293: Identifying Hose To Headlight Cleaning System & Bumper Cover Connector(s)
    • Fig. 294: Pulling Back Wheelhousing Liner & Engaging Bumper Rear Edge Into Catch
    • Fig. 295: Radiator Grille (From Model Year 2006) - Assembly Overview
    • Fig. 296: Removing Radiator Grille
    • Fig. 297: Removing Panel For Fog Lights
    • Fig. 298: Disengaging Fog Lights Locking Mechanisms
    • Fig. 299: Disengaging Covers Locking Mechanisms
    • Fig. 300: Removing Bumper Cover Bolts
    • Fig. 301: Bumper Crossmember (Up To Model Year 2005) Remove/Install Components
    • Fig. 302: Guide Piece Remove/Install Components
    • Fig. 303: Crossmember, removing from cover and installing
    • Fig. 304: Bumper, Mounting To Shock Absorber Overview
    • Fig. 305: Impact Absorber Remove/Install Components
    • Fig. 306: Bumper Cover Remove/Install Components
    • Fig. 307: Checking To See If Threaded Pins On Bumper Side Walls And Grommets In Fenders Are Present
    • Fig. 308: Guide Piece, Removing And Installing
    • Fig. 309: Panel Gap Dimensions
    • Fig. 310: Bumper Crossmember Remove/Install Components
    • Fig. 311: Identifying Special Tools - Flush-Bonded Windows, Removing And Installing - General Information
    • Fig. 312: Spooling Tool V.A.G 1654 A
    • Fig. 313: Double Cartridge Gun VAS 5237
    • Fig. 314: Windshield Repair Set VAS 1993
    • Fig. 315: A-Pillar And Roof Frame Trim, Removing Overview
    • Fig. 316: A-Pillar Trim, Removing Overview
    • Fig. 317: Windshield - Assembly Overview
    • Fig. 318: Removing Protective Piping For Grip Channel
    • Fig. 319: Rain Sensor Remove/Install Components
    • Fig. 320: Removing Rest Of The Sensor Foil From Rain Sensor
    • Fig. 321: Removing Silicone Paper From Sensor Foil
    • Fig. 322: Placing Sensor Foil On Rain Sensor With Help Of Transparent Protective Foil
    • Fig. 323: Pressing Sensor Foil Onto Rain Sensor Without Bubbles
    • Fig. 324: Removing Transparent Protective Foil From Sensor Foil
    • Fig. 325: Spraying Entire Surface Of Sensor Foil With Cleaning Solution D 009 401 04 And Inserting Sensor In Mirror Base
    • Fig. 326: Cleaning Sensor Contact Surface On Windshield With Cleaning Solution D 009 401 04
    • Fig. 327: Spraying Entire Surface Of Sensor Foil With Cleaning Solution D 009 401 04 And Inserting Sensor In Mirror Base
    • Fig. 328: Piercing Hole In Adhesive Sealing Material From Inside Of Vehicle Using Awl V.A.G 1755 Or Awl V.A.G 1351 At Bottom-Left Of Windshield
    • Fig. 329: Laying Cutting Cord Underneath And All Around Inside Of Windshield
    • Fig. 330: Securing End Of Cutting Cord At Bolt For Securing Window Wiper Frame
    • Fig. 331: Laying Cutting Cord Underneath And All Around Inside Of Windshield
    • Fig. 332: Moving Spooling Tool And Continue Cutting
    • Fig. 333: Moving Spooling Tool And Attaching Relay Pulley
    • Fig. 334: Removing Relay Pulley And Continue To Cut Adhesive
    • Fig. 335: Moving Spooling Tool And Attaching Relay Pulley In Upper Corner Of Window
    • Fig. 336: Applying Primer
    • Fig. 337: Dimensions For Adhesive Application
    • Fig. 338: Positioning Complete Surface Of Nozzle Onto Window
    • Fig. 339: Applying Adhesive Sealing Material All Around
    • Fig. 340: Varying Spacing Dimensions To Window Edge
    • Fig. 341: Affixing Stickers On Windshield In Same Position On New Windshield
    • Fig. 342: A-Pillar And Roof Frame Trim, Removing Overview
    • Fig. 343: A-Pillar Trim, Removing
    • Fig. 344: Replacing Side Protective Moldings
    • Fig. 345: Window Shaft Strips, Replacing
    • Fig. 346: Trim Cover For Side Member Remove/Install Components
    • Fig. 347: Outer Door Sill Panel Trim, Replacing
    • Fig. 348: Sill Panel Cover - Assembly Overview
    • Fig. 349: Cover Cap, Installing
    • Fig. 350: Rear Wheel Spoiler Remove/Install Components
    • Fig. 351: Identifying Pry Lever 80-200
    • Fig. 352: Rearview Mirror - Assembly Overview
    • Fig. 353: Side Mirror Remove/Install Components
    • Fig. 354: Mirror Lens, Installing
    • Fig. 355: Mirror Adjusting Motor Remove/Install Components
    • Fig. 356: Mirror Housing Remove/Install Components
    • Fig. 357: Lower Mirror Locking Tab
    • Fig. 358: Front Wheel Housing Liner Remove/Install Components
    • Fig. 359: Rear Wheel Housing Liner Remove/Install Components
    • Fig. 360: Rear Lid Lettering (Dimensional Data For Front-Wheel Drive Vehicles)
    • Fig. 361: Rear Lid Lettering (Dimensional Data For All Wheel Drive (AWD) Vehicles)
    • Fig. 362: Identifying Trim Removal Wedge 3409
    • Fig. 363: Using Trim Removal Wedge 3409 To Press Upper Edge Of Rubber Strip Down Until It Slides Over Upper Edge Of Window Shaft Strip
  • TABLES

ACCESSORIES & EQUIPMENT

Body Exterior - Cabriolet

00 - General, Technical Data

Wiring, routing and securing

When loosing or removing and installing hydraulic, pneumatic or electrical lines, draw sketches or take pictures. This ensures installation is the same as the original.

Contact corrosion

Contact corrosion

Contact corrosion can occur if inappropriate connecting elements (bolts, nuts, washers, etc.) are used.

For this reason, only connecting elements with a special surface coating are installed.

In addition, rubber or plastic parts and adhesives consist of non-conductive materials.

NOTE:
  • The use of original replacement parts is recommended, they are tested and are compatible with aluminum.
  • The use of Audi accessories is recommended.
  • Damage via contact corrosion is not covered by warranty!

50 - Body - Front

Body, front

Lock carrier with attachments - assembly overview

Fig. 1: Lock Carrier With Attachments - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Lock carrier

2 - Left engine cover

  • Model variations

3 - Right engine cover

  • Model variations

4 - Screw

  • 10 Nm

5 - Screw

  • 50 Nm

Lock carrier with attachments, removing and installing

Removing

Fig. 2: Lock Carrier With Attachments Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove air duct between lock carrier and air filter at lock carrier.
  • Disconnect electrical connectors.
  • Drain coolant.

Fig. 3: Removing Coolant Hose Connecting Flange Retainer On Top Of Cooler And Connecting Flange
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove coolant hose connecting flange retainer on top of cooler and connecting flange - arrows -.

Fig. 4: Removing Coolant Hose Connecting Flange Retainer On Bottom Of Cooler And Connecting Flange
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove coolant hose connecting flange retainer on bottom of cooler and connecting flange - arrows -.
  • Loosen condenser only from water cooler (do not disconnect any lines).
  • Secure A/C system condenser using wire e.g. to front wheel --> 87 AIR CONDITIONING .

NOTE:
  • Do not hang condenser on lines. Condenser lines should not be pinched under any circumstances.

  • Disconnect hoses to power steering oil cooler.

Fig. 5: Disconnecting Hydraulic Oil Cooler
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove power steering oil cooler --> 48 - STEERING .
  • Disconnect hoses from hydraulic oil line.
  • Unscrew power steering line for power-assisted steering on lock carrier.

NOTE:
  • The power steering oil cooler line must not be bent under any circumstances.

Fig. 6: Disconnecting Hoses For Charge Air Cooler
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • On vehicles with charge air cooler, loosen bolts on hose clamps - arrows -.
  • Disconnect hoses.
  • Remove gasket for left and right front flap at juncture of fender at lock carrier.
  • Remove upper lock carrier bolts.

NOTE:
  • A 2nd technician will be needed to hold the lock carrier.

  • Remove bolt.
  • Pull lock carrier toward front.

Installing

Installation is reverse of removal.

  • Bleed cooling system --> .

Tightening torques --> Lock carrier with attachments - assembly overview.

Lock carrier service position

Special tools, testers and auxiliary items required

Fig. 7: Support Tool 3369
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Support Tool 3369

Fig. 8: Lock Carrier Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove engine cover - 2 - and - 3 -.
  • Unscrew intake air duct between lock carrier and air cleaner housing at lock carrier and remove.

Fig. 9: Install Support Tool 3369 At Left/Right
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Install Support Tool 3369 at left and right as shown.
  • Remove bolts - 5 - at left and right.
  • Remove bolts - 4 - and pull lock carrier - 1 - toward front.
  • Pull lock carrier forward until rear hole in lock carrier aligns with front threaded hole in fender flange.

Fig. 10: Securing Lock Carrier At Left/Right With Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Secure lock carrier at left and right with bolts - arrow -.

Assembly is performed in the reverse order of removal.

Tightening torques --> Lock carrier with attachments - assembly overview.

NOTE:
  • After assembly of lock carrier, check headlight positioning and adjust if necessary --> .

Cowl panel trim, removing and installing

Fig. 11: Cowl Panel Trim Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Cowl panel trim

  • Removing:
  • Remove wiper arms --> .
  • Remove plenum chamber cover.
  • Remove securing pins
  • Remove trim from retaining strip at windshield, bottom.
  • Remove trim upward.
  • When installing, make sure that the trim engages completely into retaining strip.

2 - Support

3 - Windshield

4 - Securing pin

5 - Plenum chamber cover

6 - Gasket

Engine compartment covers

Model variations

Fig. 12: Engine Compartment Covers
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Right engine compartment cover

2 - Toggle bolt

3 - Brake line bracket

4 - Left engine compartment cover

5 - Ball stud

6 - Coolant reservoir

7 - Grommet

8 - Bolt

  • 3 Nm

9 - Bolt

  • 9 Nm

10 - Grommet

Front fender - assembly overview

NOTE:
  • Bolts and washers are micro-encapsulated and must be replaced after loosening or after removing the fender.

Fig. 13: Front Fender - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Fender

  • Disconnect side blinker electrical connections.

2 - Screw

  • 7 Nm

3 - Screw

  • 10 Nm

4 - Screw

  • 10 Nm

5 - Screw

  • 10 Nm

6 - Bolt

  • 10 Nm

7 - Bracket

8 - Screw

  • 10 Nm

Bracket for fender

Fig. 14: Bracket For Fender
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Fender removed.
  • Remove bolts - 2 - and remove bracket - 1 -.

Fender insulation

Fig. 15: Fender Insulation
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • Only installed with 3.0L gasoline engine.

  • Before installation, break out at EVAP canister perforated line.

Left fender seal

Fig. 16: Left Fender Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • A new seal must always be installed after removal.

  • Seal must be broken out at perforated line before installation.
  • Remove protective adhesive film from seal - 1 - , insert in fender and press on firmly.

2 - Fender seal

Right fender seal

Fig. 17: Right Fender Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • A new seal must always be installed after removal.
  • Both seals are installed on the right side only on vehicles with diesel engine.

  • Remove protective adhesive film from seal - 1 - and insert in fender.

2 - Fender seal

3 - Seal connecting piece (only on vehicles with TDI engine)

Remove and install end plate

Fig. 18: Remove And Install End Plate
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Front wheel removed.
  • Wheel housing liner removed.
  • Unscrew bolts - 1 - from expanding clip - 3 - and remove end plate - 2 - from fender - 4 -.

1 - Screw (2 Nm)

Noise insulation panel - assembly overview

Fig. 19: Noise Insulation Panel - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Quick release screw

  • Only loosen these quick release screws for lock carrier service position.
  • Qty. 3

2 - Noise insulation, front

3 - Wheel spoiler

4 - Quick release screw

  • Qty. 3

5 - Noise insulation panel rear

  • Installed only with specific engine versions.

6 - Quick release screw

  • Qty. 2

7 - Noise insulation mount

  • Marking (recess) must point to left vehicle side.

8 - Screw

  • 7 Nm
  • Qty. 2

9 - Spring nut

  • Qty. 3

10 - Spring nut

  • Qty. 2

11 - Clamping pin

  • Qty. 6

12 - Wheel housing liner

13 - Bumpers

14 - Lock carrier with attachments

55 - Hood, Lids

Hood

Hood, removing, installing and adjusting (up to model year 2005)

Up to model year 2005

Fig. 20: Hood Remove/Install/Adjusting Components (Up To Model Year 2005)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Hood

  • Removing:
  • Disconnect line to windshield washer system and unclip line.

NOTE:
  • A 2nd technician is needed to support and raise the hood.

  • Install in reverse sequence.
  • Adjusting:

2 - Hood hinge

3 - Screw

  • 21 Nm

4 - Nut

  • 21 Nm

5 - Gas strut

Buffer stop for height adjustment

Fig. 21: Buffer Stop For Height Adjustment
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Buffer stops - 1 - and - 2 - must make contact lightly against lock carrier when hood is closed.

NOTE:
  • The buffer stops can be used for adjusting the height of the hood.

Hood, removing, installing and adjusting (from model year 2006)

From model year 2006

Fig. 22: Hood Remove/Install/Adjusting Components (From Model Year 2006)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Hood

  • Removing:
  • Disconnect line to windshield washer system and unclip line.
  • Second person is required to support and lift hood.
  • Remove gas-filled strut - 5 - from hood - 1 - Gas-filled strut, removing and installing.
  • Remove nuts - 4 -.
  • Remove hood.
  • Installing:
  • Install in reverse order of removal.

2 - Hood hinge

  • Hood - 1 - must be removed or propped up securely.
  • To remove, remove bolts - 3 - and nuts - 4 -.

3 - Screw

  • 21 Nm

4 - Nut

  • 21 Nm

5 - Gas strut

  • Tube of gas-filled strut must be installed on body side

Gas-filled strut, removing and installing

Fig. 23: Gas-Filled Strut, Removing/Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Support hood or secure it from falling down.
  • Gently lift retaining springs at both ends of gas-filled strut using a screwdriver and unclip gas-filled strut.
  • To install, press gas-filled strut onto ball stud and engage.
  • Install with tube end of strut at body.

Removing and installing lower part of hood lock

Fig. 24: Removing/Installing Lower Part Of Hood Lock
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Disengage hood release --> Hood cable, removing and installing.
  • Remove bolts - 2 - (4x).
  • Remove lower part of lock - 1 -.
  • To adjust hood, move lower section of lock up or down as required.

2 - Screw (14 Nm)

Gas-filled strut, removing and installing

Fig. 25: Gas-Filled Strut, Removing/Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Support hood or secure it from falling down.
  • Gently lift retaining springs - arrow - at both ends of gas-filled strut using a screwdriver and unclip gas-filled strut.
  • To install, press gas-filled strut onto ball stud and engage.
  • Install with tube end of strut at body.

Gas-filled strut, venting

Fig. 26: Gas-Filled Strut, Venting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

CAUTION: Clamp only within this area, otherwise accident could occur!

  • Clamp gas-filled strut in vice area - x - = 50 mm (2 in.).
  • Cover area of sawn portion with a rag to absorb oil spraying out.

CAUTION: Always wear eye protection when performing this procedure.

  • Cut through cylinder of gas strut within first third of cylinder s overall length using piston rod end of cylinder as reference point.

Radiator grille, removing

Up to model year 2005

Fig. 27: Radiator Grille, Removing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolts - 1 -.
  • Move decorative grille - 2 - forward slightly and pull up out of bumper cover.

Catch hook, removing and installing

Fig. 28: Catch Hook, Removing/Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • To remove, remove nuts - 2 - and remove catch hook - 1 -.

2 - Nut (11 Nm)

Lower portion of hood lock, removing and installing

Fig. 29: Lower Portion Of Hood Lock, Removing/Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Disengage hood release --> Hood cable, removing and installing.
  • Remove bolts - 2 - (4x).
  • Remove lower part of lock - 1 -.
  • To adjust hood, move lower section of lock up or down as required.

2 - Screw (14 Nm)

Front hood seal (up to model year 2005) - assembly overview

Fig. 30: Front Hood Seal (Up To Model Year 2005) - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Lock carrier seal

  • Position seal at center on lock carrier (note center marking) and slide onto flange at lock carrier and fender at side.

2 - Plenum chamber seal

  • Bring molded part - arrows - into contact and press seal onto flange from above, working from outside toward inside.

3 - Hood

4 - Sealing profile

  • Self-adhesive.
  • Before installing, adhesion surface must be free of dust and grease.

5 - Fender

Front hood seal (from model year 2006) - assembly overview

Fig. 31: Front Hood Seal (From Model Year 2006) - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Gasket for lock carrier

  • Apply gasket at left and right on foam piece.
  • When doing this, make sure it is applied without gaps.
  • Compress excess length of gasket along lock carrier.

2 - Left sealing profile

  • Self-adhering, adhesion surfaces must be free of dust and grease.

3 - Gasket for plenum chamber

  • Apply gasket at left and right on foam piece.
  • When doing this, make sure it is applied without gaps.
  • Compress excess length of gasket along front panel of plenum chamber.

Front hood trim, removing

Fig. 32: Front Hood Trim, Removing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Unclip clips - 2 -.
  • Remove cover - 1 -.

Hood cable, removing and installing

Fig. 33: Hood Cable Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Hood cable

  • Removing:
  • Unclip cable for lower part of hood lock and disengage attachment lug - arrow A -.
  • Remove cable from retaining clips opened earlier and pull into wheelhousing toward lock carrier.
  • Install in reverse sequence.
  • Bring ball on cable for lower part of hood lock into installation position.

2 - Operating lever

3 - Screw

  • 2.4 Nm

4 - Retaining clamp

5 - Lower part of hood lock

6 - Retaining clip

Convertible top compartment cover

Convertible top compartment cover, removing and installing

Fig. 34: Convertible Top Compartment Cover Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Convertible top compartment cover seal

  • Begin installation at molded parts.
  • Install molded part along flange toward outside, not from above.
  • Install seal on both sides from inside toward outside.

2 - Hydraulic cylinder

3 - Ball head pin

  • 21 Nm

4 - Convertible top compartment cover

  • Removing:
  • Disengage push rod from hydraulic cylinders at ball stud.
  • Remove bolts on cover side of hinge Cover side hinge, removing.
  • Remove convertible top compartment cover.

