General body repairs, exterior

Kapitelübersicht

• Body - front
  1
• 1 Body - front section
  1
• 1.1 Front end with complementary parts - assembly overview
  1
• 1.2 Front end with complementary parts - remove and install
  2
• 1.3 Front end - service position
  3
• 1.4 Front wing - assembly overview
  4
• 1.5 Engine compartment upper partition panel - replacing
  6
• 1.6 Spare wheel mechanism - assembly overview
  8
• Bonnet, rear lid
  9
• 1 Bonnet
  9
• 1.1 Assembly overview
  9
• 1.2 Bonnet - remove and install
  10
• 1.3 Bonnet - adjust
  10
• 1.4 Bonnet hinge - remove and install
  11
• 1.5 Bonnet latch operation cable - assembly overview
  12
• 1.6 Bonnet latch Bowden cable - remove and install
  13
• 1.7 Bonnet upper latch - remove and install
  16
• 1.8 Bonnet lower latch - remove and install
  16
• 2 Rear lid (Gol)
  17
• 2.1 Assembly overview
  17
• 2.2 Rear lid shock absorber - remove
  18
• 2.3 Rear lid shock absorber - remove the gas
  19
• 2.4 Rear lid trim - remove and install
  19
• 2.5 Rear lid - remove and install
  19
• 2.6 Rear lid hinge - remove and install
  21
• 2.7 Rear lid - adjust
  23
• 2.8 Housing with latch cylinder - assembly overview
  25
• 2.9 Housing with Latch cylinder - remove and install
  26
• 2.10 Latch cylinder - remove and install
  28
• 2.11 Cylinder - assembly and disassembly
  28
• 2.12 Door latch - remove and install
  29
• 2.13 Rear lid unlocking motor V139 - remove and install
  31
• 3 Rear lid (Voyage)
  32
• 3.1 Assembly overview
  32
• 3.2 Rear lid trim - remove and install
  33
• 3.3 Rear lid - remove and install
  34
• 3.4 Rear lid hinge - remove and install
  36
• 3.5 Rear lid - adjust
  38
• 3.6 Housing with latch cylinder - assembly overview
  40
• 3.7 Housing with Latch cylinder - remove and install
  41
• 3.8 Latch cylinder - remove and install
  43
• 3.9 Latch cylinder - disassemble and assemble
  43
• 3.10 Door latch - remove and install
  43
• 3.11 Rear lid unlocking motor V139 - remove and install
  44
• 4 Tailgate (Saveiro)
  45
• 4.1 Tailgate buffer (►CP 122368) - adjust
  45
• 4.2 Tailgate buffer (CP 122369 ►) - adjust
  46
• 4.3 Tailgate lock (►CP 122368) - remove and install
  47
• 4.4 Tailgate lock (CP 122369 ►) - remove and install
  50
• 4.5 Rod driver - remove and install
  53
• 4.6 Tailgate handle with cylinder - remove and install
  56
• 4.7 Tailgate sustaining cable - remove and install
  57
• 4.8 Latch cylinder - remove and install
  60
• 4.9 Latch cylinder - disassemble and assemble
  60
• 4.10 Tailgate damper - remove and install
  60
• 4.11 Cargo cover damper - replace
  62
• 4.12 Tailgate - remove and install
  63
• 4.13 Tailgate - adjust
  65
• 4.14 Bucket sealing membrane - remove and install
  65
• 5 Fuel reservoir nozzle compartment and lid set
  68
• 5.1 Fuel reservoir nozzle compartment lid (Gol and Voyage) - remove and install
  68
• 5.2 Fuel reservoir nozzle compartment lid (Saveiro) - remove and install
  69
• Front doors, door components, central locking
  70
• 1 Front door
  70
• 1.1 Tools
  70
• 1.2 Assembly overview
  71
• 1.3 Door - remove and install
  72
• 1.4 Door - adjust
  74
• 1.5 Door - disassemble and assemble
  77
• 1.6 Door - replace
  77
• 1.7 Front door arrester - adjust
  77
• 1.8 Door limiter - remove and install
  78
• 1.9 Internal handle - replace
  79
• 1.10 Front door external handle and lock - assembly overview
  79
• 1.11 Lock cylinder housing - remove and install
  81
• 1.12 Latch cylinder - remove and install
  82
• 1.13 Latch cylinder - disassemble and assemble
  83
• 1.14 Door handle - remove and install
  83
• 1.15 External door handle - replace
  85
• 1.16 Door lock (► 02.09) - remove and install
  85
• 1.17 Door lock (Saveiro , Gol and Voyage 03.09 ►) - remove and install
  87
• 1.18 Lock button (locking rod) - remove and install
  89
• 1.19 Door lock - replace
  90
• 1.20 Lock Bowden cable - replace
  90
• 1.21 Door sealing membrane - remove and install
  91
• 1.22 Internal door trim - remove and install
  93
