Convertible Top - Headliner Modification

Condition

61 07 02 Feb. 9, 2007, 2010633, Supersedes Technical Bulletin Group 61 number 04-02 dated May 11, 2004 due to inclusion into ElsaWeb, Metadata, and Content.

Convertible Top, Headliner Modification
Original equipment or replacement headliner, will not install into rear glass channel due to plastic ring is too large.

Technical Background
May be caused by headliner rear glass plastic ring tolerance.

Production Solution
Process improvements were applied to the plastic ring starting with VIN: 1Y_6M321235.

Service
Modify headliner rear glass plastic ring as follows:

- Locate bottom center of rear glass opening in headliner. This is indicated by a center line in plastic ring -arrow-.

Tip: Production date clocks are located to the right of the center line of the bottom of rear glass opening.

- Measure and mark 3 mm on each side of center line -arrows-.
- Using razor, cut partway (1/3-1/2) through plastic ring in locations marked in last step.
- Using fingers only, snap remainder of plastic ring in same locations.

- Cut fabric stitching on detached piece of plastic ring -arrows-.
- Remove detached piece of plastic ring. If necessary, increase the cutout to 4 mm, 5 mm, or 6 mm to allow for a better fit of the plastic ring.

- To prevent fabric stitching from unraveling, apply 3M(TM) Automix(TM) Quick Fix Adhesive (Part No. 08224) to stitching locations shown -arrows-.
- To quick dry adhesive, spray 3M(TM) Automix(TM) Quick Fix Adhesive Accelerator (Part No. 08224) to adhesive.

WARNING:
Always read and follow Manufacturers Cautions and Warning on product.

Tip:
Obtain 3M(TM) Automix(TM) Quick Fix Adhesive Kit at your local 3M(TM) Automix(TM) authorized distributor.

- Turn headliner over, to expose fabric side.

- Use soft jawed pliers to install plastic ring in rear glass channel.

Tip: Do not use rubber hammer to install plastic ring in rear glass channel.

If plastic ring is still too large to be installed.
- Remove plastic ring from rear glass lower channel only.

Tip: It is not necessary to remove headliner from vehicle to remove more material from plastic ring.

- Remove an additional 1 mm of plastic ring. Follow step previously outlined in this technical bulletin.
- Install plastic ring in rear glass lower channel.
- Repeat as necessary until plastic ring installs correctly.

- After headliner is completely installed a small wrinkle may be visible in location where plastic ring was removed.

Warranty

Required Parts and Tools

Description Description Tool No:
3M" Automix" Quick Fix Adhesive Kit 3M 08224*

* Call Volkswagen Tools and Equipment Program (EQS), which is Equipment Solutions.