Volkswagen New Beetle Body - Exterior

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either the driver's or front passenger's door is opened. The rotary ... The sunroof must not moved to position "Open" when removed, because the water channel .... With sliding cover from M.Y. 2000 .... speedometer cable approx.1500 mm long).
Volkswagen New Beetle Body - Exterior (Page GR-60)

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Sunroof Automatic preselector switch for sunroof, removing Carrier unit, removing and installing Drive for sunroof, adjusting (setting "0" position) Drive for sunroof, removing Function Panel seal, adjusting Panel seal, replacing Parallel running, adjusting Parallel running, checking Sliding headlining, removing Slotted guide, removing Sunroof glass panel, adjusting height Sunroof glass panel, installing Sunroof glass panel, removing Sunroof with glass panel, assembly overview Tools Water drain hoses, cleaning Wind deflector, removing

Volkswagen New Beetle Body - Exterior 60 Sunroof (Page 60-1)

Tools Special tools, workshop equipment, testers, measuring instruments and auxiliary items required 3370 Assembly hooks

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-2)

Function The sunroof is opened and closed or tilted and closed using the rotary switch with the ignition on. After switching off the ignition the siding/tilting sunroof can be opened or closed until either the driver's or front passenger's door is opened. The rotary switch has markings for preset opening or tilting positions for the glass sunroof panel. But any intermediate position for the opening or tilting position can be selected by moving the rotary switch in the relevant direction.

Opening the sunroof to switch position - 1 - , the "comfort position," prevents wind noises which to a great extent which would occur if opening fully with switch position - 2 - .

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-3)

Sunroof with glass panel, assembly overview

1 - Glass panel for sunroof (single pane safety glass) Removing sunroof glass panel Page 60-7 Installing sunroof glass panel Page 60-8 Adjusting sunroof glass panel Page 60-9 2 - Panel seal Adjusting panel seal Page 60-11 Seal joint located centrally at rear Renewing panel seal Page 60-11

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-4)

3 - Sliding headlining Removing and installing sliding headlining 4 - Countersunk screws (micro encapsulated) Always use new countersunk screws 3.5 Nm 5 - Slide 6 - Upper trim Removing

Page 60-7

7 - Lower trim Removing

Page 60-7

8 - Water channel Removed together with slotted guide rail. 9 - Guide locking hook

Page 60-14

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-5)

10 - End piece Use Butyl adhesive sealing cord AKL 450 005 05 to seal 11 - Carrier unit Removing and installing carrier unit Page 60-25 If required, guide channels are to be greased with special grease G 000 450 02 only, otherwise correct operation cannot be guaranteed. 12 - Bolt Qty. 3 13 - Electrical drive Removing Page 60-15 Adjusting drive (0 position) 14 - Wind deflector Removing Page 60-13 15 - Spring

Page 60-20

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-6)

16 - Torx screw Torx key T 25 4.5 Nm 17 - Rear guide Removed together with slotted guide rail. 18 - Slotted guide rail Removing Page 60-27 19 - Spacer Removed together with slotted guide rail.

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-7)

Sunroof glass panel, removing - Slide sliding headlining to rear. - Tilt sunroof open.

- Unclip lower trim - 2 - in forward area, inwards to center of vehicle and unhook at rear. - Unclip upper trim - 1 - at front and center and unhook at rear.

- Remove securing screws (Torx insert T 25; 4.5 Nm). - Take sunroof panel out upwards. Note: The sunroof must not moved to position "Open" when removed, because the water channel will not be compressed by the glass panel and can cant inside the roof.

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-8)

Sunroof glass panel, installing Panel must be installed in "0 position" (panel closed). "0" position:

The mark - arrow - on the rear of the guide upper section - 1 - must, on both sides, lie within the marks - dimension a - on the guide rail gate - 2 - . The slotted guide rail - 2 - must be located in the guide rails (cannot be moved by hand). If this is not the case, adjust parallel running Page 60-24 .

- Place sunroof on from above and screw in securing screws (guide rail/panel). - Lightly tighten securing screws (Torx T 25). Note: After adjusting panel height tighten securing screws (4.5 Nm).