5 - Screw

  • 8 Nm

6 - Hold-down fastener

  • Remove convertible top compartment cover insulation.
  • Pull hold-down fastener out sideways and remove.

7 - Screw

  • 21 Nm

8 - Tension plate

  • Striker pin is aligned to convertible top compartment cover latch.
  • It must align with latch housing on inside.
  • When closed, striker pin must have enough clearance in latch cover opening.

9 - Window

10 - Ball head pin

  • 21 Nm

Cover side hinge, removing

Fig. 35: Cover Side Hinge, Removing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolts - 2 - from convertible top compartment cover - 1 -.

3 - Hinge

4 - Cover cap

5 - Cover caps for bolts

Hinge, removing

Fig. 36: Removing/Installing Bolts & Hinge
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • Only remove both outer bolts - 2 - to remove convertible top compartment cover or hinges.
  • Hinge base plate must not be removed.

  • Remove lid side hinge - 1 -.
  • Remove cover caps from bolts.
  • Remove bolts - 2 - and remove hinge.

2 - Screw (21 Nm)

Convertible top compartment cover insulation, removing and installing

Fig. 37: Convertible Top Compartment Cover Insulation Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove clips - 1 - (Qty. 17) and insulation - 2 - from convertible top compartment cover - 3 -.
  • Install stop buffer - 4 - with 2 mm gap to system.

Tension plate, removing

Fig. 38: Tension Plate, Removing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Convertible top compartment cover insulation removed.
  • Remove bolts - 1 - and remove tension plate - 3 - from convertible top compartment cover.

2 - Window

Hold-down fastener, removing and installing

Fig. 39: Hold-Down Fastener Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Convertible top compartment cover insulation removed.
  • Remove bolt - 1 - , slide hold-down fastener sideways out of convertible top compartment cover and remove.

1 - Screw (8 Nm)

Convertible top compartment cover seal

Fig. 40: Convertible Top Compartment Cover Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Begin installation at outer molded parts.
  • Slide molded parts on not from above, but rather along flange toward outside.
  • Press sealing profile from above onto body flange.
  • Center any excess length to middle of vehicle.

Cover for convertible top compartment cover, removing and installing

Fig. 41: Cover For Convertible Top Compartment Cover Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Cover for convertible top compartment cover

  • Removing:

2 - Trim molding

3 - Convertible top

4 - Convertible top compartment cover

5 - Screw

  • 6.5 Nm
  • Maintain torque, otherwise impressions will be visible on trim.

Rear lid

Rear lid, removing and installing and adjusting

Fig. 42: Rear Lid Remove/Install/Adjusting Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear lid

  • Removing:

NOTE:
  • A 2nd technician is needed to support and raise the rear lid.

2 - Stop buffer

3 - Gas strut

4 - Rear lid hinge

5 - Striker

6 - Nut

  • 8 Nm

Striker, removing and installing

Fig. 43: Striker Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Screw (21 Nm)

Rear lid, adjusting

Fig. 44: Rear Lid Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • The gas-filled struts must be attached before installing a new rear lid.

  • Loosen bolts - 1 - , it must be possible to slide striker - 2 -.
  • Carefully close rear lid until lid is flush with side panels.
  • Carefully open lid and tighten nuts - 1 -.

2 - Nut (8 Nm)

Panel gap dimensions

Fig. 45: Panel Gap Dimensions
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Dimension - A - = 4.5 mm ± 0.5 mm.
  • Dimension - B - = 3.5 mm ± 0.5 mm.
  • Dimension - C - = 3.5 mm ± 0.5 mm.
  • Dimension - D - = 4.5 mm ± 0.5 mm.
  • Dimension - E - = 2.5 mm ± 0.2 mm.
  • Dimension - F - = 2.5 mm ± 0.2 mm.
  • Dimension - G - = 3.3 mm ± 0.2 mm.
  • Dimension - H - = 3.0 mm ± 0.2 mm.

Rear lid lock and handle mechanism, removing and installing

Fig. 46: Rear Lid Lock And Handle Mechanism Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear lid lock

  • To remove, unclip operating rod from swiveling bush and disengage.

2 - Swiveling bush

  • After installing rear lid lock, engage operating rod and secure.

3 - Nut

  • 8 Nm

4 - Operating rod

5 - Release

6 - Lock cylinder

  • Removing:
  • Disconnect electrical connectors.
  • Disengage release from lock cylinder.
  • Remove bolt.
  • Twist lock cylinder 90°.
  • Remove lock cylinder from handle mechanism.

7 - Screw

  • 8 Nm

8 - Motor

  • Country versions

9 - Handle

  • Removing:
  • Remove rear lid trim.
  • Remove lock cylinder.
  • Remove bolts.
  • Press in catches - arrows -.
  • Remove grip piece.

10 - Nut

  • 8 Nm

Gas-filled strut, removing and installing

Fig. 47: Gas-Filled Strut Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

NOTE:
  • When removing or installing the gas-filled strut, push back the opened rear lid only slightly so as to avoid damaging components.

  • Lift retaining springs in succession on both ends using screwdriver and remove gas-filled strut - 1 -.

Installing

  • Clip in gas-filled strut at bottom first, then at top.
  • Install with tube end of strut at rear lid.

Gas-filled strut, venting

Fig. 48: Gas-Filled Strut, Venting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

CAUTION: Clamp only within this area, otherwise accident could occur!

  • Clamp gas-filled strut in vice area - x - = 50 mm (2 in.).
  • Cover area of sawn portion with a rag to absorb oil spraying out.

CAUTION: Always wear eye protection when performing this procedure.

  • Cut through cylinder of gas strut within first third of cylinders overall length using piston rod end of cylinder as reference point.

Rear lid hinge, removing and installing

Fig. 49: Rear Lid Hinge Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • For easier adjustment of the rear lid hinges, use gradations marked on the hinges.

  • Loosen nut - 1 -.
  • Unscrew nut - 2 -.
  • Lift off lid from hinge.

3 - Height adjusting screw

  • Remove bolts - 4 - and - 6 -.
  • Only loosen center bolt - 5 -.
  • Remove hinge - 7 -.

Installation is reverse of removal.

1 - Nut (21 Nm)

2 - Nut (21 Nm)

4 - Screw (21 Nm)

5 - Screw (21 Nm)

6 - Screw (21 Nm)

Rear lid seal, installing

Fig. 50: Rear Lid Seal, Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Rear lid seal butt joint - item A - must be aligned on left hinge ball socket - arrow -.
  • Press seal on.

Stop buffer, adjusting

Fig. 51: Stop Buffer, Adjusting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Open rear lid.
  • Remove rubber cap.
  • Screw in buffer stops until they reach stop.
  • Unscrew stop again in steps.
  • Press rubber cap on.
  • When adjusted correctly and with lid closed, buffer stops must make contact lightly on luggage compartment edge.

Fuel filler flap

Fuel filler flap, removing and installing

Fig. 52: Fuel Filler Flap Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Screw

  • 1.5 Nm

2 - Fuel filler flap

3 - Circlip

  • Remove before removing filler neck cup.

4 - Filler neck cup

  • Removing:
  • Remove securing clip.
  • Raise cup out of opening slightly.
  • Remove drain hose from lower guide piece and completely remove from opening with cup.
  • Installing:
  • Coat cup with lubricant (e.g. soap solution).
  • Slide drain hose into body opening.
  • Press cup completely into opening.
  • Insert circlip.

Insert filler neck cup drain hose into guide piece

Fig. 53: Insert Filler Neck Cup Drain Hose Into Guide Piece
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove rear wheel housing liner bolts in guide piece area.
  • Pull wheel housing liner back slightly and insert drain hose - 2 - for cup - 1 - in bumper guide piece eyelet - 3 -.

57 - Front doors, Central locking system

Front door

Door, removing and installing

Fig. 54: Door Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • For various assembly work, the entire door can be completely raise from the door hinges after electrical connectors on lower A-pillar have been disconnected.
  • Adjustments must not be made after installation.

  • Pull bellows down from A-pillar.
  • Disconnect electrical connectors on bottom of A-pillar.
  • Loosen bolt - 1 - on upper door hinge - 2 -.
  • Remove lower bolt - 4 - on bottom door hinge - 3 -.
  • Raise door with a second technician.

Installation is reverse of removal.

Tightening torques --> Door hinge - assembly overview.

Window regulator - assembly overview

Fig. 55: Window Regulator - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Side impact member

2 - Front door

3 - Screw

  • 8 Nm
  • Qty. 2

4 - Screw

  • For impact member
  • 30 Nm

5 - Nut

  • For window regulator
  • 8 Nm

6 - Screw

  • 4 Nm
  • 3x

7 - Window regulator motor

8 - Window regulator

9 - Nut

  • For window regulator
  • 8 Nm

10 - Screw

  • For impact member
  • 30 Nm

11 - Nut

  • For window regulator
  • 8 Nm

Window regulator, removing and installing

NOTE:
  • Position of adjusting screws and nuts should be marked before loosening.

Removing

Fig. 56: Window Regulator, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolts - 1 - , - 3 - and - 4 -.
  • Unclip cables.
  • Tip rear lower linkage - 5 - forward.
  • Tip front upper linkage - 2 - back.
  • Remove window regulator from door.

Installing

Installation is reverse of removal.

Tightening torques --> Window regulator - assembly overview.

Side impact absorber, removing and installing

Fig. 57: Side Impact Absorber, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolts - 2 - and - 4 -.
  • Rotate side impact absorber - 3 - 180° and remove it toward rear from door - 1 -.

Installation is performed in the reverse order of removal.

Tightening torques --> Window regulator - assembly overview.

Window regulator, basic setting

Special tools, testers and auxiliary items required

  • Caliper
  • Steel ruler

NOTE:
  • When removing regulator or working with extreme adjusted values, it is necessary to perform a window regulator basic setting. The door trim, window regulator motor, speaker and door insulation are removed for this --> .

Window tension, checking

Fig. 58: Window Tension, Checking
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Close convertible top.
  • Open door.
  • Raise window (window is in short lift).
  • Close door until upper edge of window touches side window seal - arrow -.
  • Measure gap between side window and inner edge of door window with steel ruler.
  • Specified dimension - a - = 6-8 mm.

Window tension, adjusting (rear lifting unit)

Fig. 59: Window Tension, Adjusting (Rear Lifting Unit)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

  • Raise window (window is in short lift).
  • Remove rubber stops - arrow -.
  • Loosen rear lifting unit lower nut through opening - 1 -.
  • Slide lifting unit in elongated hole toward door outer panel as far as stop.
  • Tighten rear lifting unit and seal opening with rubber plugs.

Tightening torques --> Window regulator - assembly overview.

Adjusting (front lifting unit)

Fig. 60: Adjusting (Front Lifting Unit)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove window regulator motor, speaker and door insulation --> .
  • Raise window (window is in short lift).
  • Remove rubber stops - arrow -.
  • Loosen front lifting unit lower nut through opening.
  • Slide lifting unit in elongated hole until frame aligns with door inner notch.
  • Tighten front lifting unit and seal opening with rubber plugs.

Tightening torques --> Window regulator - assembly overview.

Shaft dimension, checking and adjusting (rear lifting unit)

Fig. 61: Shaft Dimension, Checking And Adjusting (Rear Lifting Unit)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Disengage door trim as shown in illustration.
  • Lay aside door seal - 1 - in B-pillar area.
  • Raise window (window is in short lift).
  • Using a caliper, measure shaft dimension (it must be possible to pull the gap gauge through with firm resistance).
  • Shaft dimension - a - = 6 mm.
  • Loosen lock nut - arrow -.
  • Adjust shaft dimension by turning threaded pin.
  • Tighten lock nut.

Tightening torques --> Window regulator - assembly overview.

Motor for window regulator, removing and installing

Removing

NOTE:
  • Motor for window regulator can be removed or installed in every position of motor or side window.

  • Disconnect electrical connectors.

Fig. 62: Removing Bolts And Motor
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolts - 2 - and remove motor - 1 -.

Installing

  • Ensure threaded pins - arrows - are engaged in door inner panel.
  • Slide on window regulator motor - 1 - and secure with bolts - 2 -.
  • Attach electrical connector.

NOTE:
  • After installing motor, switch ignition on and off again with wires connected.
  • Then move door window upward to stop and keep pressing switch for window regulator for approx. 2 seconds longer.
  • This position is the base position and the high- and low-running function is activated.

Tightening torques --> Window regulator - assembly overview.

Door window - assembly overview

Fig. 63: Door Window - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Window regulator

2 - Clamping brackets

  • With attached bolt.
  • 6 Nm

3 - Locking screw

  • 6 Nm

4 - Door window

5 - Fastener

6 - Pressure plate

Door window, removing and installing

Removing

Fig. 64: Door Window Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Loosen clamping bracket connection - 1 -.
  • Remove bolt - 2 - and remove fastener - 4 - and pressure plate - 5 -.
  • Remove window - 3 - upward.

Installing

Installation is reverse of removal.

Tightening torques --> Door window - assembly overview.

Door window, adjusting

Special tools, testers and auxiliary items required

  • Masking tape

Fig. 65: Window Immersion Depth, Determining
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Window immersion depth, determining

  • Close convertible top.
  • Raise window.
  • Tape masking tape - arrows - overlapping on window with door open.
  • Close door completely.
  • Dimension - a - = 80 mm.
  • Dimension - b - = 40 mm.

Fig. 66: Identifying Convertible Top Fabric & Applying Marking To Making Tape At Front And Back Directly Below Roof Frame Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • Raise convertible top fabric - 1 - in place.

  • Apply a marking - arrow - to making tape at front and back directly below roof frame seal.
  • Open door.
  • Measure distance between marking and upper end of window.
  • Front immersion depth: max. 5 mm.
  • Rear immersion depth: max. 7 mm.

Fig. 67: Window Immersion Depth, Adjusting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Window immersion depth, adjusting

  • Lower window.
  • Remove front and rear rubber stops - arrow - at bottom of door.
  • Insert a thin 5 mm hex socket head wrench through opening on door.
  • Door seal - 1 - does not need to be removed to insert hex socket head wrench.
  • Adjust front and rear window immersion depth by evenly turning both lifting units.
  • Turn right = greater immersion depth.
  • 1 turn corresponds to approx. 1.2 mm.
  • Seal off openings with rubber plugs.
  • Raise window and measure change.
  • Ensure window is parallel to side window, adjust if necessary --> Side window, adjusting.

Door hinge - assembly overview

Bottom door hinge

Fig. 68: Door Hinge - Assembly Overview (Bottom Door Hinge)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Lower A-pillar

2 - Screw

  • 32 Nm

3 - Screw

  • 32 Nm
  • Installed from vehicle interior.

4 - Bottom door hinge

  • Two-part
  • Mark hinge location before removal.

5 - Pop rivet

  • Qty. 2

6 - Backing

7 - Impact member mount

8 - Front door

9 - Screw

  • 32 Nm

Upper door hinge

Fig. 69: Door Hinge - Assembly Overview (Upper Door Hinge)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  1. Bolt (installed from inside of vehicle) (32 Nm)
  2. Upper door hinge
  3. Cover cap
  4. Screw (32 Nm)
  5. Screw (32 Nm)

Front door, adjusting

Panel gap dimensions

Fig. 70: Panel Gap Dimensions
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • Panel gap dimensions can be checked with Adjusting Gauge 3371.
  • Dimension - a - = 3.5 mm ± 0.5 mm.
  • Dimension - b - = 3.5 mm ± 0.5 mm.
  • Dimension - c - = 5.0 mm ± 1 mm.

Door handle and door lock - assembly overview

Fig. 71: Door Handle And Door Lock - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Door handle mount

2 - Door handle

3 - Door handle trim

4 - Lock cylinder

5 - Lock cylinder cover

  • To remove, remove lock cylinder and unclip cover.

6 - Screw

  • 20 Nm

7 - Operating rod

8 - Door lock

Lock cylinder - assembly overview

Fig. 72: Lock Cylinder, Lock Cylinder Cover Cap Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Cover cap

  • Pry out

2 - Securing bracket

  • Engages in groove on lock cylinder.

3 - Door handle

4 - Lock cylinder

5 - Lock cylinder cover cap

Lock cylinder, removing and installing

Fig. 73: Lock Cylinder, Lock Cylinder Cover Cap Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Open drivers door and pry out cover cap - 1 -.
  • Remove bolt - arrow - counter-clockwise as far as stop.

This moves the securing clip - 2 - back and releases lock cylinder.

  • Remove lock cylinder - 4 - from door handle.

Installation is reverse of removal.

Lock cylinder cover cap, removing and installing

Removing

Fig. 74: Lock Cylinder, Lock Cylinder Cover Cap Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Carefully loosen hooks from retainer and remove cover cap sideways toward rear from locking pins.

Installing

  • Insert brace with square hole on pins on housing.
  • Press cover cap onto housing until locking hooks engage.

Door handle, removing and installing

Remove door trim -->

.

Fig. 75: Door Handle Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig. 76: Inserting Screwdriver Through Door Plate And Releasing Slider From Door Handle
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Insert screwdriver through door plate and release slider - 2 - in - direction of arrow - from door handle - 1 -.
  • Remove door handle.

Door handle trim, removing and installing

Remove door handle --> Door handle, removing and installing.

Fig. 77: Door Handle Trim Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pull door handle - 1 - up and slide retainer - 3 - out lengthwise with a small screwdriver.
  • Unlatch upper trim - 2 - sideways and remove it downward from door handle.

Installation is reverse of removal.

Door lock (up to model year 2005) - assembly overview

Fig. 78: Door Lock (Up To Model Year 2005) Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Screw

  • M8
  • 20 Nm

2 - Backing

3 - Door lock

4 - Release lever

5 - Inside door release mechanism release

Door lock (up to model year 2005), removing and installing

Removing

Fig. 79: Door Lock (Up To Model Year 2005) Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Unclip cable from inside door release mechanism - 5 - on door lock, rotate it 90° and remove it from release lever - 4 -.
  • If the same door lock is installed again, disengage operating rod at door handle.
  • If door lock is replaced, unclip operating rod from door lock at casing Engaging operating rod in door lock.
  • Remove bolts - 1 - and remove door lock.

Installing

Installation is reverse of removal.

Engaging operating rod in door lock

Fig. 80: Engaging Operating Rod In Door Lock
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • When installing a new door lock, clip operating rod - 1 - into casing.
  • Move slide - 2 - of casing upward to engage operating rod.
  • Pull securing pin - 3 - out of door lock.

Tightening torques --> Door lock (up to model year 2005) - assembly overview.

Door lock (from model year 2006) - assembly overview

Fig. 81: Door Lock (From Model Year 2006) Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Screw

  • M8
  • 20 Nm

2 - Backing

3 - Door lock

4 - Clip

5 - Operating rod

6 - Release lever

7 - Inside door release mechanism release

Door lock (from model year 2006), removing and installing

Removing

Fig. 82: Door Lock (From Model Year 2006) Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Disengage operating rod to door handle - 5 - at upper clip - 4 -.

