FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Volkswagen >> 2004 >> New Beetle Convertible (1Y1) L4-1.8L Turbo (AWV) >> Repair and Diagnosis >> Body and Frame >> Interior Moulding / Trim >> Headliner >> Service and Repair >> Convertible Top >> From 12/2003 >> Headliner Tensioning System, Removing and Installing

Headliner Tensioning System, Removing and Installing



Headliner Tensioning System, Removing And Installing 12.03 -->

Vehicles --> 11.03

NOTE:
- Open or close (half way open position is suitable) convertible top as needed to ease working (repair work, servicing) on headliner tensioning system.
- Before opening and closing convertible top, make sure there is enough room above.
- Each side of vehicle has a tensioning system, consisting of a guide, weaving guide, retaining plate with cable (eyelets and deflectors) and a reinforcement plate (with cable attached and eyelet in inner trim).
- The following description is for right-hand side of convertible top cover.

Removing
- Remove rear panel trim







- Remove two rivets - 1 - and loosen guide - 2 - from frame - 3 - and weaving guide - 4 -.

NOTE:
- Replace guide if scratched, damaged or plastic shavings are present.
- Observe installation position of eyelets -5- and do not damage when removing rivet.







- Drill out three rivets - 1 - from frame and loosen eyelets as well as weaving guides - 2 -.

NOTE:
- Observe installation position of cables.
- Observe installation position of weaving guides - 2 - at lower cable end.
- If necessary, use drift to drive out.







- To remove retaining plate with cable - 1 - from reinforcement plate - 2 - in headliner, unclip retaining clips - 3 - from retaining plate, starting at bottom, using screwdriver - arrow -.
- Release weaving guide - 4 - from reinforcement plate - 2 - at inner headliner.







- Remove both cables - 1 - from retaining plate with cable and remove from lower, middle and upper deflectors as well as from handle trim - arrows - (upper deflector and upper headliner handle are not shown in this illustration).

NOTE:
- When using a new retaining plate with cables, cut cables to ease procedure.
- Observe installation position of cables in retaining plate with cables, deflectors and headliner handles.







- Push securing clips - 1 - inward toward headliner.
- Remove roof edge trim







- Loosen securing bolts and pull out strap together with retaining plate in - direction of arrow -.

Installing
- Tie an approx. 92 cm (3 feet) long cable to eyelet.







- Insert retaining plate with strap in inner headliner - arrow -.

NOTE:
- Use strong flexible piece of wire (long enough to insert into headliner) in form of "Y" at end of wire, to insert retaining plate into headliner.
- Observe original mounting position of retaining plate.







- Press securing clips - 1 - of retaining plate out of headliner.

NOTE: When using a new retaining plate with cables, remove new deflectors from cables. Only use new deflectors if already installed deflectors are damaged.







- Guide lower cable - 1 - through middle deflector - 2 - and then through lower deflector - 3 -.







- Guide upper cable - 1 - through upper deflector - 2 - and then through headliner handle - 3 - in - direction of arrow -.







- Insert both cables in retaining plate with cable and tie in initial position - 1 -.

NOTE:
- Knots must be located on back side of retaining plate with cables.
- Tie knot as close to cable end as possible.







- Secure weaving guide - 1 - with securing clips - 3 - to reinforcement plate - 2 -.







- Secure retaining plate with cables - 1 - to reinforcement plate - 2 - (inside of headliner). Carefully press together securing clips - 3 - using pliers while doing so. Make sure that securing clips are seated correctly in mounting holes of retaining plate with cables.

NOTE: Make sure that cables are not jammed between retaining plate with cables and reinforcement plate.







- Insert guide - 1 - into weaving guide - 2 - and secure lower point of guide to convertible top frame - 4 - using rivet - arrow -.

NOTE: Make sure to pass lower cable - 3 - in front of frame - 4 -.







- Secure upper point of guide - 1 - and eyelets - 2 - to convertible top frame - 3 - using rivet - arrow -.

NOTE:
- Make sure that guide - 1 - is installed in upper and lower point on inner side of convertible top frame - 3 - and eyelets - 2 - are installed on outer side of convertible top frame.
- Observe original position of eyelets.







- Guide upper cable - 2 - behind cross rail - 1 - and over extended frame - 3 -.

NOTE: Guide cable through highest and rearmost point.







- Guide upper cable - 1 - with sliding cable eyelet - 2 - to inclined frame - 3 -.
- Rivet sliding cable eyelet - 2 - (flat side of eyelet on frame) to vertical convertible top frame - 4 - in an angle of 45° with horizontal line of vehicle.
- Rivet sliding cable eyelet - 1 - (flat side of eyelet on frame) to inclined frame - 3 - in an angle of 45° with horizontal line of vehicle - arrow -.

CAUTION:
- Cable may be damaged when riveted into lower bore.
- Place flat side of both cable eyelets onto frame, otherwise there is risk of malfunction.







- Rivet lower eyelet - 1 - and weaving guides - 2 - to frame - 3 -.

NOTE: Observe that weaving guides are installed between frame - 3 - and eyelet - 1 -.







- Pull string tied to strap eyelet until eyelet is reached - arrow -.
- Install cable eyelet.
- Untie string from cable eyelet.
- Open/close convertible top to check correct operation.
- After completing repair work, install roof edge in headliner tensioning system.
- Install rear side trim
pro multis Credits:Operation CHARM About Operation CHARM