General body repairs, exterior

Kapitelübersicht

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Tools
  1
• 1.2 Fitting locations of adaptive cruise control senders
  1
• 1.3 Assembly overview - lock carrier, service position
  2
• 1.4 Service position
  4
• 1.5 Assembly overview - lock carrier with attachments
  6
• 1.6 Removing and installing lock carrier with add-on parts
  6
• 1.7 Assembly overview - lock carrier attaching parts
  9
• 1.8 Installation instructions for longitudinal members
  10
• 1.9 Installation instructions for vehicles with adaptive cruise control
  10
• 1.10 Removing and installing ACC senders
  11
• 2 Wing
  13
• 2.1 Tools
  13
• 2.2 Assembly overview - front wing
  13
• 2.3 Removing and installing front wing
  15
• 2.4 Front wing - bolting sequence
  17
• 3 Noise insulation
  18
• 3.1 Tools
  18
• 3.2 Assembly overview - noise insulation in vehicles up to 05.2010
  18
• 3.3 Assembly overview - noise insulation in vehicles up to 06.2010
  19
• Bonnet, rear lid
  20
• 1 Contact corrosion!
  20
• 2 Bonnet
  21
• 2.1 Tools
  21
• 2.2 Assembly overview - bonnet of vehicles up to 05.2010
  21
• 2.3 Assembly overview - bonnet of vehicles up to 06.2010
  23
• 2.4 Removing gas strut
  24
• 2.5 Service position for bonnet
  24
• 2.6 Removing and installing insulation of vehicles up to 05.2010
  25
• 2.7 Removing and installing insulation of vehicles up to 06.2010
  25
• 3 Lock and release components of bonnet
  28
• 3.3 Removing and installing bonnet lock
  29
• 3.4 Adjusting bonnet and bonnet lock
  33
• 3.5 Detaching Bowden cable
  35
• 3.6 Removing and installing release lever
  35
• 4 Rear lid
  38
• 4.1 Tools
  38
• 4.2 Assembly overview - aluminium hinge and hydraulic unit
  39
• 4.3 Removing and installing hydraulic unit
  40
• 4.4 Assembly overview - steel hinge
  41
• 4.5 Removing gas strut
  42
• 4.6 Releasing gas from gas strut
  42
• 4.7 Adjusting rear lid
  42
• 4.8 Basic adjustment of rear lid
  42
• 4.9 Adjusting striker plate with lock cover removed
  44
• 4.10 Adjusting striker plate with lock cover installed
  44
• 4.11 Adjusting dampers
  45
• 5 Lock parts with servo rear lid opener
  46
• 5.1 Assembly overview - lock parts with servo rear lid opener
  46
• 5.2 Removing and installing lock cylinder carrier
  47
• 5.3 Removing and installing lid lock
  48
• 6 Lock parts with basic rear lid opener
  49
• 6.1 Assembly overview - lock parts with basic rear lid opener
  49
• 6.2 Removing and installing lock cylinder carrier
  50
• 6.3 Removing and installing lid lock
  51
• 7 Tank flap unit
  52
• 7.1 Tools
  52
• 7.2 Removing and installing tank flap unit
  52
• Front doors, door components, central locking
  54
• 1 Contact corrosion!
  54
• 2 Front door
  55
• 2.1 Tools
  55
• 2.2 Assembly overview - front door
  56
• 2.3 Removing and installing door
  58
• 2.4 Adjusting door
  59
• 2.5 Adjusting striker pin
  59
• 2.6 Assembly overview - door handle and door lock
  60
• 2.7 Removing and installing lock cylinder housing
  61
• 2.8 Removing and installing door handle
  63
• 2.9 Door handle with (Keyless Entry) cable routing
  65
• 2.10 Removing and installing door lock
  65
• 2.11 Assembly overview - door power latching motor (V 278)
  69
• 2.12 Door seals
  70
• 2.13 Removing and installing door inner seal
  71
• 2.14 Removing and installing door outer seal
  71
• 2.15 Door insulation
  73
• 2.16 Removing and installing insulation
  74
• 2.17 Adapting ignition keys to remote control
  75
• 2.18 Removing and installing batteries for folding main key with remote control system
  75
• Rear doors, door components
  81
• 1 Contact corrosion!
