Special tools and workshop equipment required

• Electric cutter - SAT 1561A-
• Knife 207 - SAT 1561/12-
• Pull handle - VAG 1351/1- (x2)
• Dual component window sealant - VAS 5237-

Materials

• Dual-component glue - D 004 660 M2- 1) 2)
• Cleaning solvent - D 009 401 04-
• Applicator - D 009 500 25-
• Glue solvent - D 002 000 A2-
• Primer (Glass/Paint) - D 009 200 02-
• Cutting thread - 357 853 999 B-

1) To apply this material use the window sealant pistol - VAS 5237- .
2) Note drying times.

Removing

• Remove panoramic window.
• Remove the trim panel of the sliding/tilting sunroof.
• Unplug electrical connectors for sliding/tilting sunroof.
• Removing roof trim .
• Remove curtain airbag with initiator Driver side curtain airbag initiator - N251- / Passenger side curtain airbag initiator - N252- .

• With help from the masking tape on the windscreen attach the sun panel connector.

Note

• The removal of the sliding/tilting sunroof frame remains when cutting the adhesive sealing material (PUR) -1 - between the frame -2- and the bodywork.
• The -arrows -identify the position of the adhesive sealant material.

• Protect the lateral and rear area of the exterior mirror housing near the work area with masking tape.
• Insert in the rear of the frame the electrical cutter - SAT 1561Awith blade 207 - SAT 1561/12- between the bodywork and trim panel. Cut open the bonding bead on both sides up to the front area of the frame.

• Cut open the front bonding bead on the front of the frame.

• From the vehicle interior cut open the bonding bead: for this insert the electrical cutter - SAT 1561A- using blade 207 - SAT 1561/12- between the centre recess -arrow -of the bodywork and the sliding/tilting sunroof frame.

• In both lateral directions cut open according to the -arrows-.

• With help from two cable holder knobs - VAG 1351/1- with cutting thread - 357 853 999 B- insert the thread via the completed cuts in the front area, and pull alternating on both knobs until the adhesive material string is completely removed.
• Remove the frame of the sliding/tilting sunroof.

Bodywork flange: preparation for installing the sliding/tilting sunroof frame

If a (new or used) frame has to be installed, the adhesive bead and adhesive sealing material (PUR) must be cut back from the body flange. For this purpose follow these instructions:

• Shortly before re-applying the adhesive to the sliding/tilting sunroof, cut back the adhesive bead stuck to the bodywork flange to a height of 1 to 2 mm using the electric knife - SAT 1561A- and set of blades - SAT 1561/20- .

Note

• The remaining material is required as a base for the new adhesive sealing material (PUR).
• If the bodywork flange has been reworked or partially replaced, after painting, the new zone must be cleaned and primed correspondingly.

Undamaged sliding/tilting sunroof frame: preparing for installation and removal

• Shortly before applying the adhesive to the frame, cut back the adhesive bead stuck to the frame to a height of 1 to 2 mm.

Note

• In areas with tabs, as displayed in the figure, the adhesive material must be cut back until it is flush with the upper part of the tabs.
• The remaining material is required as a base for the new adhesive sealing material (PUR).

• Remove the sliding/tilting sunroof frame and install according to the instructions.

Install the undamaged trim panel of the sliding/tilting sunroof

Special tools and workshop equipment required

• Adjustment gauges - 3371-

• Thrust piece - T20098-

• Undamaged window of the sliding/tilting sunroof is prepared for installation.
• Bodywork flange is prepared for the installation of sliding/tilting sunroof frame.
• Install on the sliding/tilting sunroof frame:
  • frame with drive mechanism
  • panoramic window

Note The rear seal of the panoramic window may NOT be installed to allow the correct alignment of the sliding/tilting sunroof frame in reference to the bodywork.

• Apply the masking tape -1- in the stated areas of the panoramic window -4- and the roof -3-.

• Mark the masking tape using a felt tip pen -2- in the centre of the panoramic window -4- and the roof -3-.

Features of the adhesive bead and adhesive sealing material (PUR)

1. - Bead of glue
2. - Primer
3. - Sliding/tilting sunroof frame.
   • Distance -a- = 8 mm
   • Dimension -b- = 12 mm
   • Dimension -c- = the area for the application of the adhesive sealing material (PUR) is different depending on the sliding/ tilting sunroof frame imprinting.

Note

•  If the sliding/tilting sunroof trim frame is not damaged, apply the material on the old adhesive bead previously cut back.

  Follow the instructions accordingly.

•  With a new frame, apply the material on the primer layer. Follow instructions below:

General requirements for applying the adhesive bead

Note In order to ensure for the homogeneous properties of the dual component mixture, apply a bead -a- with 10 cm to a clean surface and dispose of the first piece of the product.

• The sleeve -2- must rest flush.
• Hold the gun permanently at right angles to the parts being treated.
• The -Arrow- indicates the direction of travel.
• The diameter of the adhesive bead -1- will depend on the width of the hole in the applicator and the speed of application.

• Apply on the indicated area of the frame using the twin cartridge gun - VAS 5237- an adhesive bead of the dual component adhesive - D 004 660 M2- -arrows-.
• -a-= about 50 mm, adhesive bead overlapping zone.

fitting

• Attach a rope -2- in the upper area of the window -1- underneath the sealing lip -3-.