• 2 Central locking
  94
• 2.1 Central locking installation locations overview
  95
• 2.2 Central control unit for convenience system J393 - remove
  96
• 2.3 Battery of key with radio remote command (articulated) - remove and install
  97
• 2.5 Key - synchronize
  100
• Rear doors, door components
  101
• 1 Rear passenger doors
  101
• 1.1 Rear passenger doors - assembly overview
  101
• 1.2 Door - remove and install
  102
• 1.3 Door - adjust
  103
• 1.4 Rear passenger door - disassemble and assemble
  105
• 1.5 Door - replace
  105
• 1.6 Rear door arrester - adjust
  106
• 1.7 Door limiter - remove and install
  106
• 1.8 Internal handle - replace
  108
• 1.9 Rear door external handle and lock - assembly overview
  108
• 1.10 External handle housing - remove and install
  109
• 1.11 External door handle - remove and install
  110
• 1.12 External door handle - replace
  112
• 1.13 Door lock - remove and install
  112
• 1.14 Door lock - replace
  116
• 1.15 Lock button (locking rod) - remove and install
  116
• 1.16 Lock Bowden cable - replace
  117
• 1.17 Door sealing membrane - remove and install
  117
• 1.18 Internal door trim - remove and install
  119
• Convertible roof, hardtop, canopy
  121
• 1 Tonneau cover (Saveiro)
  121
• 1.1 Assembly overview
  121
• 1.2 Tonneau cover - remove and install
  122
• Bumpers
  125
• 1 Front bumper
  125
• 1.1 Front protector - assembly overview
  125
• 1.2 Front protector - remove and install
  125
• 1.3 Front protector support - assembly overview
  128
• 2 Rear bumper (Gol)
  129
• 2.1 Rear protector - assembly overview
  129
• 2.2 Rear protector - remove and install
  129
• 2.3 Rear protector support (► 03.11) - assembly overview
  132
• 2.4 Foamed rear protector support (04.11 ►) - assembly overview
  133
• 3 Rear bumper (Voyage)
  134
• 3.1 Rear protector - assembly overview
  134
• 3.2 Rear protector - remove and install
  134
• 3.3 Rear protector support (► 03.11) - assembly overview
  137
• 3.4 Foamed rear protector support (04.11 ►) - assembly overview
  138
• 4 Rear bumper (Saveiro)
  139
• 4.1 Support and side protector - assembly overview
  139
• 4.2 Side protector - remove and install
  139
• 4.3 Support and central protector - assembly overview
  141
• 4.4 Central protector - remove and install
  142
• Glazing
  144
• 1 Glasses glued with adhesive
  144
• 1.1 Tools
  144
• 1.2 Auxiliary materials - Brazilian market
  145
• 1.3 Auxiliary materials for the export market
  146
• 1.4 Matching table
  146
• 1.5 Stickers for engraving the VIS number on the windows (only for Brazil) - supply
  146
• 1.6 Windscreen - assembly overview
  147
• 1.7 Windscreen - remove
  148
• 1.8 Windscreen - install
  148
• 1.9 Rear window (Gol) - assembly overview
  148
• 1.10 Undamaged rear window (Gol) - remove
  149
• 1.11 Damaged rear window (Gol) - remove
  150
• 1.12 Rear window (Gol) - install
  151
• 1.13 Rear window (Voyage) - assembly overview
  151
• 1.14 Undamaged rear window (Voyage) - remove
  151
• 1.15 Damaged rear window (Voyage) - remove
  152
• 1.16 Rear window (Voyage) - install
  153
• 1.17 Rear door fixed window - assembly overview
  153
• 1.18 Undamaged fixed rear door window - remove
  154
• 1.19 Damaged fixed rear door window - remove
  154
• 1.20 Fixed rear door window - install
  154
• 1.21 Fixed rear side window (Saveiro) - assembly overview
  154
• 1.22 Undamaged fixed rear side window (Saveiro) - remove
  155
• 1.23 Damaged fixed rear side window (Saveiro) - remove
  156
• 1.24 Fixed rear side window (Saveiro) - install
  157
• 1.25 Fixed rear side window (Saveiro - single cab) - assembly overview
  157
• 1.26 Fixed rear window (Saveiro - extended cab) - assembly overview
  158
• 1.27 Sliding rear window (Saveiro - single cab) - assembly overview
  159
• 1.28 Sliding rear window (Saveiro - extended cab) - assembly overview
  160
• 1.29 Undamaged fixed or sliding rear window (Saveiro) - remove
  160
• 1.30 Rear fixed or sliding window (Saveiro) - install
  162