  81
• 2 Rear door
  82
• 2.1 Tools
  82
• 2.2 Assembly overview - rear door
  83
• 2.3 Removing and installing door
  84
• 2.4 Adjusting door
  85
• 2.5 Adjusting striker pin
  86
• 2.6 Assembly overview - door handle and door lock
  86
• 2.7 Removing and installing door handle
  88
• 2.8 Door handle with (Keyless Entry) cable routing
  90
• 2.9 Removing and installing door lock
  91
• 2.10 Assembly overview - door power latching motor (V 278)
  95
• 2.11 Door seals
  96
• 2.12 Removing and installing door inner seal
  97
• 2.13 Removing and installing door outer seal
  97
• 2.14 Door insulation
  99
• 2.15 Installing insulation
  100
• Sunroof
  101
• 1 Sunroof with glass panel
  101
• 1.1 Tools
  101
• 1.2 Function
  101
• 1.3 Assembly overview
  102
• 1.4 Removing sliding/tilting sunroof glass panel
  104
• 1.5 Installing sliding/tilting sunroof glass panel
  104
• 1.6 Adjusting height of sliding/tilting sunroof glass panel
  105
• 1.7 Checking parallel running of glass panel
  106
• 1.8 Adjusting parallel running of glass panel
  106
• 1.9 Renewing panel seal
  107
• 1.10 Removing and installing wind deflector
  107
• 1.11 Adjusting wind deflector
  108
• 1.12 Removing and installing sliding headliner
  108
• 1.13 Adjusting parallel running of sliding headliner
  109
• 1.14 Removing and installing sliding/tilting sunroof drive
  110
• 1.15 Adjusting drive for sliding/tilting sunroof (zero position)
  111
• 1.16 Removing and installing drive for sliding headliner
  112
• 1.17 Removing and installing wind deflector drive
  113
• 1.18 Removing and installing sliding/tilting sunroof automatic preselector
  114
• 1.19 Removing switches for sunroof roller blind
  116
• 1.20 Removing and installing carrier unit
  117
• 1.21 Operating without current
  119
• 1.22 Cleaning water drain hoses
  119
• 1.23 Adapting components of sliding/tilting sunroof
  121
• 1.24 Coding sliding/tilting sunroof
  122
• 2 Remove sliding/tilting sunroof with solar panel
  123
• 2.1 Tools
  123
• 2.2 Function
  123
• 2.3 Assembly overview
  124
• 2.4 Removing sliding/tilting sunroof solar panel
  126
• 2.5 Installing sliding/tilting sunroof solar panel
  126
• 2.6 Adjusting sliding/tilting sunroof solar panel height
  127
• 2.7 Checking parallel running of solar panel
  128
• 2.8 Adjusting parallel running of solar panel
  128
• 2.9 Renewing panel seal
  129
• 2.10 Removing and installing wind deflector
  129
• 2.11 Adjusting wind deflector
  130
• 2.12 Removing and installing solar panel trim
  130
• 2.13 Removing and installing sliding/tilting sunroof drive
  131
• 2.14 Adjusting drive for sliding/tilting sunroof (zero position)
  132
• 2.15 Removing and installing wind deflector drive
  132
• 2.16 Removing and installing sliding/tilting sunroof automatic preselector
  134
• 2.17 Removing and installing DC-DC converter
  135
• 2.18 Removing solar contact
  135
• 2.19 Removing and installing carrier unit
  136
• 2.20 Operating without current
  138
• 2.21 Cleaning water drain hoses
  138
• 2.22 Adapting components of sliding/tilting sunroof
  140
• 2.23 Coding sliding/tilting sunroof
  141
• Bumpers
  142
• 1 Front bumper cover of vehicles up to 05.2010
  142
• 1.1 Repairing front bumper cover
  142
• 1.2 Tools
  142
• 1.3 Assembly overview - front bumper cover
  142
• 1.4 Removing and installing front bumper cover
  143
• 1.5 Front bumper cover add-on parts
  146
• 1.6 Front bumper cover substructure parts
  147
• 1.7 Installation notes for ACC sensor on right G259 / left -G 258-
  148
• 1.8 Removing and installing adaptive cruise control sensor -ACC-
  148
• 1.9 Removing and installing bumper cover insert
  149
• 1.10 Assembling bumper cover insert
  150
• 2 Front bumper cover of vehicles from 06.2010
  152
• 2.1 Repairing front bumper cover
  152
• 2.2 Tools
  152
• 2.3 Assembly overview - front bumper cover