Note

• Keep the rope in this position until the bonding process for the sliding/tilting sunroof frame is completed.
• The rope is used to reposition the lip in reference to the sliding/ tilting sunroof trim panel.

• At each side of the panorama roof install a suction lifter - VAG 1344- .

• With the assistance of a second mechanic, lay the frame and glass -1- on the roof flange and insert the centring pin -2- into the opening in the bodywork -3-. Push evenly against the frame.

• Check to make sure the felt pen markings are aligned on top of each other. If necessary, adjust.
• In the rear area of the panoramic window (with the rear seal removed) insert on each side, a 5 millimetre long brake lever from the brake lever kit - 3371- , between the window -1- and the roof flange -2-. Push frame and window into the -direction of the arrow- to make sure that the distance -a- = 5 mm.

Note During the task described last, check the front and rear parts of the frame (for example with an 8 mm drill bit) and make certain that the gap to the roof flange is equal on both sides. If necessary, adjust.

• For this purpose use the suction lifters - VAG 1344- as an aid and hold everything steady with the support equipment - T10038- .

• Check the front of the sliding/tilting sunroof with a setting gauge in at least three places for height -a= 7.1 mm- between the top edge of the frame and the bodywork. If necessary, push with the pressure piece - T20098- in order to achieve the specified height.

New frame on sliding/tilting sunroof: Assembly

Special tools and workshop equipment required

• Adjustment gauges - 3371-

• Bodywork flange is prepared for the installation of sliding/tilting sunroof frame
• Install on the sliding/tilting sunroof frame:
  • frame with drive mechanism
  • panoramic window

Note The rear seal of the panoramic window may NOT be installed to allow the correct alignment of the sliding/tilting sunroof frame in reference to the bodywork.

• Attach a rope -2- in the upper area of the window -1- underneath the sealing lip -3-.

Note

• Keep the rope in this position until the bonding process for the sliding/tilting sunroof frame is completed.
• The rope is used to reposition the lip in reference to the sliding/ tilting sunroof trim panel.

The following steps must be followed for preparing installation of the new frame:

• Using a cleaning solvent - D 009 401 04- clean the surface for the adhesive bead -arrows-. Then rub edge of window dry using a lint-free cloth.
• Apply glass/paint primer - D 009 200 02- on the surface for the adhesive bead -arrows-.

Note Apply the primer evenly and in one step using a fully drenched felt.

• Primer width approx. 20 mm
• Apply primer centrally in relation to adhesive bead.
• Flashing-off time, approx. 10 minutes.

Features of the adhesive bead and adhesive sealing material (PUR)

1. - Bead of glue
2. - Primer
3. - Sliding/tilting sunroof frame.
   • Distance -a- = 8 mm
   • Dimension -b- = 13.5 +- 1.5 mm
   • Dimension -c- = the area for the application of the adhesive sealing material (PUR) is different depending on the sliding/ tilting sunroof frame imprinting.

General requirements for applying the adhesive bead

• The sleeve -2- must rest flush.
• Hold the gun permanently at right angles to the parts being treated.
• The -Arrow- indicates the direction of travel.
• The diameter of the adhesive bead -1- will depend on the width of the hole in the applicator and the speed of application.

• Apply on the indicated area of the frame using the twin cartridge gun - VAS 5237- an adhesive bead of the dual component adhesive - D 004 660 M2- -arrows-.
• -a-= about 50 mm, adhesive bead overlapping zone.

fitting

• Set the frame and window -1- on the roof flange and insert the centring pin -2- in the opening -3-.

• Exercise even pressure on the frame until the spacer caps are resting on the bodywork flange.
• Check to make sure the felt pen markings are aligned on top of each other. If necessary, adjust.
• In the rear area of the panoramic window (with the rear seal removed) insert on each side, a 5 millimetre long brake lever from the brake lever kit - 3371- , between the window -1- and the roof flange -2-. Push the frame and window against the feeler gauges to maintain the clearance -a-= 5 mm.

• Push the frame and window down to make sure that the seal -1- of the trim panel -2- touches the bodywork -arrow-.

Note The bodywork form allows the frame and window to be positioned in centre.

• Minimum curing period.

• Taking the sliding/tilting sunroof trim panel -2- as a reference, reposition the sealing lip -3- previously mounted in area of windscreen -1-.
• Install sealing of the panoramic window.

Touching up paint damage

Repair paint work according to specifications in - repair guidelines for vehicle paint work ; if necessary, perform recommended corrosion protection measures.

For damage to paintwork in unseen zones, proceed as follows:

• Repaint twice (wet on wet) leaving both coats to air.

Frame on sliding/tilting sunroof: Minimum curing time

Removing any soiling that has been caused by the adhesive material

• Use of glue removal is recommended for cleaning - Electronic parts catalogue . Observe safety precautions when using.

• First clean painted surface as well as possible using a dry cloth. Remove contamination residues with glue remover - Electronic parts catalogue .
• Cleaning plastic trims: Allow the sealant to harden (approx. 1 hour) and then remove.