NOTE:

  • Remove bolts - 1 - and remove door lock - 3 -.

Fig. 83: Raising Locking Pin Slightly, Rotating Guide 90° And Removing It Sideways From Door Lock
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Raise locking pin - 1 - slightly, rotate guide - 2 - 90° and remove it sideways from door lock - 3 -.
  • Disengage door inside release mechanism cable at release lever.

Installing

Installation is reverse of removal.

Tightening torques --> Door lock (from model year 2006) - assembly overview.

Door lock operating rod (from model year 2006), adjusting

The door handle is adjusted correctly when it contacts handle molding and can be operated without noticeable play.

  • Door trim removed.
  • Rear window regulator rail removed.

Fig. 84: Door Lock Operating Rod (From Model Year 2006), Adjusting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pry out clip - 1 - on opening lever - 2 -.
  • Move operating rod - 3 - and check adjustment.

Rear window regulator

Rear window regulator - assembly overview

Fig. 85: Rear Window Regulator - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Side panel

2 - Retaining strip

3 - Nuts

  • 8 Nm

4 - Side window

5 - Window regulator

6 - Adjustment screw

  • 3x
  • 20 Nm
  • Side Window Installation Tool V.A.G 1739 is needed for adjusting.
  • Angle of side window can be adjusted using these screws.

7 - Nut

  • Union nut
  • 20 Nm

8 - Screw

  • Qty. 4
  • 8 Nm

Rear window regulator, removing and installing

Fig. 86: Rear Window Regulator Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Mark position of nuts - 3 - , adjusting screws - 6 - and bolts - 8 -.
  • Remove nuts - 3 -.
  • Remove bolts - 8 - and remove cover - 2 -.
  • Loosen Convertible Top Control Module J256 on right side of vehicle --> Convertible Top Control Module J256 , removing.
  • Loosen nuts - 7 - from adjusting screws - 5 -.

NOTE:
  • The lower nuts - 6 - can remain on the adjusting screws - 5 - , the upper ones must be removed.

  • Disconnect window regulator motor connector.
  • Remove window regulator - 5 - from side panel - 1 -.

Installation is reverse of removal.

Tightening torques --> Rear window regulator - assembly overview.

Side windows - assembly overview

Fig. 87: Side Window Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Angle bracket

2 - Spacer discs

3 - Side window

4 - Seal retaining strip

  • No replacement part.

5 - Gasket

  • Installing.

6 - Washers

  • Must engage on angle bracket retaining pins when pressing on.

7 - Window regulator

8 - Nut

  • 6 Nm

9 - Window regulator motor

10 - Screw

  • 4.5 Nm

Spacer installation location

Fig. 88: Spacer Installation Location
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  1. Angle bracket
  2. Spacer plate
  3. Side window
  4. Window regulator
  5. Spacer plate
  6. Nut

Side window, removing and installing

Removing

Fig. 89: Side Window Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Mark position of side window - 3 - to window regulator - 7 -.
  • Remove nuts - 8 -.
  • Remove side window - 3 - together with angle bracket - 1 - , spacers - 2 - and washers - 6 -.

Installing

Fig. 90: Spacer Installation Location
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Place spacer - 2 - as shown on angle bracket pins - 1 - and insert pre-assembled side window - 3 - in window regulator - 4 -.
  • Press window - 5 - onto pins from rear side and tighten nut.

Fig. 91: Coating New Side Window Seal With Lubricant & Inserting Upper Seal In Retaining Strip
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Coat new side window seal - 2 - with lubricant (e.g. soap solution).
  • Insert upper seal in retaining strip - 1 - and pull it down.
  • Seal must be flush with retaining strip at top.

Further installation is performed in the reverse order of removal.

Tightening torques --> Side windows - assembly overview.

Motor for window regulator, removing and installing

Fig. 92: Removing Bolts And Carefully Prying Motor Off Tensioner
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolts - 1 - and carefully pry motor - 2 - off tensioner.

NOTE:
  • When removing, cable tensioner must not be loosened from window regulator.

Installation is reverse of removal.

Tightening torques --> Side windows - assembly overview.

Side window, adjusting

Special tools, testers and auxiliary items required

Fig. 93: Side Window Installation Tool V.A.G 1739
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Side Window Installation Tool V.A.G 1739

Distinctive features can be:

  • Low window tension.
  • Wind noise.
  • Window rattles with convertible top open.
  • Window runs poorly into roof frame seal.

Fig. 94: Check Window To See If It Is Parallel
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Check window to see if it is parallel

  • Close convertible top.
  • Raise all windows.
  • Close both doors.
  • Using a steel ruler, measure gap dimension between door window and side window.
  • Gap must be parallel, dimension - a - and dimension - b - = 9-10 mm.
  • Deviation from parallel: 0.5 mm.

Fig. 95: Side Window Height And Parallelism, Adjusting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Side window height and parallelism, adjusting

  • Raise all windows.
  • Loosen nuts - arrows -.
  • Adjust parallelism or side window height to door window by moving side window.
  • Tighten nuts.

Fig. 96: Side Window Distance, Checking
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Side window distance, checking

  • Open convertible top.
  • Raise side windows.
  • Open both doors.
  • Using a tape measure on inner edge of side windows - arrow - , measure distance of side windows to each other.
  • Distance - a - = 1169 -1171 mm.

NOTE:
  • Because this measurement cannot determine symmetry to both windows, the window that is still noticeable after all pre-adjustments is adjusted in case of a deviation from the dimension.

Fig. 97: Side Window Distance, Adjusting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Side window distance, adjusting

  • Adjust window angle with Side Window Installation Tool V.A.G 1739 Angle, adjusting.

Fig. 98: Identifying Window Regulator Can Be Adjusted In Respective By Turning Adjusting Screw In/Out
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • The window regulator - 4 - can be adjusted in the respective - direction of arrow - by turning adjusting screw - 2 - in or out.
  • Turning right: distance is increased.
  • 1 turn corresponds to approx. 2 mm.

  • Tighten nuts and bolts.

Tightening torques --> Side windows - assembly overview.

Comfort system

Component locations

Fig. 99: Comfort System Component Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Front Passengers Door Control Module J387

2 - Radar Interior Monitoring Control Module 2 G305

3 - Right Rear Window Regulator Motor V27

4 - Alarm Horn H12

5 - Motor for fuel tank lid unlock V155

6 - Motor for rear lid release V139

7 - Left Rear Window Regulator Motor V26

8 - Radar Interior Monitoring Control Module 1 G303

9 - Driver s Door Control Module J386

10 - Central control module for comfort system J393

11 - Front hood switch F266

Front Passengers Door Control Module J387

Fig. 100: Front Passengers Door Control Module J387
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Integrated in window regulator.

Radar Interior Monitoring Control Module 2 G305

Fig. 101: Radar Interior Monitoring Control Module 2 G305
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Between front seats in center console below parking brake lever handle recess.

Right Rear Window Regulator Motor V27

Fig. 102: Right Rear Window Regulator Motor V27
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Right rear behind side trim.

Alarm Horn H12

Fig. 103: Alarm Horn H12
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • In convertible top compartment at right behind side trim.

Motor for fuel tank lid unlock V155

Fig. 104: Motor For Fuel Tank Lid Unlock V155
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • In luggage compartment at right behind side trim.

Motor for rear lid release V139

Fig. 105: Motor For Rear Lid Release V139
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • in luggage compartment on rear lid lock.

Left Rear Window Regulator Motor V26

Fig. 106: Left Rear Window Regulator Motor V26
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Left rear behind side trim.

Radar Interior Monitoring Control Module 1 G303

Fig. 107: Radar Interior Monitoring Control Module 1 G303
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Below rear seat bench.

Drivers Door Control Module J386

Fig. 108: Drivers Door Control Module J386
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Integrated in window regulator.

Central control module for comfort system J393

Fig. 109: Central Control Module For Comfort System J393
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • On left front sill.

Front hood switch F266

Fig. 110: Front Hood Switch F266
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • In lock carrier.

Fuel filler flap

Fig. 111: Fuel Filler Flap Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

5 - Tightening torque: 1.5 Nm

Fuel Tank Lid Unlock Motor V155, removing and installing

Fig. 112: Fuel Tank Lid Unlock Motor V155 Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  1. Motor for fuel tank lid unlock V155
  2. Locking pin
  3. Fuel filler flap

Fig. 113: Loosening Bolts Using Socket Wrench T10010, Sliding Actuator Up And Removing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

  • Disconnect electrical connector.
  • Loosen bolts - arrows - using Socket Wrench T10010 , slide actuator - 1 - up and remove.

Fig. 114: Fuel Filler Flap Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing

  • Before installing actuator, emergency release - 2 - must be slid over the locking pin.
  • Locking pin of actuator must move cleanly into closed fuel filler flap - 2 -.
  • Clip in grommets - 1 -.

NOTE:

Tightening torques --> Component locations.

61 - Convertible top

Convertible top, servicing

Safety precautions

CAUTION: Observe measures when disconnecting battery --> .

CAUTION: The convertible top hydraulic system loses pressure with ignition on 10 minutes after last use.

By pressing Convertible Top Operation Switch E137 briefly, the convertible top remains in respective position for another 10 minutes.

Secure convertible top mechanism against unintentional folding up and down during all installation work as this can lead to personal injury or vehicle damage.

Rivet connections, loosening

  • Cover areas that are difficult to reach to protect against shavings.
  • Drill out rivet head.
  • Carefully drive out rivet head using a chisel.
  • Drive rest of rivet out with a punch.
  • Remove shavings, e.g. with a workshop vacuum.

NOTE:
  • Drill shavings lead to damage of convertible top parts and vehicle paint.

Convertible top - assembly overview

Fig. 115: Convertible Top - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Convertible top

2 - Front roof frame seal

3 - Center roof frame seal

4 - Bracket/rear roof frame seal

5 - Convertible top switch unit

Consists of:

6 - Bolts

  • 21 Nm

7 - Convertible top compartment cover

8 - Main bracket

9 - Bolts

  • 36 Nm

10 - Plastic washers

11 - Main hydraulic cylinder retaining bracket

12 - Nut

  • 20 Nm

Convertible top compartment cover

Fig. 116: Removing/Installing Bolts & Hinge
Courtesy of VOLKSWAGEN UNITED STATES, INC.

2 - 21 Nm

3 - 21 Nm

Convertible top, removing and installing

  • The convertible top installation is described so that opening or removing the hydraulic system is not necessary.
  • All assembly work is described for the right side of the vehicle and is performed the same or in a similar way on the left side.
  • When installing, ensure convertible top moves easily when closing.
  • When operating convertible top, ensure front and rear windows have lowered at least 50 mm.

Removing

NOTE:
  • For easier removal of convertible top, remove convertible top compartment cover.

Fig. 117: Bringing Convertible Top Into Center Position
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Bring convertible top into center position.

Fig. 118: Removing/Installing Bolts & Hinge
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Only remove bolts - 2 - on hinge - 1 -.

Bolt - 3 - must not be removed. That way, no installation work arises when installing convertible top compartment cover.

Fig. 119: Removing Ball Sockets And Placing Cylinder In Convertible Top Compartment
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Loosen lift cylinder securing springs - 1 - at top of convertible top compartment cover. Remove ball sockets - 2 - and place cylinder in convertible top compartment.
  • Raise convertible top compartment cover.

CAUTION: Protect vehicle from paint damage by using suitable protective covers and fabric reinforced adhesive tape.

Fig. 120: Removing Hydraulic Lines And Cylinders From Convertible Top Frame
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Install bracket hydraulic cylinder - 1 - on ball sockets - 2 -.
  • Unclip hydraulic lines from brackets - 3 - (Qty. 6) and loosen cable ties - 4 - (Qty. 2).
  • Remove hydraulic lines and cylinders from convertible top frame and place them in convertible top compartment.

Fig. 121: Disconnecting Connectors At Right In Vehicle
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Disconnect connectors - arrows - at right in vehicle.
  • Remove convertible top cable from guides and cable ties for body wall and convertible top frame.

NOTE:
  • All cable ties that are loosened or cut off when removing convertible top frame should be re-installed in the same places during installation.

Right side of vehicle

Fig. 122: Removing Convertible Top Switch Unit Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove convertible top switch unit bolts - 1 -. The switch unit consists of Convertible Top Closed Position Switch F202 and Convertible Top Open Position Switch F171.
  • Carefully remove convertible top switch unit from bolting point mounts.

NOTE:
  • The convertible top should be brought to the appropriate position to remove respective convertible top switch unit bolt.

Continuation for both sides of vehicle

  • Remove main hydraulic cylinder securing pins - 2 -.
  • Loosen nuts on main hydraulic cylinder bracket until they are removed from the center and can be stored in the vehicle.

Fig. 123: Loosening Main Bracket Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Loosen main bracket bolts - 1 - , - 2 - and - 3 - approx. 2 turns.
  • Two technicians must balance out the convertible top at the left and right.
  • Remove bolts - 1 - and - 2 -.
  • Bolt - 3 - remains as retainer in body wall.
  • Raise convertible top approx. 20 cm and pull convertible top cable upward out of body.
  • Raise convertible top toward rear over vehicle and out.

Installing

Installation is reverse of removal, noting the following:

  • When inserting convertible top frame, ensure hydraulic lines and electrical wires are not damaged.
  • When installing main hydraulic cylinder, ensure plastic washers are inserted in center of main hydraulic cylinder.
  • Adjust door windows --> Side windows, adjusting.
  • Adjust side window --> Side windows, adjusting.
  • Perform function test.
  • With convertible top closed, check whether front and rear windows run into seals when raised.

Convertible top lock, removing and installing

  • Front rail trim removed.
  • Mark position of convertible top lock on front rail.

Fig. 124: Removing Wire Bracket Retainer, Pressing Push Rod Off Ball Stud & Removing Bolts And Convertible Top Lock
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove wire bracket retainer and press push rod - 1 - off ball stud.
  • Remove bolts - 2 - and remove convertible top lock.

Installation is reverse of removal.

Tightening torque --> Attachments - assembly overview.

Convertible top locks, checking and adjusting

  • Front rail trim and cowl panel trim removed.
  • Close convertible top.
  • Check position of convertible top lock and anchor plate to one another.

Fig. 125: Convertible Top Locks, Checking And Adjusting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Convertible top lock pins - 1 - must not contact anchor plate - 2 -.

  • If necessary, adjust position of anchor plate - 2 -.
  • Loosen wire bracket retainers and press both push rods - 3 - off ball studs.
  • Check whether convertible top locks have reached their end position by pressing firmly on ball studs - 4 - in closing direction.

The push rods - 3 - must be able to be placed on the ball studs - 4 - in this position.

Convertible top locks and linkages, adjusting

  • Push rods - 3 - removed from ball studs - 4 - on both sides.
  • Loosen Convertible Top Locking Motor V223 bolts approximately one turn.
  • On right side of vehicle, place push rod - 3 - on ball stud - 4 -.
  • Tighten Convertible Top Locking Motor V223 bolts.
  • Loosen lock nut - 5 - on left side of vehicle and adjust ball stud by screwing threads in or out.
  • Adjust ball stud - 3 - so that it can be placed on ball stud - 4 -.
  • Tighten lock nut in this position.

Tightening torques --> Attachments - assembly overview.

Side windows, adjusting

Special tools, testers and auxiliary items required

Fig. 126: Side Window Installation Tool V.A.G 1739
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Side Window Installation Tool V.A.G 1739

NOTE:
  • The adjustment steps are described on the rear windows as an example and can be done the same way on the door windows.

Angle, adjusting

Fig. 127: Angle, Adjusting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Using Side Window Installation Tool V.A.G 1739 , loosen lock nuts - 1 - on adjusting collar screws.
  • Adjust angle of inclination by turning hex socket - 2 -.
  • Tighten lock nut.

Longitudinal angle and closing height, adjusting

Fig. 128: Longitudinal Angle And Closing Height, Adjusting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Loosen bolts - arrows -.
  • Slide side window into convertible top seal groove.
  • Tighten screws.

Adjustment, checking

Fig. 129: Adjustment, Checking
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • With convertible top closed, check whether front and rear windows run into seals when raised - arrow -.

Tightening torques --> Rear window regulator - assembly overview.

Convertible top frame seals - assembly overview

Fig. 130: Convertible Top Frame Seals - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Front roof frame seal

2 - Screw

  • 5.2 Nm

3 - Center roof frame seal

4 - Bracket/rear roof frame seal

5 - Front rail trim

Front roof frame seal, removing and installing

Fig. 131: Front Roof Frame Seal Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolts - arrows -.
  • Remove seal sideways out of seal carrier.
  • Remove retaining strip with seal.

Installation is reverse of removal.

Tightening torque --> Convertible top frame seals - assembly overview.

Rear bracket/roof frame seal or center roof frame seal, removing and installing

  • To remove, open convertible top until center roof frame seal and rear roof frame seat do not touch at rear edges.

Fig. 132: Removing Seal From Retaining Track
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove seal from retaining track in - direction of arrow -.

NOTE:
  • When installing, ensure seal is positioned exactly in sealing profile.
  • Center roof frame seal, rear roof frame seal and bracket seal are removed in the same way.

Front rail trim, removing and installing

Fig. 133: Front Rail Trim Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolts - arrows -.
  • Carefully remove trim.

Installation is reverse of removal.

Tightening torque --> Convertible top frame seals - assembly overview.

Convertible top - parts designations

NOTE:
  • These parts designations are used in the description for removal and installation of convertible top headliner, convertible top cover and convertible top upholstery.

Fig. 134: Convertible Top - Parts Designations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rail "1"

2 - Rail "2"

3 - Rail "3"

4 - Rail "4"

5 - Rail "5"

6 - Bracket

7 - Center brace

8 - Main bracket

9 - Main guide

10 - Roof guide "2"

11 - Roof guide "1"

12 - Front rail

Convertible top headliner - assembly overview

Fig. 135: Convertible Top Headliner - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Convertible top headliner

2 - Plastic profile

3 - Plastic profile

4 - Zip fastener

5 - Rear window frame

6 - Tab

7 - Rivet

8 - Plastic profile

9 - Tensioning band 3

10 - Strap

11 - Tensioning band 2

12 - Tensioning band 1

13 - Tab

14 - Screw

15 - Securing profile

Convertible top headliner, removing and installing

Fig. 136: Identifying Special Tools - Convertible Top Headliner, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

  • Closing Pliers VAS 6138
  • Staple Gun VAS 6148 with Replacement Staples F/VAS6148 VAS 6148/1
  • Pop rivet pliers VAS 5072

Removing

NOTE:

Fig. 137: Bringing Convertible Top Into Center Position
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Bring convertible top into center position.