• 1.31 Undamaged glass - prepare for install
  163
• 1.32 New glass - prepare for install
  163
• 1.33 Body flange - prepare to install the window
  164
• 1.34 Assembly instructions
  164
• 1.35 Minimum adhesive drying time
  166
• 1.36 Paint damage - repair
  166
• 1.37 Cleaning in case of resulting adhesive residues
  166
• 2 Door window glass
  168
• 2.1 Front door window glass - assembly overview
  168
• 2.2 Front door window glass - remove and install
  168
• 2.4 Window drive mechanism - remove and install
  171
• 2.5 Driver/passenger window control motor V147 / V148 - remove and install
  172
• 2.6 Front door window crank - remove and install
  173
• 2.7 Front door window channel - remove and install
  173
• 2.8 Front door window internal trim - remove and install
  174
• 2.9 Front door window external trim - replace
  174
• 2.10 Rear door window glass - assembly overview
  175
• 2.11 Rear door window glass - remove and install
  175
• 2.12 Rear door window drive mechanism - remove and install
  176
• 2.13 Left/right rear window control motor V26 / V27 - remove and install
  177
• 2.14 Rear door window drive crank - remove and install
  178
• 2.15 Rear door window channel - remove and install
  178
• 2.16 Rear door window internal trim - remove and install
  179
• 2.17 Rear door window external trim - replace
  179
• Exterior equipment
  180
• 1 Materials used and operational care required
  180
• 1.1 Auxiliary materials for Brazilian market
  180
• 1.2 Auxiliary materials for export market
  180
• 1.3 Matching table
  180
• 1.4 Paint damage - repair
  181
• 1.6 Minimum adhesive drying time
  181
• 2 Wheel arch protector
  182
• 2.1 Front wheel arch protector - remove and install
  182
• 2.2 Rear wheel arch protector - remove and install
  183
• 3 External rear-view mirror
  184
• 3.1 External rear-view mirror - assembly overview
  184
• 3.2 External rearview mirror - assembly overview - continued
  185
• 3.3 Exterior rear-view mirror - remove and install
  185
• 3.4 Mirror glass - remove and install
  186
• 3.5 Mirror glass - remove and install
  187
• 3.6 Turn signal (Blinker) - remove and install
  188
• 4 External linings
  189
• 4.1 Lower windscreen covering - assembly overview
  189
• 4.2 Lower windscreen covering - remove and install
  190
• 4.3 External linings on pillars and doors - replace
  191
• 4.4 External B-pillar coverings (Saveiro - single cab) - replace
  193
• 4.5 Footwell cover (Saveiro) - replace
  195
• 5 Internal covering
  198
• 5.1 Front wing side cover - remove and install
  198
• 6 Side trims, roof
  199
• 6.1 Side trims (Gol ► BT 003067 and Voyage ► AT 255034) - replace
  199
• 6.2 Side trims (Gol BT 003068 ►and Voyage AT 255035 ►) - replace
  201
• 6.3 Side trims (Saveiro Cross) - Assembly overview
  203
• 6.4 Front door trim (Saveiro Cross) - replace
  203
• 6.5 Rear side panel trim (Saveiro Cross) - replace
  206
• 6.6 Decorative side stripe (Saveiro Trooper) - replace
  209
• 6.7 Decorative stripe on the front and rear door (Gol Rallye) - replace
  210
• 6.8 Decorative stripe on the front and rear door (Gol Rock in Rio) - replace
  213
• 6.9 Decorative stripe on the front and rear door (Gol Rock in Rio) - replace
  214
• 6.10 Rear cover trim (Voyage) - replace
  215
• 6.11 Roof trim (► 07.08 - Gol and Voyage) - assembly overview
  217
• 6.12 Roof trim (08.08 ► - Gol e Voyage) - assembly overview
  218
• 6.13 Roof lining (Saveiro) - remove and install
  219
• 6.14 Rear protector fixed window (Gol) - replace
  220
• 6.15 Rear protector fixed window (Gol Vintage) - replace
  222
• 6.16 Front protector fixed window (Gol Vintage) - replace
  224
• 6.17 Decorative stripe and side lettering (Gol Vintage) - replace
  227
• 7 Side member trim
  232
• 7.1 Longitudinal member lower trim (Saveiro Cross ) - assembly overview
  233
• 7.2 Longitudinal member lower trim (Saveiro Cross) - replace
  233
• 7.3 Longitudinal lower trim (Gol Rallye) - general overview of assembly
  237
• 7.4 Longitudinal lower trim (Gol Rallye) - replace