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-9)

Sunroof glass panel, adjusting height Sunroof "0" position OK. - Tilt sunroof open. - Slide sliding headlining to rear.

- Unclip lower trim - 2 - in forward area, inwards to center of vehicle and unhook at rear. - Unclip upper trim - 1 - at front and center and unhook at rear. - Remove securing screws - 3 - (Torx key T 25; 4.5 Nm). - Run glass panel into "closed" position. - Carry out height adjustment of glass panel at front and rear on both sides as follows:

Panel adjustment front: a = 0...1 mm lower than roof level Arrow = Direction of travel (forwards)

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-10)

Panel adjustment rear: b = 0...1 mm higher than roof level Arrow = Direction of travel (forwards) - Tighten screws for glass panel (4.5 Nm). Always tighten left and right - hand glass panel sides symmetrically. - Tilt sunroof open.

- Hook in upper trim - 1 - at rear and clip front and center in. - Hook in rear of lower trim - 2 - and clip front in.

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-11)

Panel seal, adjusting

- Check that the pre - tension between panel seal - 2 - and body is uniform all - round using a 0.3 mm thick strip of paper (or a plastic credit - type card, for example). It must be possible to pull the paper strip through between the panel seal and body under tension. - If the pre - tension is insufficient, the panel seal can be pushed apart with a wedge 1 - , or if the pre - tension is excessive pushed together. To adjust the panel seal the glass panel - 3 - must be removed.

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-12)

Panel seal, replacing - Remove glass panel for sunroof

Page 60-7 .

- Pull seal - 1 - off glass panel.

- Pull new seal onto glass panel - 2 - from bottom to top starting at center of rear. Note: To ease fitting of seal, coat panel edge with a soapy solution. - Cut panel seal to length after installing.

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-13)

Wind deflector, removing Sunroof completely open.

- Insert assembly hooks 3370 between edge of roof and wind deflector mounting and release wind deflector mounting - 1 - from locking devices on sides (left and right hand sides) by pulling on 3370. - Lever wind deflector mounting out from guide rail (left and right - hand sides) using a screwdriver. - Take out wind deflector. Note: When installing, ensure that the wind deflector mounting engages in the assembly panel in the prescribed position.

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-14)

Sliding headlining, removing - Remove glass panel for sunroof - Slide headlining to rear.

Page 60-7 .

- Remove forward bolts - arrow - on left and right - hand sides. Pull out slide forwards over the stop - 1 - . - Slide headlining forwards.

- Remove rear bolts - arrow - on left and right - hand sides. Pull out slide to rear and take out sliding head liner - 1 - .

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-15)

Drive for sunroof, removing Note: Remove and install drive for sunroof only when roof is closed ("0" position). - Disconnect battery earth strap from battery.

- Unclip trim - 1 - in direction of arrow and remove.

- Remove screws - 1 - and carefully release the locking lugs - arrows - of the preselector automatic retaining frame.

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-16)

- Separate connection - arrow - .

- Pull rear edge of trim (with clock) - 1 - down off roof trim and unhook trim from front edge. - Separate connection - 2 - for interior light (and clock).

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-17)

- Press interior rear - view mirror - 1 - downward at an angle off retaining plate (spring clip in mirror base).

- Lever out make - up lights with a screwdriver and separate connections.

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-18)

- Release sun visor - 1 - from mounting - 2 - . With sliding cover from M.Y. 2000 - Lever off cover cap - 6 - . - Remove screw - 5 - . - Release sun visor mounting - 4 - from mounting and separate connector - 3 - . - Lever off cover cap - 7 - . - Remove screws - 8 - and remove mounting - 2 - . - Remove spectacle compartment on left side and grab handle on right side of roof.

- Fold handle - 1 - down. - Lever cover - 2 - up with screwdriver and fold open. - Unscrew cross - head screws - 3 - and take off handle - 1 - .

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-19)

- Remove left and right - hand A pillar trims: Repair Manual, Body-Interior, Repair Group 70; Pillars and side panel trims; Removing and installing A pillar upper trim

- Carefully unhook moulded headliner at front of roof cut - out - arrows - pull down until the screws for the sunroof can be accessed. - Unclip and separate connector.