Fig. 138: Removing Bolts & Retaining Strip With Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolts - arrows -.
  • Remove seal sideways out of seal carrier.
  • Remove retaining strip - 1 - with seal.

Fig. 139: Removing Bolt & Securing Profile From Rail
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolt - A -.
  • Remove securing profile - B - from rail - C -.

NOTE:
  • The tensioning cable and front strap on convertible top are fastened together with bolt - A -.

Fig. 140: Removing Rivet From Eyelet & Rubber Cable From Eyelet On Inner Side Of Roof Guide
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove rivet - 1 - from eyelet.
  • Remove rubber cable - 2 - from eyelet - 3 - on inner side of roof guide "2".

Fig. 141: Disengaging Tensioning Cable From Spring And Pulling Through Eyelet On Rear End Of Roof Guide And Forward
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Disengage tensioning cable from spring - arrow - and pull through eyelet on rear end of roof guide and forward.

NOTE:
  • The spring is visible at the rear end of the roof guide "2" when the convertible top is brought into center position.

Fig. 142: Identifying Cable Tie, Tensioning Cable & Rivet
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Loosen cable tie - 1 -.
  • Fold hose back and disengage tensioning cable - 2 -.
  • Remove rivet - 3 -.
  • Remove tensioning bands from sealing element bushings on convertible top frame.

Fig. 143: Loosening Guide Bracket Upper Bolted Connection And Disengage Strap
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Loosen guide bracket upper bolted connection - 1 - and disengage strap - 2 -.

Fig. 144: Removing Convertible Top Headliner Plastic Strips From Roof Rail
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove convertible top headliner plastic strips from roof rail "2" and "3".

Fig. 145: Clamping Replacement Staples VAS 6148/1 Onto Ends Of Zip Fasteners
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Clamp Replacement Staples VAS 6148/1 onto ends of zip fasteners - arrow -.
  • Pull zip fasteners apart.

NOTE:
  • Ensure zip fastener is not damaged.

Fig. 146: Drilling Convertible Top Headliner Tab Rivet On Bracket & Removing Convertible Top Headliner Securing Strip From Groove In Bracket
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Drill convertible top headliner tab rivet - 1 - on bracket.
  • Remove convertible top headliner securing strip - 2 - from groove in bracket.
  • Remove convertible top headliner from rear window guide frame. Ensure no clips remain in rear window guide frame.

NOTE:
  • Replace faulty clips.

Installing

Fig. 147: Bringing Convertible Top Into Center Position
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Bring convertible top into center position.

Fig. 148: Checking Whether Clips Are Located Completely In Convertible Top Headliner Frame
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Check whether clips - 1 - are located completely in convertible top headliner frame.
  • Press convertible top headliner frame into rear window frame with wide pliers.

Fig. 149: Ensuring Center Markings Align
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • When closing zip fastener, ensure center markings - arrows - align.

The remaining convertible top headliner installation is done in reverse order.

NOTE:
  • Ensure all convertible top components are positioned and function properly.
  • Perform function test.

Tightening torques --> Convertible top headliner - assembly overview or --> Attachments - assembly overview.

Convertible top cover - assembly overview

Fig. 150: Convertible Top Cover - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Convertible top cover

2 - Zip fastener

3 - Zip fastener

4 - Zip fastener

5 - Zip fastener

6 - Rear window

7 - Plastic profile

8 - Rivet

9 - Tensioning strap

10 - Screw

11 - Tab

12 - Molding

  • 3-part

13 - Plastic profile

Convertible top cover, removing and installing

Fig. 151: Identifying Special Tools - Convertible Top Cover, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

  • Closing Pliers VAS 6138
  • Staple Gun VAS 6148 with Replacement Staples F/VAS6148 VAS 6148/1
  • Pop rivet pliers VAS 5072

Removing

NOTE:

Fig. 152: Bringing Convertible Top Into Center Position
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Bring convertible top into center position.

Fig. 153: Removing Bolts For Seal Retaining Strip From Front Rail
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolts - arrows - for seal retaining strip - 1 - from front rail.
  • Carefully remove front rail trim.

Fig. 154: Removing Convertible Top Headliner Straps On Front Rail
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove convertible top headliner straps - 1 - on front rail.
  • Remove molding band - 2 - and convertible top cover - 3 - from front rail groove.

Fig. 155: Removing Sealant On Front Corners Or Front Rail
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove sealant - arrow - on front corners or front rail.
  • Remove convertible top sideways from convertible top frame.

Fig. 156: Removing Tensioning Strap On Roof Guide Between Rail And Rail
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove tensioning strap - 1 - on roof guide between rail - 3 - and rail - 4 -.

NOTE:
  • When installing, ensure tensioning cable - 2 - is not pinched.

Fig. 157: Removing Tensioning Cable From Mounting Hole In Roof Guide
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove tensioning cable - 1 - from mounting hole - 2 - in roof guide - 1 -.
  • Pull tensioning cable back out of convertible top cover canvas pockets.

NOTE:
  • Use a suitable welding wire when pulling in tensioning cable.

  • Fold back convertible top cover.

Fig. 158: Clamping Replacement Staples VAS 6148/1 Onto Ends Of Zip Fasteners
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Clamp Replacement Staples VAS 6148/1 onto ends of zip fasteners - arrow -.

NOTE:
  • When installing, mark the convertible top cushion where the corresponding center line on the underside of the convertible top cover meets with the cushion. This will ensure exact centering of the top cover during installation

  • Pull zip fasteners apart (Qty. 4).

NOTE:
  • Ensure zip fastener is not damaged.

Fig. 159: Folding Bracket In Vertical Position (Convertible Top In Center Position) And Removing Bolt
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Fold bracket in vertical position (convertible top in center position) and remove bolt - arrow B -.

NOTE:
  • To provide a better explanation, the adjoining illustration shows the convertible top frame without convertible top headliner, convertible top cover and convertible top upholstery to.

Fig. 160: Removing Washer On Rear Window Cable Guide
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove washer on rear window cable guide and pull cable out of its guide - arrow -.

Fig. 161: Drilling Convertible Top Headliner Tab Rivet On Bracket & Removing Convertible Top Headliner Securing Strip From Groove In Bracket
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Drill convertible top headliner tab rivet - 1 - on bracket.
  • Remove convertible top headliner securing strip - 2 - from groove in bracket.
  • Remove convertible top headliner from rear window guide frame. Ensure no clips remain in rear window guide frame.

NOTE:
  • Replace faulty clips.
  • The convertible top headliner is now separated from the convertible top cover (rear window frame).

Fig. 162: Removing Plastic Profile From Bracket Groove
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove plastic profile - 1 - from bracket groove - 2 -.

Fig. 163: Cutting Cable Tie & Opening Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Cut cable tie - 1 -.
  • Open housing - 2 - and disconnect rear window defroster electrical connectors.
  • Remove convertible top frame on main guide downward.

Installing

Installation of the convertible top cover is the reverse of removal.

NOTE:
  • Ensure all convertible top components are positioned and function properly.
  • Perform function test.

Convertible top upholstery - assembly overview

Fig. 164: Convertible Top Upholstery - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Convertible top upholstery

2 - Molding

3 - Profile strip

4 - Zip fastener

  • Outside

5 - Round molding

6 - Zip fastener

  • Outside

7 - Round molding

8 - Zip fastener

  • Outside

9 - Round molding

10 - Zip fastener

  • Outside

11 - Zip fastener

  • Inner

12 - Round molding

13 - Round molding

14 - Adhesive surface

  • Double-sided tape can be used several times.
  • Use Double-Sided Adhesive Tape 434 019 25 if damaged.

Convertible top upholstery, removing and installing

Fig. 165: Bringing Convertible Top Into Center Position
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

NOTE:

Fig. 166: Removing Molding Band And Convertible Top Upholstery From Front Rail Groove
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove molding band - 1 - and remove convertible top upholstery from front rail groove - 2 -.

Fig. 167: Removing Convertible Top Upholstery From Adhesive Tape On Main Guide
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove convertible top upholstery from adhesive tape on main guide - 1 -.

NOTE:
  • The double-sided tape can be reused if in good condition.

  • Remove bolt from back end of convertible top upholstery in bracket.
  • Slide convertible top upholstery forward out of bracket upper groove - 2 -.
  • Pull convertible top upholstery to side and out of rails.

Installing

Installation of the convertible top upholstery is the reverse of removal.

NOTE:
  • Ensure all convertible top components are positioned and function properly.
  • Perform function test.

Inner headliner, servicing

Inner headliner strap with hose B6C 003 05D

Fig. 168: Bringing Convertible Top Into Position
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Bring convertible top into position shown.

CAUTION: The convertible top hydraulic system is depressurized after 10 minutes.
  • Risk of injury from lowering convertible top.

NOTE:
  • To prevent convertible top from lowering, press convertible top switch, secure top against lowering if necessary.

  • For better accessibility, completely lower side windows.

Fig. 169: Removing Cable Ties On Jacketed Pull-Spring
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove cable ties - arrow - on jacketed pull-spring.

Fig. 170: Checking Diverting Eyelet For Damage Or Deformation & Folding Sheathing Back And Disengage Headliner Cord At Pull-Spring
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Check diverting eyelet - 1 - for damage or deformation.
  • If necessary, replace both diverting eyes.
  • Fold sheathing - 2 - back and disengage headliner cord at pull-spring.

Fig. 171: Identifying Rubber Hose, Sheathing & Over Pull-Spring
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Guide headliner cord through rubber hose - 1 - and re-engage it at pull-spring - 2 -.
  • Slide sheathing - 3 - over pull-spring - 2 -.
  • Guide a cable tie through slit - arrow - present on sheathing - 3 - and tighten it.
  • Close convertible top until bracket is vertical (on stop) and convertible top compartment cover is closed.

NOTE:
  • Cover convertible top compartment cover and side panel to protect against paint damage.

Fig. 172: Identifying Molding, Rivet & Sewn Seam
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove molding - 1 - from bracket.
  • Remove rivet - 2 -.
  • Separate sewn seam - 3 - on torn off mounting strap and remove "old strap".

Fig. 173: Laying Mounting Strap From Repair Kit Flush On Convertible Top Headliner
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Lay mounting strap from repair kit flush on convertible top headliner - arrows - and sew with a double seam.

NOTE:
  • Before sewing, ensure strap is positioned correctly on headliner to avoid a twisted seam.

Fig. 174: Securing Strap To Convertible Top Frame With Accompanying Rivet
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Secure strap to convertible top frame with accompanying rivet - arrow -.
  • Install inner headline molding on bracket.
  • Perform function test.

Convertible top emergency release

NOTE:
  • If the convertible top cannot be operated because of implausible reasons, it may be in an undefined position (for the control module). Pull bracket up as far as stop and operate switch.

Convertible top compartment cover, unlocking and locking

Fig. 175: Convertible Top Emergency Release Key In Basic Position
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Convertible top emergency release key in basic position - arrow -.

Fig. 176: Convertible Top Emergency Release Key In Work Position
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Convertible top emergency release key in work position - arrow -.

NOTE:
  • Convertible top emergency release key is located at left under instrument panel fuse cover.
  • The designation "NES" is used for the convertible top emergency release key in the following description.

Fig. 177: Lowering Side Windows
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Lower side windows approx. 20 cm.
  • Close luggage compartment cover.

Fig. 178: Opening Drivers Door And Removing Fuse Carrier Cover On Instrument Panel
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Open drivers door and remove fuse carrier cover on instrument panel.
  • There is a groove on the lower edge of the fuse cover in which a screwdriver, for example, can be inserted - arrow - in order to raise.

Fig. 179: Removing "NES" From Bracket Over Fuse Carrier In Instrument Panel
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove "NES" from bracket over fuse carrier in instrument panel.

Fig. 180: Removing Center Piece Of Rear Backrest By Pushing Small Tabs Town Slightly And Pulling
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove center piece of rear backrest by pushing small tabs town slightly and pulling.

Fig. 181: Pressing Grip Holes Together And Folding Cover Up
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Press grip holes together and fold cover up.
  • Press ski sack down and remove if necessary.

Fig. 182: Inserting "NES" In Opening At Top Center Of Ski Sack Tunnel
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Bring "NES" into basic position as follows:

  • Turn red grip piece left as far as stop.
  • Insert "NES" in opening at top center of ski sack tunnel.

Fig. 183: Turning Entire "NES" Until Small Tabs On Key Head Engage In A Groove
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Turn entire "NES" until small tabs on key head engage in a groove.
  • Turn entire "NES" 1 /4 turn clockwise against stop in lock.

Fig. 184: Turning Red Grip Clockwise (1.5 Turns) Until Both Grip Recesses On "NES" Audibly Engage
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Turn red grip clockwise (1.5 turns) until both grip recesses on the "NES" audibly engage.
  • The "NES" is secured in the lock system and can be operated.

Fig. 185: Opening Convertible Top Compartment Cover By Turning "NES" Counter-Clockwise As Far As Stop
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Open convertible top compartment cover by turning "NES" counter-clockwise as far as stop.

Fig. 186: Pulling Convertible Top Compartment Cover Out As Far As Stop
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pull convertible top compartment cover out as far as stop.
  • The convertible top compartment cover engages in open position.
  • Raise convertible top out of compartment by pulling roof edge up forcefully.

Bring convertible top into center position manually as follows:

  • Close convertible top until it stays half closed by itself. Slide roof edge forward as far as possible.
  • Raise convertible top bracket until it stays in vertical position.
  • Carefully press convertible top compartment cover shut.
  • Turn entire "NES" clockwise as far as stop.
  • The convertible top compartment cover is locked.

Fig. 187: Removing "NES"
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove "NES" as follows:

  • Turn red grip piece counter-clockwise as far as stop.
  • Turn entire "NES" 1 /4 turn counter-clockwise and pull it down.

Fig. 188: Convertible Top, Unlocking And Locking
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Convertible top, unlocking and locking

  • Press bracket onto convertible top compartment cover.
  • Press convertible top at front of vehicle onto upper windshield frame.
  • The convertible top may spring out slightly.
  • Remove cover in center of the front rail trim inside vehicle.

Fig. 189: Bringing "NES" Into Basic Position
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Bring "NES" into basic position as follows:

  • Turn red grip piece left as far as stop.
  • Insert "NES" in opening in center of front rail trim.
  • Turn entire "NES" until small tabs on key head engage in a groove.
  • Turn entire "NES" 1 /4 turn clockwise against stop in lock.

Fig. 190: Turning Red Grip Clockwise (1.5 Turns) Until Both Grip Recesses On "NES" Audibly Engage
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Turn red grip clockwise (1.5 turns) until both grip recesses on the "NES" audibly engage.
  • The "NES" is secured in the lock system and can be operated.

Fig. 191: Turning Entire "NES" Clockwise As Far As Stop
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Turn entire "NES" clockwise as far as stop.
  • Pull convertible top down using "NES".
  • Turn entire "NES" counter-clockwise as far as stop.
  • The convertible top is locked.

Fig. 192: Removing "NES"
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove "NES" as follows:

  • Turn red grip piece counter-clockwise as far as stop.
  • Turn entire "NES" 1 /4 turn counter-clockwise and pull it down.
  • Re-install cover cap.
  • Close side windows.

Convertible top frame

Safety precautions

CAUTION: Observe measures when disconnecting battery --> .

CAUTION: Secure convertible top mechanism against unintentional folding up and down during all installation work as this can lead to personal injury or vehicle damage.

Attachments - assembly overview

Fig. 193: Attachments - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Guide cable - rear window

2 - Bracket strap - rail "4"

3 - Bracket strap - rail "5"

4 - Rubber strap for rail "3" and "4"

5 - Center brace strap - rail "4"

6 - Convertible Top Locking Motor V223 bolts

  • 10 Nm

7 - Convertible Top Locking Motor V223 , (Convertible Top Lock Switch (open) F294 , Convertible Top Lock Switch (closed) F295)

8 - Convertible top lock

9 - Convertible top lock bolts

  • 9 Nm

10 - Nut

  • 6 Nm

11 - Cable eyelet- headliner

12 - Plastic profile

13 - Screw

  • 4 Nm

14 - Tensioning wire - headliner

15 - Tensioning element - headliner

16 - Convertible top cover tensioning cable

17 - Cable spring - headliner (lengthwise)

18 - Cable spring - headliner (across)

19 - Cable eyelet- headliner

20 - Center brace spring - rail "5"

21 - Bracket insulation element

Attachments, removing and installing

NOTE:
  • It is not always necessary to perform all preliminary work listed above to service individual convertible top frame attachments.
  • In the instructions, the work on the convertible top frame is described without the convertible top headliner, convertible top cover, convertible top upholstery and seals.
  • The description is based on the right side of the convertible top frame and can be applied to the left side the same way or in a similar way.
  • The convertible top can be disassembled and pre-assembled in the vehicle when installed in vehicle.
  • When working on the convertible top electrical system, disconnect vehicle battery ground strap.

Fig. 194: Removing Bolts For Tensioning Wire And Tensioning Element On Main Guide Diverting Linkage
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolts for tensioning wire and tensioning element - arrows - on main guide diverting linkage.
  • The tensioning wire and tensioning element are secured together at the threaded connection - arrow B -.

NOTE:
  • To install convertible top headliner, bolt - arrow B - must be removed on some models in order to slide side strap on convertible top headliner over tensioning wire.

Fig. 195: Folding Bracket In Vertical Position (Convertible Top In Center Position) And Removing Bolt
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Fold bracket in vertical position (convertible top in center position) and remove bolt - arrow B -.
  • Remove bolt - arrow A - on rail - 5 -.

Fig. 196: Unclipping Tensioning Cable Sideways Out Of Guide On Main Guide
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Unclip tensioning cable - 1 - sideways out of guide - 2 - on main guide.
  • Remove rivet - 3 - and remove tensioning cable.

NOTE:
  • On first generation vehicles, the tensioning cable - 1 - is bonded into the guide - 2 - with super glue.

Fig. 197: Identifying Bolts, Tensioning Cable, Cable Guide & Convertible Top Frame Position Sensor G356
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolt - A - for tensioning cable - 1 - and cable guide - 2 -.
  • Remove cable guide - 2 - from linkage.
  • Remove bolt - B - and remove Convertible Top Frame Position Sensor G356 - 3 -.
  • Remove wiring harness from its retainers on bracket.

Fig. 198: Removing Band From Eyelet On Bracket & Bracket Insulating Element From Ball Head
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove band - 2 - from eyelet on bracket.
  • Remove bracket insulating element from ball head - 1 -.