  237
• 8 Rear wing and side panel trim (Saveiro)
  242
• 8.1 Front protector trim (Saveiro) - replace
  242
• 8.2 Front protective trim (Gol Rallye) - remove and install
  244
• 8.3 Front wing trim (Saveiro) - assembly overview
  247
• 8.4 Front bumper trim (Saveiro) - replace
  248
• 8.5 Front wing trim (Saveiro Cross) - assembly overview
  249
• 8.6 Front wing trim (Saveiro Cross) - replace
  250
• 8.7 Front wing trim (Gol Rallye) - replace
  253
• 8.8 Rear side panel trim (Saveiro) - assembly overview
  258
• 8.9 Rear side panel trim (Saveiro) - replace
  258
• 8.10 Rear side panel trim (Saveiro Cross) - assembly overview
  260
• 8.11 Rear side panel trim (Saveiro Cross) - replace
  261
• 8.12 Rear side panel trim (Gol Rallye) - replace
  264
• 8.13 Rear side protector trim (Saveiro) - replace
  268
• 8.14 Front protective trim (Gol Rallye) - remove and install
  270
• 9 Cargo compartment and frames protector (Saveiro)
  274
• 9.1 Upper tailgate frame - replace
  274
• 9.2 Cargo compartment upper frame - replace
  275
• 9.3 Cargo compartment protection grid - remove and install
  279
• 9.4 External B-pillar frame - replace
  280
• 9.5 Rear window glass upper and lower frame - remove and install
  283
• 9.6 Bedliner - remove and install
  285
• 9.9 Cargo compartment adjustable hooks - remove and install
  291
• 10 Front grid, front protector grids, rear protector frames
  292
• 10.1 Front grid and front protector grids - assembly overview
  292
• 10.2 Front spoiler (Saveiro Cross and Gol Rallye) - replace
  293
• 10.3 Front protector central grid (Saveiro Cross and Gol Rallye) - replace
  295
• 10.4 Front protector side grid (Saveiro Cross and Gol Rallye) - remove and install
  297
• 10.5 Lower rear protector frame (Saveiro Cross) - replace
  299
• 10.6 Lower rear side protector frame (Saveiro Cross) - replace
  302
• 10.7 Rear spoiler (Gol) - replace
  304
• 11 Badges
  307
• 11.1 Volkswagen Badge - replace
  307
• 11.2 Model badge (Gol) - replace
  308
• 11.3 Model badge (Voyage) - replace
  308
• 11.4 (1.6 - Gol) version distich - replace
  309
• 11.5 (1.6 - Voyage) version badge - replace
  309
• 11.6 “Total flex” badge - remove and install
  310
• 11.7 Version badge (on door - Gol and Voyage) - replace
  311
• 11.8 “TREND” Badge (Saveiro) - replace
  312
• 11.9 Sticker “I Trend” (Gol 2012) - replace
  313
• 11.10 Badge “Gol 25 anos” on front wing - replace
  314
• 11.11 Badge “Gol 25 anos” on rear window - replace
  316
• 11.12 “Saveiro” Badge and “VW” badge on tailgate - replace
  317
• 11.13 “Saveiro Cross” Badge and on tailgate - replace
  319
• 11.14 “Seleção” Badge (Gol Seleção) - replace
  320
• 11.15 “Seleção” Side Badge (Gol Seleção) - replace
  321
• 11.16 Lettering “Rallye” (Gol Rallye) - replace
  322
• 11.17 Side lettering of the front wing (Gol Vintage) - replace
  322
• 11.18 Lettering model “Vintage” (Gol Vintage) - replace
  324
• 11.19 Sticker “Rock in Rio” (Gol Rock in Rio) - replace
  325
• 11.20 “Blackgol” badge on front door (Gol Blackgol) - replace
  326
• 11.21 “Blackgol” badge on rear lid (Gol Blackgol) - replace
  327
• 12 Roof rack (Saveiro)
  330
• 12.1 Roof rack (Single cab) - remove and install
  330
• 12.2 Roof rack (Extended cab) - remove and install
  333
• 12.3 Roof rack (Saveiro Cross) - remove and install
  337
• 12.4 Roof rack extensor (Saveiro Cross) - remove and install
  341
• 12.5 Roof rack extensor cover (Saveiro Cross) - remove and install
  344
• 12.6 Cargo compartment rack (Saveiro Cross) - remove and install
  345
• 13 Spoiler
  349
• 13.1 Spoiler (Gol) - remove and install
  349
• 13.2 Assembly overview
  349
• 13.4 Remove
  350
• 13.5 Install
  351
• 13.6 Spoiler (Voyage) - remove and install
  352
• 13.7 Assembly overview
  353
• 13.9 Remove
  354
• 13.10 Install
  355
• 14 Saveiro Cross Components
  358
• 14.1 Assembly overview
  358
• 15 Gol Rallye Components
  359
• 15.1 Assembly overview
  359
• 16 Gol Vintage Components
  360
• 16.1 Assembly overview
  360