- Remove bolts - arrows - and pull out drive for sunroof. The bolts for the drive are micro encapsulated and must always be replaced (3.5 Nm).

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-20)

Drive for sunroof, adjusting (setting "0" position) There may be a requirement to adjust the "0" position if the drive was removed when not in "0" position or the sunroof was closed using the emergency key. Drive removed but still connected electrically. - Select "tilt roof" with preselection automatic rotary switch. - Select "close roof" with preselection automatic rotary switch. - Select "open roof" with preselection automatic rotary switch. - Select "close roof" with preselection automatic rotary switch. - Install drive in this position ("0" position) with sunroof closed.

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-21)

Automatic preselector switch for sunroof, removing

- Unclip trim - 1 - in direction of arrow and remove.

- Remove screws - 1 - and carefully release the locking lugs - arrows - of the switch retaining frame.

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-22)

- Separate connection.

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-23)

Parallel running, checking - Remove glass panel for sunroof

Page 60-7 .

The mark - arrow - on the rear of the guide upper section - 1 - must, on both sides, lie within the marks - dimension a - on the guide rail gate - 2 - . The slotted guide rail - 2 - must be located in the guide rails (cannot be moved by hand).

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-24)

Parallel running, adjusting Note: The parallel running adjustment can only be undertaken when the drive and glass panel are removed ("0" position). - Remove sunroof Page 60-15 .

The mark - arrow - on the rear of the guide upper section - 1 - must, on both sides, lie within the marks - dimension a - on the guide rail gate - 2 - . The slotted guide rail - 2 - must be located in the guide rails (cannot be moved by hand). - Slide guide upper part - 1 - from front to rear only centrally between the marks. - Install drive in this position ("0" position). Then check "0" position.

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-25)

Carrier unit, removing and installing

Removing - Removing preselection automatic for sunroof - Remove moulded headlining

Page 60-21 .

Repair Manual, Body-Interior, Repair Group 70; Roof trim - Pull water drain hoses - arrows - off carrier unit - 1 - . - Remove bolts - 2 - and - 4 - (with sleeves) and lift carrier unit out of vehicle with help of second mechanic.

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-26)

Installing - Insert carrier unit - 1 - , align with bolt holes and insert bolts - 2 - and - 4 - (with sleeves). - Check electrical consumers electrical wiring and connections on roof and reinstate if necessary. - Tighten carrier unit - 1 - , starting at sunroof drive - 3 - on left and right - hand sides moving rearward (8 Nm). - Fit water drain hoses - arrows - . - Fit connection for drive - 3 - .

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-27)

Slotted guide, removing - Remove glass panel for sunroof Page 60-7 . - Remove assembly unit Page 60-25 . - Remove sunroof Page 60-15 .

- Unclip end cap - 1 - - arrows - from guide rail - 2 - and then pull off. Note: When installing seal end piece - 1 - to guide rail with Butyl adhesive sealing cord AKL 450 005 05.

- Unclip water channel - 1 - from locking lug guide - 2 - on both sides carefully with a screwdriver and take off.

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-28)

- Slide rear guide - 1 - in guide rail - 4 - in direction of arrow until the locking lug guide - 3 - is released. - Pull rear guide - 1 - , Locking lug guide - 3 - and slotted - 2 - together out from guide rails - 4 - . Note: Always renew guide with cable as a pair.

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-29)

Water drain hoses, cleaning

Front water drain hoses: The front water drain hoses - 1 - run in the A pillars and end with a water drain valve - 2 in the plenum chamber. Clean from sunroof cut - out. 1 - Front water drain hoses 2 - Front water drain valve Note: It is recommended that a probe is used to clean (locally manufactured from a piece of speedometer cable approx.1500 mm long).

Volkswagen New Beetle Body - Exterior Sunroof (Page 60-30)

Rear water drain hoses: The rear water drain valves - 4 - are fitted directly onto the sunroof - 5 - water drains and exit under the tailgate in the roof channel. The cleaning can be performed from the rear by removing cover - 3 - . 3 - Cover 4 - Water drain hose with valve 5 - Assembly unit Note: It is recommended that a probe is used to clean (locally manufactured from a piece of speedometer cable or similar).