Fig. 199: Removing Shared Band Rivet Connection For Bracket Rail "4" And Bracket Rail "5" On Bracket
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove shared band rivet connection for bracket rail "4" and bracket rail "5" on bracket - arrow -.

NOTE:
  • Both bands must be re-riveted on shared mounting point in bracket - arrow - during installation.

Fig. 200: Removing Bolt For Center Brace Rail Spring
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolt - B - for center brace rail spring "5" - A -.
  • On first generation vehicles, check protective glide foil - arrows - on center bracket and on rail "5" for damage.

Fig. 201: Identifying Bracket Strap, Cable Spring, Cable Eyelet & Center Brace Spring
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove rivet - arrow - on rail "5".

The following parts are secured at this rivet connection:

  1. Bracket strap - rail 5
  2. Cable spring - headliner (across)
  3. Cable eyelet- headliner
  4. Center brace spring - rail 5

Fig. 202: Identifying Bolts, Rivets, Bands & Rubber Strap
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolt - A - and slide rubber strap - 1 - sideways from rail "3".
  • Remove rivet - B - on rail "4" and remove band - 2 -.
  • Remove rivet - C - from center brace and rivet - D - from rail "4".
  • Remove band - 1 - and band - 3 -.

Fig. 203: Identifying Bolt & Plastic Profile
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolt - A - on inside of roof guide "2" and remove eye.
  • On first generation vehicles, remove plastic profile - B - on bottom of roof guide "2".

NOTE:
  • The plastic profile - B - must be secured with suitable adhesive during installation.

Fig. 204: Removing Bolt On "Lengthwise Headliner Cable" Eye
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Open convertible top until roof guide "2" and main guide do not touch at their rear edges.
  • Remove bolt - arrow - on "lengthwise headliner cable" eye.

NOTE:
  • On some versions, the eyelet may be riveted to the main guide.

Fig. 205: Removing Rivet On Inside Of Main Guide
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove rivet - arrow - on inside of main guide.
  • Remove "lengthwise headliner cable" spring.

Fig. 206: Unclipping Convertible Top Latch Wiring Harness From Its Guide Beginning At Front Rail To Cable Bracket On Main Guide
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Unclip convertible top latch wiring harness from its guide - arrow - beginning at front rail to cable bracket on main guide.

Fig. 207: Removing Rivet, Cable Bracket From Roof Guide, Bolt And Cable Channel From Diverting Linkage
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove rivet - A - and remove cable bracket - 1 - from roof guide "2".
  • Remove bolt - B - and remove cable channel - 2 - from diverting linkage on inside of main guide and from main guide.
  • Remove wiring harness.

NOTE:
  • When installing, ensure there are sufficient wire loops between wiring bracket - 1 - and cable channel - 2 - so that wiring harness will not be rubbed or bent.

Fig. 208: Checking Double-Sided Tape On Outside Of Main Guide For Damage
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Check double-sided tape on outside of main guide - arrows - for damage.

NOTE:
  • The convertible top upholstery is secured to the main guide with the help of the adhesive tape.

Installation is reverse of removal.

Convertible top hydraulic system

Hydraulic system, general information

CAUTION: Observe measures when disconnecting battery --> .

CAUTION: Secure convertible top mechanism against unintentional folding up and down during all installation work as this can lead to personal injury or vehicle damage.

The hydraulic system is self-bleeding and maintenance-free.

When replacing the hydraulic cylinder or hoses, it is not necessary to top off hydraulic oil. There is sufficient hydraulic oil in the system so that the oil level does not go over or under the minimum markings.

If work is done as a result of hydraulic oil loss, the oil level should be checked before operating and adjusted if necessary.

Vehicles through 04.2006

The hydraulic system is switched off when the ignition is switched off or 10 minutes after the convertible top switch is operated when the ignition is switched on.

If the hydraulic pressure is maintained, the convertible top switch should be operated briefly with the ignition switched on.

Vehicles from 05.2006

When the ignition is switched off, the hydraulic system is switched off after 10 minutes.

To depressurize the system before this (for manual convertible top operation), the convertible top switch must be operated for 3 seconds with "ignition off".

If the hydraulic pressure is maintained, the convertible top switch should be operated briefly with the ignition switched on.

Cleanliness rules

CAUTION: Hydraulic oil damages paint. Immediately remove any hydraulic oil that has come in contact with painted surfaces.

  • Clean connecting points and surrounding areas before loosening.
  • Place removed parts on a clean surface and cover. Use foil and paper. Do not use cloths with lint!
  • Carefully cover or seal opened components if the repair will not be done immediately.
  • Only install clean parts: Only remove replacement parts from packaging right before installation.
  • Place collecting container or foil and cloths under connections to be opened so that hydraulic oil does not come into contact with painted surfaces.
  • Seal open hydraulic lines with cover caps to prevent hydraulic oil from leaking out.

Hydraulic system - assembly overview

Fig. 209: Hydraulic System - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Right bracket drive motor cylinder

2 - Right main drive motor cylinder

3 - Right convertible top compartment cover drive motor cylinder

4 - Nut

  • 3x
  • 10 Nm

5 - Hydraulic pump with valve block

6 - Hydraulic lines

7 - Left convertible top compartment cover drive motor cylinder

8 - Left bracket drive motor cylinder

9 - Left main drive motor cylinder

Fig. 210: Hydraulic System, Filling And Bleeding
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Oil filler screw

Pfeil - 2 Nm

Fig. 211: Hydraulic Pump Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hydraulic pump housing

Arrow - 6 Nm

Fig. 212: Solenoid Valves
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Solenoid valves

  1. 6 Nm
  2. 22 Nm

Fig. 213: Connecting Plate
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connecting plate

Arrow - 10 Nm

Hydraulic system, function overview

Fig. 214: Hydraulic System, Function Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Convertible top compartment cover cylinder

2 - Main cylinder

3 - Bracket cylinder

4 - Check valve S1

5 - Solenoid valve F3

6 - Pressure regulation valve D2

7 - ABS Hydraulic Pump

8 - Two-way valve W2

9 - Pressure regulation valve D1

  • On-board voltage in contact = flow
  • Solenoid valve with no current = return open

10 - Solenoid valve F2

  • On-board voltage in contact = flow
  • Solenoid valve with no current = return open

11 - Pump pressure

12 - Return pressure

13 - Line depressurized

14 - Two-way valve W1

15 - Solenoid valve F1

  • On-board voltage in contact = flow
  • Solenoid valve with no current = return open

Hydraulic function "open" , raise bracket

Fig. 215: Hydraulic Function "Open" , Raise Bracket
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pump rotation direction: right
  • Energized solenoid valve F2
  • Energized solenoid valve F3

Convertible top compartment cover cylinder

The convertible top compartment cover cylinder rebound stages are charged with pressure via the energized solenoid valve F2. In this way, the convertible top compartment cover remains in closed position.

Main cylinder

Solenoid valves F2 and F3 are energized.

In this way, the main cylinder pressure stage and rebound stage are charged with pressure.

The pressure is evenly distributed to the cylinder rebound and pressure stages.

Because the pressure stage has the larger piston surfaces in comparison to the rebound stage, different forces can be generated with the same pressure ratios. The force acts on the pressure stage, whereby the cylinder moves out to the end stop and remains there. The convertible top remains tilted forward.

Bracket cylinder

Both bracket cylinders are activated by solenoid valve F3 during the rebound stage and raise the bracket.

Because it is activated simultaneously from both sides, the two-way valve W1 is permeable in the direction of the bracket cylinder rebound stage. Flow to the cylinder pressure stages is blocked by a check valve active on one side.

Through this, the bracket cylinders are retracted and the bracket is raised. Hydraulic oil displaced in the pressure stages is transferred into the hydraulic reservoir.

Component overview Hydraulic system, function overview.

Hydraulic function "open" , convertible top compartment cover open

Fig. 216: Hydraulic Function "Open" , Convertible Top Compartment Cover Open
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pump rotation direction: right
  • Energized solenoid valve F1
  • Energized solenoid valve F2
  • Energized solenoid valve F3

Convertible top compartment cover cylinder

The convertible top compartment cover cylinders are charged with pressure from both sides simultaneously by the energized solenoid valves F1 and F2 and in this way are run out.

The reason for this lies in the larger piston surface in the pressure stage and the different power ratios due to this resulting from the same large pressure charge.

The convertible top compartment cover is raised.

Main cylinder

Solenoid valves F2 and F3 are energized.

In this way, the main cylinder pressure stages and rebound stages are charged with pressure.

Bracket cylinder

The two-way valve S1 is charged with pressure from both sides simultaneously via the energized solenoid valves F2 and F3. In this way, it is interconnected and the hydraulic pressure is directed to the bracket cylinder rebound stages.

Through this, the bracket cylinders remain retracted and the bracket is raised.

Component overview Hydraulic system, function overview.

Hydraulic function "open" , store bracket.

Fig. 217: Hydraulic Function "Open" , Store Bracket.
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pump rotation direction: left
  • Energized solenoid valve F1
  • Energized solenoid valve F3

Convertible top compartment cover cylinder

The convertible top compartment cover cylinders are not activated.

The check valve contained within comes into use through the energized solenoid valve F1. This prevents the cylinder from becoming depressurized in the pressure stage and the convertible top compartment cover from being closed.

Main cylinder

The hydraulic pressure is channeled directly to the main cylinder pressure stages via check valve S1.

These remain run out and hold the convertible top in forward position.

The hydraulic pressure cannot vent in the system through two-way valve S1 and energized solenoid valve F3.

Bracket cylinder

Both bracket cylinders are directly charged with pressure via the pressure stage.

They are run out and the bracket is stored in the convertible top compartment.

In the rebound stage, displaced hydraulic oil is directed in the system and discharged into the hydraulic oil reservoir via F2.

Component overview Hydraulic system, function overview.

Hydraulic function "open" , store convertible top

Fig. 218: Hydraulic Function "Open" , Store Convertible Top
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pump rotation direction: right
  • Energized solenoid valve F1
  • Energized solenoid valve F2

Convertible top compartment cover cylinder

The convertible top compartment cover cylinders are charged with pressure simultaneously from both sides via energized solenoid valves F1 and F2.

The cylinders remain run out and the convertible top compartment cover is raised.

Main cylinder

The hydraulic pressure is channeled directly to the main cylinder rebound stage via solenoid valve F2.

These are retracted and store the convertible top in the convertible top compartment.

The hydraulic oil displaced from the pressure stage is directed into the hydraulic oil reservoir via F3.

Bracket cylinder

Both bracket cylinders are not activated.

Both bracket cylinders are partially retracted by the convertible top mechanics.

Component overview Hydraulic system, function overview.

Hydraulic function "open" , close convertible top compartment cover

Fig. 219: Hydraulic Function "Open" , Close Convertible Top Compartment Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pump rotation direction: right
  • Energized solenoid valve F2

Convertible top compartment cover cylinder

The convertible top compartment cover cylinders are charged with pressure at the rebound stage via the energized solenoid valve F2.

They are retracted and in this way, the convertible top compartment cover is closed.

The hydraulic oil escaping from the pressure stage is directed into the hydraulic oil reservoir via F1.

Main cylinder

The hydraulic pressure is channeled directly to the main cylinder rebound stage via solenoid valve F2.

In that way, they remain retracted and leave the convertible top in the convertible top compartment.

Bracket cylinder

The bracket cylinders are not activated.

They remain partially retracted.

Component overview Hydraulic system, function overview.

Hydraulic functions "close" , raise convertible top compartment cover

Fig. 220: Hydraulic Functions "Close" , Raise Convertible Top Compartment Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pump rotation direction: right
  • Energized solenoid valve F1
  • Energized solenoid valve F2

Convertible top compartment cover cylinder

The convertible top compartment cover cylinders are charged with pressure from both sides simultaneously by the energized solenoid valves F1 and F2 and in this way are run out.

The convertible top compartment cover is raised.

Main cylinder

The hydraulic pressure is directed to both main cylinders in the rebound stages via solenoid valve F2. Both main cylinders remain retracted.

Bracket cylinder

The bracket cylinders are not activated.

They remain partially retracted.

Component overview Hydraulic system, function overview.

Hydraulic functions "close" , raise convertible top from convertible top compartment

Fig. 221: Hydraulic Functions "Close" , Raise Convertible Top From Convertible Top Compartment
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pump rotation direction: right
  • Energized solenoid valve F1
  • Energized solenoid valve F3

Convertible top compartment cover cylinder

The convertible top compartment cover cylinders are not activated.

The check valve contained within comes into use through the energized solenoid valve F1. This prevents the cylinder from running idle in the pressure stage and the convertible top compartment cover from being closed.

Main cylinder

The pressure stages for both main cylinders are directly charged with hydraulic pressure via the energized solenoid valve F3.

The cylinders run out and the convertible top is raised.

Bracket cylinder

The bracket cylinders are not activated.

Both bracket cylinders are partially run out by the convertible top mechanics.

Component overview Hydraulic system, function overview.

Hydraulic functions "close" , raise bracket

Fig. 222: Hydraulic Functions "Close" , Raise Bracket
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pump rotation direction: right
  • Energized solenoid valve F1
  • Energized solenoid valve F2
  • Energized solenoid valve F3

Convertible top compartment cover cylinder

The convertible top compartment cover cylinders remain charged with pressure from both sides simultaneously by the energized solenoid valves F1 and F2 and in this way remain run out.

The convertible top compartment cover remains raised.

Main cylinder

Both pressure stages for the main cylinder are charged simultaneously by the energized solenoid valves F2 and F3.

The cylinders remain run out and ensure the convertible top remains in forward position.

Bracket cylinder

The two-way valve S1 is charged with pressure from both sides simultaneously via the energized solenoid valves F2 and F3. In this way, it is interconnected and the hydraulic pressure is directed to the bracket cylinder rebound stage.

The bracket cylinders are retracted and the bracket is raised.

The hydraulic oil escaping from the pressure stage is directed into the hydraulic oil reservoir via W2.

Component overview Hydraulic system, function overview.

Hydraulic functions "close" , close convertible top compartment cover

Fig. 223: Hydraulic Functions "Close" , Close Convertible Top Compartment Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pump rotation direction: right
  • Energized solenoid valve F2
  • Energized solenoid valve F3

Convertible top compartment cover cylinder

The convertible top compartment cover cylinders are charged with pressure at the rebound stage via the energized solenoid valve F2.

They are retracted and in this way, the convertible top compartment cover is closed.

The hydraulic oil displaced from the pressure stage is directed into the hydraulic oil reservoir via F1.

Main cylinder

Solenoid valves F2 and F3 are energized.

In this way, the main cylinder pressure stage and rebound stage are charged with pressure.

The cylinders remain run out and ensure the convertible top remains in forward position.

Bracket cylinder

The two-way valve W1 is charged with pressure simultaneously from both sides.

In this way, it is interconnected and the hydraulic pressure is directed to the bracket cylinder rebound stages.

The flow to the cylinder pressure stages is blocked by check valve S1 active on one side.

Through this, the bracket cylinders remain retracted and the bracket is raised.

Component overview Hydraulic system, function overview.

Hydraulic functions "close" , store bracket

Fig. 224: Hydraulic Functions "Close" , Store Bracket
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pump rotation direction: left
  • Energized solenoid valve F3

Convertible top compartment cover cylinder

The convertible top compartment cover cylinders are not activated because solenoid valve F2 is not energized.

They remain retracted and the convertible top compartment cover remains closed.

Main cylinder

The hydraulic pressure is channeled directly to the main cylinder pressure stage via check valve S1.

These remain run out and hold the convertible top in forward position.

The hydraulic pressure cannot vent in the system through two-way valve S1 and energized solenoid valve F3.

Bracket cylinder

Both bracket cylinders are charged with pressure in the pressure stage.

They run out and the bracket is stored on the convertible top compartment cover. The hydraulic oil displaced from the rebound stages is directed in the system and channeled into the hydraulic oil reservoir via F2.

Component overview Hydraulic system, function overview.

Hydraulic system, filling and bleeding

NOTE:
  • The electro-hydraulic convertible top operation involves a closed hydraulic system. Generally, filling is necessary after a loss of oil (accident, leaks, etc.).
  • Due to the lift and displacement effect of the pistons in the hydraulic cylinders, the hydraulic system must be filled when the convertible top is stored in the compartment.
  • The convertible top must be moved with electro-hydraulic operation.

CAUTION: Do not fill system above "MAX" marking as the pressure in the system can become so great that damage can result.

Fig. 225: Hydraulic System, Filling And Bleeding
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Filling

  • Remove luggage compartment trim --> .
  • Remove oil filler plug - arrow -.
  • Fill Hydraulic Oil G 004 000 with a fill container until oil level is between "MIN" and "MAX" markings.

Bleeding

NOTE:
  • Hydraulic system is self-bleeding. The system is bled after opening and closing the convertible top several times.

  • Start the engine.
  • Close and open the convertible top 4 - 5 times with electro-hydraulic operation.
  • The convertible top must move smoothly and without jerking.
  • Check oil level in oil reservoir - 2 - when convertible top is stored in compartment.
  • Oil level must be between "MIN" and "MAX" markings.
  • Top off hydraulic oil if necessary.

Tightening torques --> Hydraulic system - assembly overview.

Hydraulic unit (hydraulic pump), removing and installing

Fig. 226: Hydraulic Unit (Hydraulic Pump)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove luggage compartment trim --> .
  • Remove bolts.
  • Remove hydraulic lines from their guides.
  • Remove electrical connectors.

Installation is reverse of removal.

Tightening torques --> Hydraulic system - assembly overview.

Hydraulic pump housing, removing and installing

Fig. 227: Hydraulic Pump Housing, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tightening torques --> Hydraulic system - assembly overview.

Pump wheel, removing and installing

Fig. 228: Checking Pump Wheel
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Solenoid valve, removing and installing

Fig. 229: Solenoid Valve Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

Follow cleanliness rules --> Cleanliness rules.

Installing

CAUTION: Solenoid valves may only be installed in hydraulic pump in activated (energized) condition. Initiate output diagnostic test mode (DTM) and activate the affected solenoid valve for this.

Fig. 230: Identifying Solenoid Valve, Electrical Harness Connector & Hydraulic Pump
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Connect electrical harness connector - 1 - to solenoid valve - 2 -.
  • Initiate output diagnostic test mode and activate solenoid valve to be installed.
  • Insert activated solenoid valve - 2 - in hydraulic pump - 3 -.
  • Tighten bolts - arrows -.

Tightening torques --> Hydraulic system - assembly overview.

Hydraulic lines, removing and installing

Fig. 231: Removing Securing Plate From The Groove
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove rear side trim --> .
  • Using pliers, remove securing plate - arrow - from the groove.
  • Remove hydraulic line from hydraulic cylinder.