  152
• 2.4 Removing and installing front bumper cover
  153
• 2.5 Front bumper cover add-on parts
  156
• 2.6 Front bumper cover substructure parts
  157
• 3 Rear bumper cover
  158
• 3.1 Repairing bumper cover
  158
• 3.2 Tools
  158
• 3.3 Assembly overview - rear bumper cover
  158
• 3.4 Removing and installing rear bumper cover
  160
• 3.5 Rear bumper cover add-on parts
  162
• 3.6 Rear bumper cover substructure parts
  163
• 3.7 Assembly overview - towing bracket
  163
• Glazing
  165
• 1 Flush bonded windows
  165
• 1.1 Tools
  165
• 1.2 Materials
  167
• 1.3 Repairing windscreen
  167
• 1.4 Assembly overview - windscreen
  167
• 1.5 Removing and installing plenum chamber cover
  169
• 1.6 Removing windscreen
  174
• 1.7 Installing windscreen
  175
• 1.9 Assembly overview - rear window
  176
• 1.10 Removing undamaged rear window
  178
• 1.11 Installing rear window
  179
• 1.12 Preparing a removed windscreen for glazing
  179
• 1.13 Preparing new window for glazing
  180
• 1.14 Preparing body flange for glazing
  181
• 1.15 Installation instructions
  181
• 1.16 Minimum curing period
  182
• 1.17 Touching up paint damage
  182
• 1.18 Cleaning off excess adhesive sealing material
  182
• 2 Front door windows
  184
• 2.1 Assembly overview - front door window
  184
• 2.2 Removing and installing door window
  185
• 2.3 Removing and installing electric window regulator
  186
• 2.4 Removing and installing assembly carrier
  187
• 2.5 Removing and installing window slot seal
  192
• 2.6 Removing and installing trim
  192
• 3 Rear door windows
  194
• 3.1 Assembly overview - rear door window
  194
• 3.2 Removing and installing door window
  195
• 3.3 Removing and installing electric window regulator
  196
• 3.4 Removing and installing assembly carrier
  197
• 3.5 Removing and installing window channel
  201
• 3.6 Removing and installing window slot seal
  203
• 3.7 Removing and installing trim
  203
• Exterior equipment
  205
• 1 Removing and installing wheel housing liner
  205
• 1.1 Front wheel housing liner
  205
• 1.2 Rear wheel housing liner
  206
• 2 Exterior mirror
  207
• 2.1 Tools
  207
• 2.2 Assembly overview - rear-view mirror
  207
• 2.3 Removing and installing mirror glass
  208
• 2.4 Removing and installing mirror housing
  208
• 2.5 Removing and installing side turn signal repeaters
  209
• 2.6 Removing and installing entry light
  210
• 2.7 Removing and installing warning lamp for lane change assist
  210
• 2.8 Assembly overview - rear-view mirror
  211
• 2.9 Removing and installing rear-view mirror
  212
• 2.10 Removing and installing cap
  212
• 3 Radiator grille of vehicles up to 05.2010
  214
• 3.1 Assembly overview - radiator grille
  214
• 3.2 Removing and installing radiator grille
  214
• 4 Radiator grille of vehicles from 06.2010
  216
• 4.1 Assembly overview - radiator grille
  216
• 4.2 Removing and installing radiator grille
  217
• 4.4 Removing and installing VW emblem on vehicles with adaptive cruise control
  222
• 5 Roof mouldings
  225
• 5.1 Assembly overview - roof strip
  225
• 5.2 Removing and installing securing clips for roof moulding
  226
• 5.3 Assembly overview - drip channel
  226
• 5.4 Assembly overview - water deflector
  228
• 6 Protective strips
  229
• 6.1 Assembly overview - protective moulding
  229
• 6.2 Renewing protective side strips
  230
• 6.3 Assembly overview - trim strips on wing and side panel
  231
• 6.4 Renewing trim strip insert
  231
• 6.5 Assembly overview - cover strips
  232
• 7 Sill trim
  233
• 7.1 Assembly overview - sill protective strip
  233
• 7.2 Assembly overview - sill panel mouldings
  234
• 7.3 Renewing sill panel moulding
  235
• 8 Lettering
  236
• 8.1 Tools
  236
• 8.2 Installation instructions for lettering and emblems
  236
• 8.3 Rear lettering - dimensions
  236
• 8.4 Dimensions of Volkswagen R GmbH emblem
  238