Removing Front Roof Cross Member

Information 

The steps are described only for the left-hand side of the vehicle. Complete some steps in the same way on the right-hand side of the vehicle.

1. Cut out front roof cross member -1-  .

   Information 

   Make a rough cut through all sheet-metal panels.

   1. 1.1 Make a rough cut measuring -dimension A-  .

      > Dimension 135 mm 

   2. 1.2 Remove front roof cross member, which you just cut out -1-  .

   Cutting out front roof cross member

2. Separate connection points on the remaining piece of the front roof outer section -1-  .
   1. 2.1 Remove punch rivet -A-  using > VAS 852 001 - Body Dent Removal System, Aluminium  and > VAS 6790 - Compact Booster  .

      > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

   2. 2.2 Drill through clinch point -B-  . > Bore diameter 6.6 mm 

   Loosening remaining piece of front roof outer section

3. Remove remaining piece of front roof outer section -1-  .

   Removing remaining piece of front roof outer section

   1. 3.1 Heat bonding areas using > V.A.G 1416 - Hot-Air Blower  .
   2. 3.2 Grind down welded seam -A-  .
   3. 3.3 Remove remaining piece of front roof outer section -1-  .
4. Drill out spotwelds on remaining piece of upper front roof cross member -1-  .

   Drilling out spotwelds

5. Drill out spotwelds -A-  on remaining piece of upper front roof cross member -1-  through two plate thicknesses.

   Drilling out spotwelds

6. Remove remaining piece of upper front roof cross member -1-  .

   Loosening remaining piece of upper front roof cross member

   1. 6.1 Heat bonding areas using > V.A.G 1416 - Hot-Air Blower  .
   2. 6.2 Grind down welded seams -A-  .
   3. 6.3 Remove remaining piece of upper front roof cross member -1-  .
7. Loosen remaining piece of lower front roof cross member -1-  .
   1. 7.1 Drill out spotwelds.
   2. 7.2 Bend up sheet-metal bracket -2-  .

   Loosening remaining piece of lower front roof cross member

8. Remove remaining piece of lower front roof cross member -1-  .

Removing remaining piece of lower front roof cross member

1. 8.1 Heat bonding areas using > V.A.G 1416 - Hot-Air Blower  .
2. 8.2 Grind down welded seam -A-  .
3. 8.3 Remove remaining piece of lower front roof cross member -1-  .