NOTE:
  • Hydraulic line seal is pressed into hydraulic cylinder and cannot be replaced separately.

Hydraulic lines to connecting plate, removing and installing

Special tools, testers and auxiliary items required

Fig. 232: Hydraulic Line Connect Tool 3335
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Hydraulic Line Connect Tool 3335

Fig. 233: Connecting Plate
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

Follow cleanliness rules --> Cleanliness rules.

Hydraulic pump connection table Hydraulic pump connection table.

Fig. 234: Identifying Spring Washer
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Raise spring washer - 1 - on hydraulic lines to be removed (supply and return) over collar on connecting piece with a small screwdriver and remove.

Fig. 235: Identifying Hydraulic Line Connect Tool 3335 Sleeve, Spring Washer & Hydraulic Line Connect Tool 3335
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing

  • Place hydraulic line with connecting piece through connecting plate.
  • Place Hydraulic Line Connect Tool 3335 sleeve - 1 - over connecting piece.
  • Slide spring washer - 2 - onto sleeve and press it on completely with Hydraulic Line Connect Tool 3335.

Fig. 236: Springing Washer Must Slide Completely Over Collar On Connecting Piece & Coat Sealing Ring With Hydraulic Oil And Slide It Onto Connecting Piece
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • Spring washer - 2 - must slide completely over collar on connecting piece - 1 -.

  • Coat sealing ring - 3 - with hydraulic oil and slide it onto connecting piece.

Hydraulic pump connection table

Fig. 237: Hydraulic Pump Connection Table
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connections shown from hose side out.

1 - Main drive motor hydraulic cylinder

11 - Left piston rod side

12 - Left piston side

13 - Right piston rod side

14 - Right piston side

2 - Bracket drive motor hydraulic cylinder

21 - Left piston rod side

22 - Left piston side

23 - Right piston rod side

24 - Right piston side

3 - Convertible top compartment cover hydraulic cylinder

31 - Left piston rod side

32 - Left piston side

33 - Right piston rod side

34 - Right piston side

Tightening torques --> Hydraulic system - assembly overview.

Hydraulic cylinder, removing and installing

Hydraulic lines, removing and installing --> Hydraulic lines, removing and installing.

Fig. 238: Removing Hydraulic Lines And Cylinders From Convertible Top Frame
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Bracket drive motor cylinder

  • Remove bracket hydraulic cylinder - 1 - from ball sockets - 2 -.
  • Unclip hydraulic lines from brackets - 3 - (Qty. 6) and loosen cable ties - 4 - (Qty. 2).
  • Remove hydraulic lines and cylinders from convertible top frame and place them in convertible top compartment.

Convertible top compartment cover cylinder

NOTE:
  • The convertible top compartment cover cylinder is installed as described above.

Fig. 239: Removing Convertible Top Switch Unit Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Main drive cylinder

  • Remove convertible top switch unit bolts - 1 -. The switch unit consists of Convertible Top Closed Position Switch F202 and Convertible Top Open Position Switch F171.
  • Carefully remove convertible top switch unit from bolting point mounts.
  • Remove main hydraulic cylinder securing pins - 2 -.
  • Loosen nuts on main hydraulic cylinder bracket until they are removed from the center and can be stored in the vehicle.

Installation is reverse of removal.

Tightening torques --> Hydraulic system - assembly overview.

Convertible top compartment cover latch

Safety precautions

CAUTION: Observe measures when disconnecting battery --> .

CAUTION: Secure convertible top mechanism against unintentional folding up and down during all installation work as this can lead to personal injury or vehicle damage.

Convertible top compartment cover latch - assembly overview

NOTE:
  • When working on the convertible top electrical system, disconnect vehicle battery ground strap.

Fig. 240: Convertible Top Compartment Cover Latch - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Right tension plate

2 - Screw

  • 21 Nm

3 - Locking washer

4 - Screw

  • 21 Nm

5 - Securing clips

6 - Lock bolt (motor/switch)

  • 10 Nm

7 - Left push rod

  • Preset.

8 - Left convertible top compartment cover lock

9 - Left tension plate

10 - Convertible Top Compartment Cover Locking Motor V222 (Convertible Top Compartment Latch Switch (unlock) F293)

11 - Right push rod

  • Preset

12 - Right convertible top compartment cover lock

Left and right convertible top compartment cover locks, removing and installing

Removing

CAUTION: Observe safety precautions when handling pyrotechnic belt tensioners --> .

Fig. 241: Bringing Convertible Top Into Center Position
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Bring convertible top into center position.
  • Remove securing clips for front convertible top compartment well trim until compartment locks are accessible.

Fig. 242: Identifying Locking Washer, Push Rod & Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove locking washer - 1 -.
  • Remove push rod - 2 -.
  • Mark exact position of bolts - 3 - and remove.
  • Remove convertible top compartment cover lock and lay it sideways,
  • Disconnect switch unit electrical connector and remove switch and lock.

NOTE:
  • The connection is located behind the belt retractor.

Installing

Installation is reverse of removal, noting the following:

  • Install bolts exactly at the markings made earlier. In this way, it is not necessary to adjust the locks.
  • Ensure the convertible top compartment cover aligns with the side panel when closed.
  • Check whether switch works with convertible top compartment cover closed.

Tightening torques --> Convertible top compartment cover latch - assembly overview.

Convertible top compartment cover, adjusting tension plates

Fig. 243: Convertible Top Compartment Cover, Adjusting Tension Plates
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Check whether convertible top compartment cover tension plates lowers into center of funnel for cover locks - arrow -.

If necessary, loosen bolts - 1 - and adjust tension plates to lock.

Tightening torque --> Convertible top compartment cover latch - assembly overview.

Convertible top compartment cover lock, removing and installing

Fig. 244: Convertible Top Compartment Cover Lock, Removing/Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

  • Bring convertible top into center position.
  • Remove convertible top compartment well front trim.
  • Mark position of Convertible Top Compartment Cover Locking Motor V222 before removal.
  • Remove securing spring from ball socket and press push rod of ball stud (version 1) or remove securing clips and press push rods from guide pins (version 2).
  • Disconnect electrical connector.

Fig. 245: Identifying Screws
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove screws - arrows -.
  • Remove Convertible Top Compartment Cover Locking Motor V222/Convertible Top Compartment Latch Switch (unlock) F293.

Installing

  • Secure motor according to markings applied earlier and tighten bolts.

Tightening torque --> Convertible top compartment cover latch - assembly overview.

Convertible top compartment cover, adjusting drive motor

  • Ensure there is sufficient voltage supply for the vehicle battery.

Fig. 246: Bringing Convertible Top Into Center Position
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Bring convertible top into center position.

CAUTION: The convertible top hydraulic system is depressurized after 10 minutes.
  • Risk of injury from lowering convertible top.

  • Remove securing clips for convertible top compartment well front trim until Convertible Top Compartment Cover Locking Motor V222 is accessible.

Fig. 247: Identifying Screws
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Loosen bolts - arrows -.
  • Bring convertible top compartment cover lock into "end position close" --> Convertible top emergency release with emergency key and hold it under tension.
  • Tighten bolts in this position - arrows -.
  • Bring convertible top compartment lock into "end position open" with emergency key.

Tightening torque --> Convertible top compartment cover latch - assembly overview.

NOTE:
  • With "motor in end position" let push rods attach to locks.

Convertible top operation electrical components

Safety precautions

CAUTION: Observe measures when disconnecting battery --> .

CAUTION: Secure convertible top mechanism against unintentional folding up and down during all installation work as this can lead to personal injury or vehicle damage.

Convertible top operation electrical components - assembly overview

NOTE:
  • When working on the convertible top electrical system, disconnect vehicle battery ground strap.
  • All cable ties that are loosened or cut off when removing convertible top should be re-installed in the same places during installation.

Fig. 248: Convertible Top Operation Electrical Components - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Convertible top latch

  • Consists of:
  • Convertible Top Locking Motor V223
  • Convertible Top Lock Switch (open) F294
  • Convertible Top Lock Switch (closed) F295

2 - Convertible Top Control Module J256

3 - Convertible top position switch

4 - Convertible Top Frame Position Sensor G356

5 - Compartment Cover Open Position Switch F201

6 - Convertible top operation hydraulic unit

  • Consists of:
  • Convertible Top Hydraulic Pump V118
  • Convertible Top Hydraulic Pump Relay J321
  • Convertible Top Hydraulic Pump Relay 2 J588

7 - Convertible Top Compartment Enclosure Position Switch F292

8 - Compartment Cover Locked Right Switch 1 F200

9 - Convertible top compartment cover lock

10 - Left Convertible Top Compartment Cover Switch F290

11 - Convertible Top Front Lock Switch F172

12 - Convertible Top Operation Switch E137

Convertible Top Front Lock Switch F172

Fig. 249: Convertible Top Front Lock Switch F172
Courtesy of VOLKSWAGEN UNITED STATES, INC.

2 - 10 Nm

Convertible Top Control Module J256

Fig. 250: Convertible Top Control Module J256
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Arrow - 2.5 Nm

Convertible Top Frame Position Sensor G356

Fig. 251: Identifying Bolts, Tensioning Cable, Cable Guide & Convertible Top Frame Position Sensor G356
Courtesy of VOLKSWAGEN UNITED STATES, INC.

B - 1.5 Nm

Compartment Cover Open Position Switch F201

Fig. 252: Compartment Cover Open Position Switch F201
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  1. 1.5 Nm

Convertible Top Locking Motor V223/Convertible Top Lock Switch (open) F294/Convertible Top Lock Switch (closed) F295 , removing and installing

Removing

Fig. 253: Locating Convertible Top Locking Motor V223/Convertible Top Lock Switch (Open) F294/Convertible Top Lock Switch (Closed) F295
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Store convertible top in convertible top compartment.
  • The convertible top compartment cover remains open.
  • Remove front roof frame seal bolts.
  • Carefully remove front rail trim.
  • Remove ball joint wire fastener and press push rods from convertible top lock ball studs.
  • Disconnect electrical connector.
  • Mark exact position of convertible top latch on rail 1.
  • Remove convertible top latch bolts and remove latch.

Installing

  • Ensure convertible top latch is installed in the position marked earlier.

Further installation is performed in the reverse order of removal.

Tightening torques --> Attachments - assembly overview.

Adjust convertible top latch --> Convertible top locks, checking and adjusting.

Convertible top position switch (Convertible Top Open Position Switch F171/Convertible Top Closed Position Switch F202), removing

Fig. 254: Identifying Convertible Top Control Module J256
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove rear side trim --> .
  • Disconnect electrical connector on Convertible Top Control Module J256.
  • Remove convertible top cable from guides and cable ties for body wall and convertible top frame.

Fig. 255: Removing Convertible Top Switch Unit Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove switch bolts - 1 -.
  • Carefully remove convertible top position switch from bolting point mounts.

NOTE:
  • The convertible top switch unit described is located on the right main guide.
  • The convertible top should be brought to the appropriate position to remove respective convertible top switch unit bolt.

Tightening torque --> Convertible top - assembly overview.

Convertible Top Frame Position Sensor G356 , removing

Fig. 256: Identifying Convertible Top Frame Position Sensor G356
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Bring convertible top into center position.

Fig. 257: Identifying Bolts, Tensioning Cable, Cable Guide & Convertible Top Frame Position Sensor G356
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Disconnect electrical connector on Convertible Top Frame Position Sensor G356 - 3 -.
  • Remove bolt - B - and carefully remove sensor - 3 - from its mounting opening.

Installation is reverse of removal.

NOTE:
  • When installing, ensure sensor slides over convertible top linkage synchronization pins.

Tightening torque --> Convertible Top Frame Position Sensor G356

Compartment Cover Open Position Switch F201 , removing

Fig. 258: Identifying Switch Bolts & Retainer
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Bring convertible top into center position.
  • Remove right trim in convertible top compartment --> .
  • Disconnect electrical connector.
  • Remove switch bolts - 1 -.
  • Carefully pry switch out of retainer - 2 -.

Installation is reverse of removal.

Tightening torque --> Compartment Cover Open Position Switch F201.

Convertible Top Control Module J256 , removing

Fig. 259: Convertible Top Control Module J256
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove control module nuts - arrows -.

Installation is reverse of removal.

Tightening torque --> Convertible top compartment cover latch - assembly overview.

Transmission Range (TR) Gear Monitoring Switch F290 and Compartment Cover Locked Right Switch 1 F200 , removing

Fig. 260: Identifying Left Convertible Top Compartment Cover Switch F290
Courtesy of VOLKSWAGEN UNITED STATES, INC.

The Left Convertible Top Compartment Cover Switch F290 is installed in left convertible top compartment cover lock.

Fig. 261: Identifying Compartment Cover Locked Right Switch 1 F200
Courtesy of VOLKSWAGEN UNITED STATES, INC.

The Compartment Cover Locked Right Switch 1 F200 is installed in right convertible top compartment cover lock.

Convertible Top Front Lock Switch F172 , removing

Fig. 262: Opening Convertible Top
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig. 263: Disconnecting Electrical Connector, Removing Bolts & Switch
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Disconnect electrical connector - 1 -.
  • Remove bolts - 2 - and remove switch.

Installation is reverse of removal.

Tightening torque --> Convertible top operation electrical components - assembly overview.

Convertible Top Operation Switch E137 , removing

Fig. 264: Convertible Top Operation Switch E137
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Carefully pry out button carrier unit on center console.
  • Disconnect electrical connector.
  • Slide convertible top latch button from carrier unit.

63 - Bumpers

Front bumper

Front bumper (up to model year 2005) - assembly overview

Fig. 265: Front Bumper (Up To Model Year 2005) - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Bumper cover

2 - Screw

  • 6 Nm

3 - Screw

  • 3 Nm

4 - Right support

5 - Center support

6 - Cross member

7 - Left support

8 - Guide piece

9 - Screw

  • 1.5 Nm

10 - Grommet

11 - Wheel housing liner

License plate securing holes, creating

Fig. 266: License Plate Securing Holes, Creating
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • Four punch marks are present in the bumper cover license plate field. They must be drilled out to secure a license plate (measurements 115 x 520 mm).

If centering punch marks are not visible, proceed as follows:

  • Determine vertical bisecting line from Audi emblem to center of grill on bumper.
  • Determine horizontal bisecting line:
  • Dimension - a - = Dimension - a -.
  • Determine mounting points for license plate symmetrically as follows:
  • Dimension - x - = 139 mm
  • Dimension - y - = 62 mm

Fender grommets, installing

Fig. 267: Fender Grommets, Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Before installing bumper cover - 1 - , grommets - 3 - must slide onto threaded pins - 2 -.

4 - Fender

  • Tighten nut - 5 - after installing.

5 - Nut (6 Nm)

Panel gap dimensions

Fig. 268: Panel Gap Dimensions
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • Panel gap dimensions can be checked with Adjusting Gauge 3371.
  • Dimension - A - = 2 mm + 0.5 mm.
  • Dimension - B - = 0 mm ± 0.5 mm.
  • Dimension - C - = 0 mm ± 0.5 mm.

Front bumper (up to model year 2005), removing and installing

Fig. 269: Loosening Bolts Or Quick Release Fasteners
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

  • Loosen bolts or quick release fasteners - 3 -. The quick release fasteners behind the sound insulation - 2 - remain installed.
  • The quick release fasteners remain in the bumper cover - 1 -.

Fig. 270: Loosening Left/Right Wheelhousing Liners In Front Area
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Loosen left and right wheel housing liners in front area - arrows -.

Fig. 271: Pulling Back Wheelhousing Liner & Unclipping Bumper Rear Edge From Catch
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pull back wheel housing liner - arrow A -.
  • Remove bolt - 2 - and nuts - 1 -.
  • Unclip bumper rear edge from catch - arrow B -.
  • Repeat procedure on opposite side of the vehicle.

Fig. 272: Radiator Grille, Removing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolts - 1 -.
  • Fold decorative grille - 2 - forward slightly and pull up out of bumper.

Fig. 273: Removing Bumper Cover Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Unscrew bolts - 8 -.
  • Remove bolts - 2 - , - 3 - and - 4 - as well as bolts - 5 - , - 6 - and - 7 -.
  • Remove side pieces - arrow - sideways out of guide piece.
  • Pull bumper cover forward slightly.

Fig. 274: Identifying Hose To Headlight Cleaning System & Bumper Cover Connector(s)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • If installed, disconnect hose - 1 - to headlight cleaning system and reserve washer fluid in a clean container for re-use.
  • Disconnect connector(s) - 2 - to bumper cover.

Fig. 275: Checking To See If Threaded Pins On Bumper Side Walls And Grommets In Fenders Are Present
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing

Installation is reverse of removal, noting the following:

NOTE:
  • Before installing bumper cover - 1 - , check to see if threaded pins - 2 - on bumper side walls and grommets - 3 - in fenders - 4 - are present.

  • Tighten nut.

5 - Nut (5 Nm)

Fig. 276: Identifying Hose To Headlight Cleaning System & Bumper Cover Connector(s)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Slide bumper cover onto lock carrier and if necessary, reconnect headlamp washer system hose - 1 - and electrical connectors - 2 -.
  • Slide bumper cover into installation position. Ensure threaded pins in bumper side walls engage into holes at the fenders.

Fig. 277: Pulling Back Wheelhousing Liner & Engaging Bumper Rear Edge Into Catch
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pull back wheel housing liner - arrow A -.
  • Engage bumper rear edge into catch - arrow B -.
  • Tighten nuts - 1 - and bolt - 2 -.
  • Repeat procedure on opposite side of the vehicle.

1 - Nut (4 Nm)

2 - Screw (1 Nm)

Front bumper (from model year 2006) - assembly overview

Fig. 278: Front Bumper (From Model Year 2006) - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Screw

  • 6 Nm

2 - Screw

  • 23 Nm

3 - Bumper crossmember

  • Bumper cover removed.
  • To remove, remove bolts - 2 -.
  • Disconnect harness connectors to signal horns and remove bumper crossmember from impact absorbers toward front.

4 - Pop rivet

5 - Signal horn

  • To remove, drill off rivet heads.

6 - Support piece

NOTE:
  • When turning adjustment screw, make sure mounting bracket raises.
  • Before installing bumper cover, adjust support piece adjusting screw Adjusting support piece.
  • Tighten adjustment screw to 2 Nm with a long Torx wrench - T30 - through holes in cover - arrows -.
  • To disassemble, drill off pop rivet heads.

7 - Pop rivet

8 - Signal horn

9 - Brace for fender

10 - Guide piece

  • Side piece of bumper cover must be clipped in between fender and guide piece Removing guide piece.

11 - Screw

  • 1 Nm

12 - Screw

  • 1 Nm

13 - Bumper cover

NOTE:
  • While installing, the following sequence described for assembling/bolting must be observed for correct assembly.

  • Set cover onto vehicle and first clip the left and right side piece into guide parts - 10 -.
  • Tighten nuts on fender connection Fender bolts.
  • Tighten bolts - 12 - to wheelhousing liner.
  • Loosely thread in bolts - 1 -.

Fender bolts

Fig. 279: Fender Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Make sure when installing that the clips - 2 - are inserted onto threaded pins.
  • Tighten nuts - 4 - after inserting bumper cover - 1 - in fender - 3 -.

4 - Nut (4 Nm)

Adjusting support piece

Fig. 280: Adjusting Support Piece
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • When turning adjustment screw - 3 - , make sure mounting bracket - 4 - raises.
  • If mounting bracket does not raise, place a small drop (very small!) of locking compound D 000 600 A2 on the adjustment screw threads - 3 - and allow locking compound to dry.
  • Turn adjustment screw up to dimension - a -.
  • The mounting bracket raises when adjustment screw is turned due to the increased friction.

  • Before installing bumper cover - 1 - , adjust adjusting screw - 3 - on support piece - 5 - to dimension - a - = 21 mm +1 mm.
  • Mounting bracket - 4 - must be screwed on completely (left-hand thread) for this.
  • Adjustment screw - 3 - and mounting bracket - 4 - belong to delivery casing for support piece and are not replacement parts.
  • When installing bolt - 3 - , mounting bracket - 4 - unscrews and holds the carrier piece - 2 - of bumper cover - 1 - in the designated position.
  • The support piece - 5 - is secured to bumper cover - 6 - with pop rivets.

Clamping pins for noise insulation

Fig. 281: Clamping Pins For Noise Insulation
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • When removing bumper cover - 1 - , turn clamping pins - 2 - 180° and remove from spring nut - 4 - on sound insulation - 3 -.

Removing guide piece

Fig. 282: Removing Guide Piece
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Bumper cover removed
  • Unscrew bolts - 3 - and pull guide piece - 2 - downward out of fender - 1 -.
  • When installing, bumper cover - 4 - must engage cleanly in guide piece.

Brace for wheelhousing liner

Fig. 283: Brace For Wheelhousing Liner
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • For mounting front wheelhousing liner - 3 -.
  • When installing brace - 1 - , tighten bolt - 2 -.

2 - Screw (10 Nm)

Front bumper (RS4) - assembly overview

NOTE:
  • Removal and installation is done the same as the standard bumper from model year 2006.
  • Only differing steps are described.

Fig. 284: Front Bumper (RS4) - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Screw

  • 6 Nm

2 - Bumper cover

  • Removal and installation as with standard production.

NOTE:
  • While installing, the following sequence described for assembling/bolting must be observed for correct assembly.

  • Set cover onto vehicle and first clip the left and right side piece into guide parts - 10 -.
  • Tighten nuts on fender connection Fender bolts.
  • Tighten bolts - 12 - to wheelhousing liner.
  • Loosely thread in bolts - 1 -.

3 - Guide piece

4 - Screw

  • 1 Nm

5 - Brace for fender

6 - Bumper crossmember

7 - Support piece

NOTE:
  • When turning adjustment screw, make sure mounting bracket raises.
  • Before installing bumper cover, adjust support piece adjusting screw Adjusting support piece.
  • Tighten adjustment screw to 2 Nm with a long Torx wrench - T30 - through holes in cover - arrows -.
  • To disassemble, drill off pop rivet heads.

8 - Front spoiler

  • Remove screws - 10 -.
  • Slide spoiler back slightly out of bumper cover guides.
  • Remove spoiler downward.

9 - Expanding rivet

10 - Screw

  • 2 Nm

11 - Spring nut

Air intake grille for S4

Fig. 285: Air Intake Grille For S4
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolt - arrows -.
  • Press air intake grille - 2 - on the inside of bumper cover - 2 - as shown toward rear out of locking mechanism.
  • Remove air intake grille forward from bumper cover.

Front bumper (from model year 2006), removing and installing

Removing

Fig. 286: Front Bumper (From Model Year 2006) Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolts - 1 - from top of bumper cover - 2 -.

Only on RS4

  • Remove bolts - 1 - from top of bumper cover - 2 -.
  • Remove screw - 4 - from inside of fender - 3 -.

NOTE:
  • The bolt is only accessible after driving wheel housing liner back.

Fig. 287: Identifying Spring Nut Placed On Bumper Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Spring nut - 5 - placed on bumper cover.

Fig. 288: Identifying Quick-Release Fasteners And Noise Insulation
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolts and quick release screws - 1 - and - 2 -. Rear noise insulation (quick release screws - 3 -) remains installed.

NOTE:
  • For the sake of a better illustration, the wheels are shown removed in the illustrations.

Fig. 289: Loosening Left/Right Wheelhousing Liners In Front Area
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Loosen left and right wheel housing liners in front area - arrows -.

Fig. 290: Pulling Back Wheelhousing Liner & Unclipping Bumper Rear Edge From Catch
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pull back wheel housing liner - arrow A -.
  • Remove bolt - 2 - and nuts - 1 -.

NOTE:

  • Unclip bumper rear edge from catch - arrow B -.
  • Repeat procedure on opposite side of the vehicle.

Fig. 291: Adjusting Support Piece
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Loosen adjustment screw - 3 - at support piece - 5 -.

The bracket - 4 - retracts into the support piece - 5 - and frees up the bumper cover - 1 -.

  • Pull bumper cover forward slightly.

Fig. 292: Identifying Hose To Headlight Cleaning System & Bumper Cover Connector(s)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • If installed, disconnect hose - 1 - to headlight cleaning system and reserve washer fluid in a clean container for re-use.
  • Disconnect harness connector(s) - 2 - to bumper.

Installing

Installation is reverse of removal, noting the following:

NOTE:
  • Before installing bumper, check to see if threaded pins at bumper rear edge as well as expanding clips and sleeves in the fenders are present.

Fig. 293: Identifying Hose To Headlight Cleaning System & Bumper Cover Connector(s)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Slide bumper cover onto impact absorber and re-connect headlight cleaning system hose - 1 - and electrical harness connectors - 2 -.
  • Slide bumper cover into installation position. Ensure threaded pins in bumper side walls engage into holes at the fenders.

Fig. 294: Pulling Back Wheelhousing Liner & Engaging Bumper Rear Edge Into Catch
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pull back wheel housing liner - arrow A -.
  • Engage bumper rear edge into catch - arrow B -.
  • Tighten nuts - 1 - and bolt - 2 -.

1 - Nut (4 Nm)

2 - Screw (1 Nm)

  • Repeat procedure on opposite side of the vehicle.

Further installation is performed in the reverse order of removal.

Radiator grille (from model year 2006) - assembly overview

Fig. 295: Radiator Grille (From Model Year 2006) - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Bumper cover

2 - Radiator grille

  • Bumper cover removed.

3 - Trim for radiator grille

4 - License plate holder

  • Bumper cover not removed.
  • To disassemble from rear side, unclip from radiator grille.

Fig. 296: Removing Radiator Grille
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing radiator grille

  • Bumper cover removed.
  • Remove bolts - arrows - around edge and pull radiator grille from bumper cover.

Arrow - 1.5 Nm

Fig. 297: Removing Panel For Fog Lights
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing panel for fog lights

  • Disengage locking mechanisms - arrows - and pull off panel toward vehicle interior.

Fig. 298: Disengaging Fog Lights Locking Mechanisms
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fog lights removed.

  • Disengage locking mechanisms - arrows - and pull off panel toward outside.

Fig. 299: Disengaging Covers Locking Mechanisms
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Covers are divided into two parts.

Disengage locking mechanisms - arrows - and pull off cover toward outside.

Bumper cover (up to model year 2005), adjusting to hood

Fig. 300: Removing Bumper Cover Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Position bumper cover, clip in side flanks - arrow - and secure with bolts - 8 -.
  • Loosely install bolt - 3 -.
  • Tighten bolts - 2 - , - 4 - , - 5 - , - 6 - and - 7 -.

NOTE:
  • Note different torque values.

  • Close hood.
  • Check projection and recess of bumper cover to hood.
  • If OK, tighten all bolts to torque.
  • If not OK, open hood.
  • Loosen bolt(s) - 2 - and/or - 4 - , correct top of bumper cover accordingly and re-tighten bolt to torque.
  • Tighten bolt - 3 -.

2 - Screw (6 Nm)

3 - Screw (6 Nm)

4 - Screw (6 Nm)

5 - Screw (3 Nm)

6 - Screw (3 Nm)

7 - Screw (3 Nm)

Bumper crossmember (up to model year 2005), removing and installing

Fig. 301: Bumper Crossmember (Up To Model Year 2005) Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Bolts

  • 3 Nm

2 - Cross member

3 - Supports

4 - Screw

  • 26 Nm

5 - Impact absorber

6 - Pop rivet

7 - Signal horn

  • To remove, drill out hollow rivet heads and drive out rivet shafts.

8 - Guide piece

Guide piece, removing and installing

Fig. 302: Guide Piece Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • When installing guide piece - 1 - , tighten bolts in the following sequence.
  • Tighten bolt - 2 - first.
  • Then secure brace - 4 - with bolt - 3 -.
  • Tighten bolt - 5 - last.

2 - Screw (4 Nm_

3 - Screw (1 Nm)

5 - Screw (6 Nm)

Bumper crossmember, removing from cover

  • Bumper cover removed.
  • Remove signal horn - 4 -.

Fig. 303: Crossmember, removing from cover and installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Disconnect hose - 5 - of headlamp cleaning system on both sides (press release buttons).
  • Unscrew bolts - 3 - of right spray jet for headlamp cleaning system - spray jet remains installed.
  • Remove bolts - 1 - (Qty. 5).
  • Pry off retaining clips - 2 - (Qty. 3).
  • Swivel spray jet for headlamp cleaning system to the side and remove crossmember from bumper cover.

Bumper crossmember to impact absorber mount

NOTE:
  • Impact absorber is self-adjusting, meaning it can compensate bearing tolerances in height between crossmember and Impact absorber when installing the bolt.
  • This holds and secures the crossmember automatically in the previously adjusted position when installing the bolt - 1 -.

Fig. 304: Bumper, Mounting To Shock Absorber Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Screw

  • 23 Nm

2 - Lower carrier bushing

  • Plastic part pressed into adjusting screw.
  • No replacement part.

3 - Lower adjusting screw

  • Before assembling bumper crossmember, install completely but do not tighten.
  • Left-hand thread
  • No replacement part.

4 - Lower threaded bushing

  • Secured against falling out with securing pin.
  • No replacement part.

5 - Securing pin

  • No replacement part.

6 - Impact absorber

7 - Upper threaded bushing

  • Secured against falling out with securing pin.
  • No replacement part.

8 - Upper adjusting screw

  • Install completely before assembling bumper crossmember.
  • Right-hand thread
  • No replacement part.

9 - Cover

10 - Nut

  • Belongs to crossmember delivery casing.

11 - Upper carrier bushing

  • Plastic part pressed into adjusting screw.
  • No replacement part.

12 - Cross member

Impact absorber, removing and installing

Fig. 305: Impact Absorber Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Bumper crossmember removed.
  • Unscrew bolts - 2 -.
  • Unscrew nut - 3 - and pull impact absorber - 1 - from longmember.

2 - Screw (50 Nm)

3 - Nut (4 Nm)

Rear bumper

Bumper cover, removing and installing

Fig. 306: Bumper Cover Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Guide piece

2 - Grommet

3 - Cross member

4 - Bumper cover

  • Removing:
  • Remove bolts in rear area of wheel housing liner.
  • Drive back wheel housing liner and remove bolts from guide piece.
  • Remove luggage compartment side trim --> .
  • Remove nuts from luggage compartment.
  • Unclip bumper cover side flanks from guide piece.
  • Pull bumper cover back slightly and if necessary, disconnect electrical connector (at left under tail light) to the parking assist system sensors.
  • Remove bumper cover toward rear.

5 - Screw

  • 1.5 Nm

6 - Wheel housing liner

7 - Nut

  • 4 Nm

Side panel grommets, installing

Fig. 307: Checking To See If Threaded Pins On Bumper Side Walls And Grommets In Fenders Are Present
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • Before installing bumper cover - 1 - , check to see if threaded pins - 2 - on bumper sides and grommets - 3 - are present.

  • Before installing bumper cover - 1 - , grommets - 3 - must slide onto threaded pins - 2 -.

4 - Side panel

5 - Nut (6 Nm)

  • Tighten nut - 5 - after installing.

Guide piece, removing and installing

Fig. 308: Guide Piece, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Bumper cover removed.
  • Remove bolts - 3 - and remove guide piece - 1 -.

2 - Clip

  • When installing, tighten bolts - 3 - in - a - , - b - and - c - sequence.

a, b, c - Screw (1.5 Nm)

Panel gap dimensions

Fig. 309: Panel Gap Dimensions
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • Panel gap dimensions can be checked with Adjusting Gauge 3371.
  • Dimension - A - = 2 mm + 0.5 mm.
  • Dimension - B - = 0 mm ± 0.6 mm.
  • Dimension - C - = 0 mm ± 0.6 mm.

Bumper crossmember, removing and installing

NOTE:
  • Bumper cover removed.

Fig. 310: Bumper Crossmember Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Screw

  • 18 Nm
  • Qty. 4

2 - Grommets

3 - Support piece

4 - Screw

  • 1.5 Nm

5 - Cross member

6 - Nut

  • 20 Nm
  • Qty. 2

7 - Screw

  • 20 Nm
  • Qty. 2

8 - Impact absorber

64 - Glass, Windows

Flush-bonded windows

Flush-bonded windows, removing and installing - general information

Fig. 311: Identifying Special Tools - Flush-Bonded Windows, Removing And Installing - General Information
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

  • Suction lifter V.A.G 1344
  • Electric Cutter V.A.G 1561 A with V.A.G 1561/10 and V.A.G 1561/11
  • Cartridge gun V.A.G 1628
  • Window Removing Kit V.A.G 1755 or Cutting Tools for Glass V.A.G 1351
  • Cutting tool kit V.A.G 1474 A
  • Cartridge heater V.A.G 1939

Fig. 312: Spooling Tool V.A.G 1654 A
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Spooling tool V.A.G 1654 A

Fig. 313: Double Cartridge Gun VAS 5237
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Double cartridge gun VAS 5237
  • Cutting cord 357 853 999

Windows, repairing with Talon Repair Resin VAS 1993/2

Fig. 314: Windshield Repair Set VAS 1993
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

  • Window repair kit VAS 1993 or VAS 6092

NOTE:
  • Windshields damaged with stone chips can be repaired with Talon Repair Resin VAS 1993/2.
  • These damaged areas must not exceed a certain dimension or lie within the drivers field of sight.
  • For further details on use, refer to Users Manual enclosed with each kit.

Materials

  • Set 2C- window adhesive DA 004 600 A2 * See note
  • 1K window adhesive DH 009 100 03 * See note
  • Glass and paint primer D 009 200 02
  • Cleaning solution D 009 401 04
  • Applicator D 009 500 25
  • Adhesive remover D 002 000 10
  • Cutting cord 357 853 999
  • Cutting cord 357 845 955

* Observe minimum curing time --> Minimum curing times.

* Double cartridge pistol VAS 5237 must be used to process this material.

* Heat according to manufacturers instructions using cartridge heater V.A.G 1939 A.

*Small cartridge (110 ml) for sealing and/or when a 400 ml double cartridge is not sufficient.

Minimum curing times

CAUTION:
  • For safety reasons, use only electrically non-conductive 2C-adhesive when installing windshield using the materials listed below.
  • Vehicle is only safe for operation after minimum curing time has elapsed and only then may it be used.

Window type Vehicle Adhesive sealing material Curing time in hours
Windshield With airbag DA 004 600 A2 3

Cleaning when soiled by adhesive sealing material

Adhesive removal solution D 002 000 10 is the recommended cleaning solution. Observe safety precautions when processing.

CAUTION: When cleaning from vehicle interior out, the window just installed must not be pressed outward.

Paint surfaces

  • First, clean paint surfaces with a dry cloth. Remove further material using adhesive removal solution D 002 000 10 .

Plastic trim

  • Allow adhesive sealing material to harden (about 1 hour) and then peel off.

Windshield

Trim, removing

Fig. 315: A-Pillar And Roof Frame Trim, Removing Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Right A-pillar trim

  • Remove A-pillar trim.
  • Remove door seal in A-pillar area.
  • Bore out side hollow rivet heads A-pillar trim, removing (Qty. 3), drive rivet shafts out and remove trim.

2 - Roof frame trim

  • Remove roof frame trim.
  • Remove left and right A-pillar trim.

3 - Nut

  • 6.5 Nm

4 - Pop rivet

5 - Retaining clamp

6 - Left A-pillar trim

  • Removal is same as right trim.

7 - Nut

  • 6.5 Nm

8 - Retaining clamp

  • Movable

9 - Retaining clamp

  • Fixed

10 - Retaining clamp

  • Movable

A-pillar trim, removing

Fig. 316: A-Pillar Trim, Removing Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove door seal in A-pillar area and remove A-pillar trim.
  • Remove nut - 6 -.
  • Drill rivet heads off hollow rivets - 2 - and - 7 - and knock rivet shafts through.
  • Remove trim - 1 -.
  • Upper and lower retaining clips - 3 - must move to balance out tolerances.
  • Retaining clip - 5 - is fixed. It is secured to A-pillar with hollow rivets - 4 -.

Windshield - assembly overview

Fig. 317: Windshield - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Windshield

NOTE:
  • Stickers on windshield (e.g. for airbag) must be replaced in same position on new windshield.

2 - Upper spacer buffer

  • Qty. 3, self-adhesive.
  • Attach in regular intervals to retaining strip.
  • Attach 1 in center of vehicle on window flange at a distance of 430 mm to left and right.

3 - Adhesive sealing material

  • Observe curing times --> Minimum curing times.
  • Note varying spacing dimensions to window edge.
  • Distances from upper and side window edge, dimension - a - = 16 mm and dimension - b - = 12 mm.
  • The distance on the lower window edge is measured from the outer side of the clip outward.
  • The distance to the lower window edge does not run in parallel distance to window edge.
  • Distances Windshield, installing.
  • Bead cross section.
  • Bead width = 8 mm + +2 mm.
  • Bead height = 13.5 mm + +1.5 mm.

4 - Lower spacer buffer

  • Qty. 2, self-adhesive.
  • Attach in corners on lower window edge.

5 - Window adjuster

  • Slide sideways on lower window edge as far as stop.

6 - Plenum chamber cover

Removing protective piping for grip channel

Fig. 318: Removing Protective Piping For Grip Channel
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pull off protective piping from grip channel only after installing window.
  • Before installing plenum chamber cover, protective piping - 1 - must be pulled out of grip channel - 2 - of windshield - 3 -.

Rain sensor, removing and installing

Fig. 319: Rain Sensor Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing rain sensor

NOTE:
  • If the sensor foil is damaged when removing rain sensor, this must be replaced before re-installing.

  • Rearview mirror removed -->
  • Remove clamps - 3 - from mirror base retaining plate - 1 -.
  • Disconnect electrical connector to rain sensor.
  • Remove rain sensor from mirror base.
  • A sensor foil remains adhered to the windshield.
  • If the same windshield is reinstalled, remove this completely from the windshield.
  • Clean the surface with cleaning solution D 009 401 04.

Installing rain sensor

NOTE:
  • If the same rain sensor is reinstalled, proceed as described.

Fig. 320: Removing Rest Of The Sensor Foil From Rain Sensor
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove the rest of the sensor foil from the rain sensor, if necessary.
  • Also clean the surface with cleaning solution D 009 401 04.

CAUTION: Sensor surface must be completely free of foil remnants.

Fig. 321: Removing Silicone Paper From Sensor Foil
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove silicone paper from sensor foil.
  • The transparent protective film remains on the sensor foil as an installation aid.

Fig. 322: Placing Sensor Foil On Rain Sensor With Help Of Transparent Protective Foil
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Place sensor foil on rain sensor with help of transparent protective foil.

Fig. 323: Pressing Sensor Foil Onto Rain Sensor Without Bubbles
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Press sensor foil as shown in - direction of arrow - onto rain sensor without bubbles.

Fig. 324: Removing Transparent Protective Foil From Sensor Foil
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Then remove transparent protective foil from sensor foil.

Fig. 325: Spraying Entire Surface Of Sensor Foil With Cleaning Solution D 009 401 04 And Inserting Sensor In Mirror Base
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Spray entire surface of sensor foil with cleaning solution D 009 401 04 and insert sensor in mirror base.

CAUTION: Rain sensor must be free of inclusions and bubbles on the windshield to function properly.

  • Press sensor retaining clamps on mirror base.

Replacing rain sensor

NOTE:
  • To remove sensor, proceed as described above.

  • If necessary, completely remove foil remnants from windshield.

Fig. 326: Cleaning Sensor Contact Surface On Windshield With Cleaning Solution D 009 401 04
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Clean sensor contact surface on windshield with cleaning solution D 009 401 04.

Fig. 327: Spraying Entire Surface Of Sensor Foil With Cleaning Solution D 009 401 04 And Inserting Sensor In Mirror Base
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Peel off protective foil from rain sensor.
  • Spray entire surface of sensor foil with cleaning solution D 009 401 04 and insert sensor in mirror base.
  • Press sensor onto windshield without bubbles and place retaining clamps on mirror base.

CAUTION: Rain sensor must be free of inclusions and bubbles on the windshield to function properly.

Windshield, removing

Necessary tools and materials --> Flush-bonded windows, removing and installing - general information.

CAUTION: When removing a window, always wear protective eyewear and leather gloves.

  • Remove windshield wiper arms --> .
  • Remove cowl panel trim.

Fig. 328: Piercing Hole In Adhesive Sealing Material From Inside Of Vehicle Using Awl V.A.G 1755 Or Awl V.A.G 1351 At Bottom-Left Of Windshield
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pull cutting cord through adhesive sealing material into inside of vehicle using awl.

Fig. 329: Laying Cutting Cord Underneath And All Around Inside Of Windshield
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Lay cutting cord underneath and all around inside of windshield.

Fig. 330: Securing End Of Cutting Cord At Bolt For Securing Window Wiper Frame
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Secure end of cutting cord at bolt - arrow - for securing window wiper frame.

Fig. 331: Laying Cutting Cord Underneath And All Around Inside Of Windshield
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Slide Cover for Audi A4 Dash Panel V.A.G 1474/13 between windshield and instrument panel.
  • Secure beginning of cutting cord in winding device and cut out first area of adhesive (up to about center of windshield).

Fig. 332: Moving Spooling Tool And Continue Cutting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Move spooling tool, as shown in illustration, and continue cutting.

Fig. 333: Moving Spooling Tool And Attaching Relay Pulley
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Move spooling tool, as shown in illustration, and attach relay pulley.
  • Route cord as shown.
  • Cut window free until cutting cord is no longer fed through idler pulley.

Fig. 334: Removing Relay Pulley And Continue To Cut Adhesive
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove idler pulley and continue cutting window free.

Fig. 335: Moving Spooling Tool And Attaching Relay Pulley In Upper Corner Of Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Move spooling tool, as shown in illustration, and attach relay pulley at upper part of window.
  • Route cord as shown.
  • Cut window free until cutting cord is no longer fed through idler pulley.
  • Remove idler pulley and continue cutting window free.
  • Repeat these steps in top left and bottom left corners of windshield.
  • Completely cut window free.
  • Cut through any adhesive beads that were not completely cut through using Electric Cutter V.A.G 1561 A and appropriate cutting blade.
  • Remove window with two double suction cups.

Preparing for window installation

NOTE:
  • If windshield flange was damaged during removal, paint structure should be repaired and if necessary, corrosion repair measures should be taken.

For undamaged removed windshield

  • When reusing an undamaged window, smoothly cut back residual adhesive sealing material on window and flange using Electric Cutter V.A.G 1561 A and Cutting Blade, Bent at Right Angle V.A.G 1561/10 ; do not remove completely.
  • Residual material acts as a base for the new adhesive sealing material.

CAUTION:
  • Keep adhesive surface free of dirt and grease.
  • Only cut back adhesive surface shortly before installation.
  • Do not prime or use a cleaning solution on the adhesive surface.

With new window

  • Clean window in adhesive area with Cleaning Solution D 009 401 04 and prime with Glass/Paint Primer D 009 200 02 .

Fig. 336: Applying Primer
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Applying primer

  • Apply primer - 2 - along circumference evenly and in one motion using applicator - 1 -.
  • Begin applying with saturated felt. Drying time approx. 10 minutes
  • Primer width dimension: Dimension a - a - = approx. 20 mm
  • Apply primer in center of adhesive bead.

CAUTION: Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material!

Fig. 337: Dimensions For Adhesive Application
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Dimensions for adhesive application

  1. Adhesive sealing material
  2. Primer
  3. Window
  • Bead width - a - = 8 ± 2 mm.
  • Bead height - b - = 12 + 3 mm.

Windshield, installing

Fig. 338: Positioning Complete Surface Of Nozzle Onto Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • After preparatory work has been performed, apply the adhesive.
  • Position complete surface of nozzle - 2 - onto window.
  • - Arrow - indicates direction of application

NOTE:
  • Cross-section thickness of adhesive bead - 1 - is determined by dimension of opening in nozzle tip and rate of application.

Fig. 339: Applying Adhesive Sealing Material All Around
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Apply adhesive sealing material all around, as shown in illustration.

Fig. 340: Varying Spacing Dimensions To Window Edge
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Note varying spacing dimensions to window edge:

CAUTION: Maintain specified distances of adhesive bead to window edges, otherwise there may be leaks.

  • In the lower corners, adhesive bead must be applied in even curves at 12 mm distance to side window edge and 25 mm to lower window edge.
  • On the lower window edge, the adhesive bead must increase from dimension - a - = 25 mm over dimension - f - = 30 mm to dimension - g - = 36 mm.
  • Dimension - a - = 16 mm.
  • Dimension - b - = 12 mm.
  • Dimension - c - = 92 mm.
  • Dimension - d - = 63 mm
  • Dimension - e - = 25 mm
  • Dimension - f - = 30 mm.
  • Dimension - g - = 36 mm.
  • Using two suction lifters, install windshield in windshield opening.

CAUTION: Window must be installed within 15 minutes, otherwise bonding properties of adhesive will be impaired.

  • Center window along sides.
  • The window must not touch the cover trim retaining clips.
  • Slide window up to upper spacer buffer stop.

Fig. 341: Affixing Stickers On Windshield In Same Position On New Windshield
Courtesy of VOLKSWAGEN UNITED STATES, INC.

"Caution- Safety information" sticker.

  • Attach stickers on windshield (e.g. for airbag) in same position on new windshield.
  • Determine dimensions - a - and - b - from removed window.

66 - Exterior equipment

A-pillar and roof frame trim, removing

Fig. 342: A-Pillar And Roof Frame Trim, Removing Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Right A-pillar trim

  • Remove A-pillar trim.
  • Remove door seal in A-pillar area.
  • Bore out side hollow rivet heads A-pillar trim, removing (Qty. 3), drive rivet shafts out and remove trim.

2 - Roof frame trim

  • Remove roof frame trim.
  • Before removal, removing left and right A-pillar trim.

3 - Nut

  • 6.5 Nm

4 - Pop rivet

5 - Retaining clamp

6 - Left A-pillar trim

  • Removal is same as right trim.

7 - Nut

  • 6.5 Nm

8 - Retaining clamp

  • Movable

9 - Retaining clamp

  • Fixed

10 - Retaining clamp

  • Movable

11 - Pop rivet

A-pillar trim, removing

Fig. 343: A-Pillar Trim, Removing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove door seal in A-pillar area and remove A-pillar trim.
  • Remove nut - 6 -.
  • Drill rivet heads off hollow rivets - 2 - and - 7 - and knock rivet shafts through.
  • Remove trim - 1 -.
  • Upper and lower retaining clips - 3 - must move to balance out tolerances.
  • Retaining clip - 5 - is fixed. It is secured to A-pillar with hollow rivets.

4 - Pop rivet

Protective moldings

Replacing side protective moldings

NOTE:
  • Protective moldings cannot be removed without destroying them.

Fig. 344: Replacing Side Protective Moldings
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • To remove, warm protective strips - 1 - , - 2 - or - 3 - with a hot air gun and remove.
  • Adhesion surface must be free of dust and grease.
  • Clean outer panel with mineral spirits, treat with silicone remover and rub dry.
  • Protective moldings must be attached only at room temperature.
  • For this purpose, bring vehicle and protective moldings to room temperature at least 2 hours before processing.
  • Protective moldings must be adhered within 90 minutes after protective foil has been removed.
  • Pull protective foil - 4 - from double-sided adhesive tape - 5 - shortly before installation.
  • Apply protective molding to be adhered at front and adhere working toward rear.
  • Heat protective molding to approx. 40°C using heat gun and forcefully press on or roll on.
  • After adhering strip, leave vehicle 4 hours in room temperature.

Window shaft strips

Fig. 345: Window Shaft Strips, Replacing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Window shaft strips, replacing

  • Completely lower window.
  • Remove window shaft strip trim - 1 - or - 2 - --> Window shaft strips, removing and installing.
  • To remove, pull window shaft strip - 3 - upward from door or shaft strip - 4 - from side panel.
  • When installing on door, first slide shaft strip under exterior mirror, then press onto door edge in stages by hand.

Trim cover for side member, removing and installing

Fig. 346: Trim Cover For Side Member Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Front trim cover

  • Remove trim cover sideways.

2 - Rear sill cover

  • Removal as for front trim cover.

3 - Screw

  • 1 Nm

4 - Clip

Outer door sill panel trim

Outer door sill panel trim, replacing

NOTE:
  • Outer door sill panel trim cannot be removed without destroying it.

Fig. 347: Outer Door Sill Panel Trim, Replacing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Unclip sill panel trim - 1 - from sill panel cover - 2 -.
  • Heat door sill molding using a hot air gun and carefully pull upward and off.
  • Clean adhesion surface with mineral spirits, treat with silicone remover and rub dry.
  • Door sill moldings must be attached only at room temperature.
  • For this purpose, bring vehicle and door sill moldings to room temperature at least 2 hours before processing.
  • Sill moldings must be adhered within 90 minutes after protective foil has been removed.
  • Heat adhesion surface to approx. 40° C using a hot air gun.
  • Pull protective foil from double-sided adhesive tape shortly before installation.
  • Clip in door sill molding and press on.
  • After adhering strip, leave vehicle 4 hours in room temperature.

Sill panel cover - assembly overview

Sill panel cover - assembly overview

Fig. 348: Sill Panel Cover - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Front cover cap

2 - Sill panel cover

  • When installing, first center trim in front clip, then slightly secure with fitting bolts.
  • Engage front end cap in bracket Cover cap, installing.
  • Tighten all bolts to specified torque.

3 - Fitting screw

  • 1.5 Nm

4 - Front clip

  • With sill panel cover centering device

5 - Rear clip

Cover cap, installing

Fig. 349: Cover Cap, Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • To install, first engage cover cap - 1 - in bracket - 3 - and tighten bolts - 2 -.

2 - Screw (1.3 Nm)

Rear wheel spoiler, removing and installing

Rear wheel spoiler, removing and installing

Fig. 350: Rear Wheel Spoiler Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear wheel spoiler

  • When installing, rear wheel spoiler must be slide under wheel housing liner or under underbody trim as shown.

2 - Screw

  • 3 Nm

3 - Underbody trim

4 - Rear wheel housing liner

Exterior rearview mirror

Rearview mirror - assembly overview

Special tools, testers and auxiliary items required

Fig. 351: Identifying Pry Lever 80-200
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pry lever 80-200

Fig. 352: Rearview Mirror - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Mirror glass

  • Use Pry Lever 80-200 to unclip.
  • Protect mirror housing against damage using textile tape above and below.
  • Press mirror lens first downward, then upward.
  • To install mirror lens into guide pins and friction finger, insert into friction spring and press on.
  • Apply pressure only on center of glass, wear protective gloves while doing so.

2 - Mirror heating connector

3 - Mirror adjusting unit

4 - Adjusting motor

5 - Mirror housing

6 - Electrical connection

  • Clip into mirror glass on rear side.

Side mirror, removing and installing

Fig. 353: Side Mirror Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Screw

  • 8 Nm

2 - Front door

3 - Exterior rearview mirror

  • Mark position of bolts.

4 - Screw

  • 8 Nm

Mirror lens, installing

Fig. 354: Mirror Lens, Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Install mirror lens - 3 - with locking tabs onto mirror lens base - 2 - in - direction of arrow -.
  • Friction finger must be inserted into friction spring - arrow - of housing - 1 - while doing so.
  • Apply pressure only on center of glass, wear protective gloves while doing so.

Mirror adjusting motor, removing and installing

Fig. 355: Mirror Adjusting Motor Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Mirror lens removed.
  • Remove bolts - arrows - from mirror adjusting unit.
  • Remove motor - 2 - from mirror adjusting unit and disconnect electrical harness connector.

Arrow - Screw (1 Nm)

Mirror housing, removing and installing

Fig. 356: Mirror Housing Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Mirror housing

  • Removing:
  • Remove bolts from cover trim and remove downward.
  • Release housing from locking tabs on mirror adjusting unit and remove it upward.
  • Installing:
  • Position mirror housing onto mirror adjusting unit from above.
  • While doing so, locking tabs - arrows - in mirror adjusting unit must engage above and below Lower mirror locking tab.

2 - Mirror adjusting unit

3 - Lower cover

4 - Bolts

  • 1 Nm

Lower mirror locking tab

Fig. 357: Lower Mirror Locking Tab
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • When installing, locking tab - arrow A - of mirror adjusting unit - 2 - must be inserted into mirror housing catches - 1 - in - direction of arrow -.

Wheel housing liner

Front wheel housing liner, removing and installing

Fig. 358: Front Wheel Housing Liner Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Fender

2 - Screw

  • 2.3 Nm

3 - Front wheel housing liner

  • Remove front wheel before disassembly.
  • Disengage wheel housing liner from fender and pull downward and out.

4 - Spreader nut

5 - Sill panel cover

6 - Quick release screw

Rear wheel housing liner, removing and installing

Fig. 359: Rear Wheel Housing Liner Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear wheel housing liner

  • Remove rear wheel before disassembly.
  • Remove wheelhousing liner downward.

2 - Screw

  • 1.5 Nm

3 - Screw

  • Inserted only on the right side of vehicle.

4 - Spreader nut

Ornamental parts

Rear lid lettering

Dimensional data for front-wheel drive vehicles

NOTE:
  • Outer edges of rear lid and lines extending from lower rear lights are used as reference edges.

Fig. 360: Rear Lid Lettering (Dimensional Data For Front-Wheel Drive Vehicles)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Name plate

  • Installation:
  • Warm vehicle and type designation to room temperature.
  • Bonding surfaces must be dry and free from dust and grease.
  • Clean outer panel with mineral spirits, treat with silicone remover and rub dry.
  • Pull off backing paper and press on characters, maintaining pressure for approx. 3 seconds.
  • - a - = 30 mm.
  • - b - = 28 mm.
  • - c - = 36 mm.
  • - d - = 28 mm.
  • - e - = 152 mm.

Dimensional data for All Wheel Drive (AWD) vehicles

NOTE:
  • Outer edges of rear lid and lines extending from lower rear lights are used as reference edges.

Fig. 361: Rear Lid Lettering (Dimensional Data For All Wheel Drive (AWD) Vehicles)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Name plate

  • Installation:
  • Warm vehicle and type designation to room temperature.
  • Bonding surfaces must be dry and free from dust and grease.
  • Clean outer panel with mineral spirits, treat with silicone remover and rub dry.
  • Pull off backing paper and press on characters, maintaining pressure for approx. 3 seconds.
  • - a - = 30 mm.
  • - b - = 28 mm.
  • - c - = 4 mm.
  • - d - = 36 mm.
  • - e - = 13 mm.
  • - f - = 53 mm.

NOTE:
  • Dimensions - g - and - h - only apply to RS4
  • - g - = 68 mm.
  • - h - = 18 mm.

Window shaft strips, removing and installing

Special tools, testers and auxiliary items required

Fig. 362: Identifying Trim Removal Wedge 3409
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Trim removal wedge 3409

Removing

Fig. 363: Using Trim Removal Wedge 3409 To Press Upper Edge Of Rubber Strip Down Until It Slides Over Upper Edge Of Window Shaft Strip
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Using Trim Removal Wedge 3409 - 1 - , press upper edge of rubber strip - 2 - down until it slides over upper edge of window shaft strip - 3 -.
  • Pull Trim Removal Wedge 3409 along strip - arrow - in this position.
  • Remove strip.

Installing

NOTE:
  • Only use Cleaning Solution D 009 401 04 as an installation aid.
  • If other lubricants are used, the trim may fall off due to vibrations.

  • Engage at top and lightly press down - rail slides over rubber
  • Engage top of trim - 3 -.
  • With flat hand, press trim down until rubber - 5 - slides over lower edge - 4 -.
  • Pull with hand in this position over complete trim.
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