General body repairs, exterior

Kapitelübersicht

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Assembly overview – lock carrier
  1
• 1.2 Removing and installing lock carrier
  2
• 1.3 Moving to and back from service position
  4
• 1.4 Pressure hose with plug-in connector
  8
• 2 Wings
  9
• 2.1 Tools
  9
• 2.2 Front wing
  9
• 2.3 Insulation and foam elements for wing and web plate
  14
• 2.4 Removing and installing wing bracket
  15
• 3 Plenum chamber bulkhead
  16
• 3.1 Tools
  16
• 3.2 Assembly overview - plenum chamber bulkhead
  16
• 4 Plenum chamber cover
  18
• 4.1 Plenum chamber cover
  18
• 5 Noise insulation
  22
• 5.1 Tools
  22
• 5.2 Assembly overview - diesel noise insulation
  22
• 5.3 Assembly overview - long noise insulation
  24
• 5.4 Assembly overview - short noise insulation
  25
• 6 Underbody cladding
  26
• 6.1 Tools
  26
• 6.2 Assembly overview - underbody cladding
  26
• 7 Bulkhead
  28
• 7.1 Tools
  28
• 7.2 Materials
  29
• 7.3 Assembly overview - bulkhead
  29
• 8 Tunnel cross-piece
  30
• 8.1 Tools
  30
• 8.2 Assembly overview - tunnel cross-piece
  30
• Bonnet, rear lid
  31
• 1 Bonnet (hood)
  31
• 1.1 Tools
  31
• 1.2 Assembly overview - bonnet
  31
• 1.3 Removing and installing bonnet
  33
• 1.4 Removing and installing bonnet hinge
  34
• 1.5 Removing and installing insulation
  37
• 1.6 Removing and installing support rod
  39
• 1.7 Assembly overview - bonnet lock and release components
  40
• 1.8 Removing and installing lid lock - LHD vehicle
  41
• 1.9 Removing and installing lid lock - RHD vehicle
  43
• 1.10 Detaching Bowden cable
  45
• 1.11 Removing and installing striker pin
  46
• 1.12 Removing and installing release lever
  47
• 1.13 Adjusting bonnet
  49
• 1.14 Adjusting striker pin
  51
• 2 Rear lid
  52
• 2.1 Tools
  52
• 2.2 Assembly overview - rear lid
  52
• 2.3 Removing and installing rear lid
  54
• 2.4 Assembly overview - gas strut
  57
• 2.5 Removing gas strut
  57
• 2.6 Releasing gas from gas strut
  59
• 2.7 Assembly overview - rear lid hinge
  59
• 2.8 Removing and installing rear lid hinge
  61
• 2.9 Removing and installing striker pin
  63
• 2.10 Removing and installing stop buffer
  64
• 2.11 Adjusting rear lid
  65
• 2.12 Removing and installing bonnet lock
  68
• 2.13 Removing and installing release element
  70
• 2.14 Rear lid seal
  71
• 2.15 Removing and installing rear lid seal
  72
• 3 Tank flap unit
  74
• 3.1 Tools
  74
• 3.2 Assembly overview - tank flap unit and actuator
  74
• 3.3 Removing and installing tank flap unit
  76
• 3.4 Removing and installing actuator
  78
• Front doors, door components, central locking
  80
• 1 Rear door
  80
• 1.1 Tools
  80
• 1.2 Assembly overview - door hinges
  81
• 1.3 Removing and installing door
  82
• 1.4 Installing after renewing A-pillar
  85
• 1.5 Door alignment
  86
• 2 Door components
  90
• 2.1 Tools
  90
• 2.2 Assembly overview - front door (2-door model)
  91
• 2.3 Assembly overview - front door (4-door model)
  92
• 2.4 Removing and installing cover (2-door model)
  93
• 2.5 Removing and installing cover (4-door model)
  95
• 2.6 Removing and installing door retaining strap
  97
• 2.7 Removing and installing striker pin
  98
• 2.8 Assembly overview - door handle and door lock
  98
• 2.9 Removing and installing lock cylinder cover cap
  99
• 2.10 Removing and installing lock cylinder
  100
• 2.11 Removing and installing cover cap (without lock cylinder)
  103
• 2.12 Removing and installing door handle
  106
• 2.13 Removing and installing door lock
  108
• 2.14 Removing and installing mounting bracket
  112
• 2.15 Removing and installing window slot inner seal
  113
• 2.16 Removing and installing outer window slot seal (2-door model)
  114
• 2.17 Removing and installing outer window slot seal (4-door model)
  117
• 2.18 Removing and installing inner door seal
  118
• 2.19 Removing and installing door outer seal (2-door model)
  120
• 2.20 Removing and installing door outer seal (4-door model)
  121
• 2.21 Assembly overview - insulation (2-door model)
  122
• 2.22 Assembly overview - insulation (4-door model)
  123
• 3 Central locking
  124
• 3.1 Fitting location overview - central locking components
  124
• 3.2 Adapting keys with remote control
  125
• 3.3 Assembly overview - battery for folding key with remote control
  126
• 3.4 Removing and installing battery for folding key with remote control
  127
• Rear doors, door components
  130
• 1 Rear door
  130
• 1.1 Tools
  130
• 1.2 Assembly overview - door hinges
  131
• 1.3 Removing and installing door
  132
• 1.4 Installing after renewing B-pillar
  135
• 1.5 Door alignment
  136
• 2 Door components
  140
• 2.1 Tools
  140
• 2.2 Assembly overview - rear door
  141
• 2.3 Removing and installing cover
  142
• 2.4 Removing and installing door retaining strap
  143
• 2.5 Removing and installing striker pin
  144
• 2.6 Assembly overview - door handle and door lock
  144
• 2.7 Removing and installing cap
  145
• 2.8 Removing and installing door handle
  148
• 2.9 Removing and installing door lock
  150
• 2.10 Removing and installing mounting bracket
  154
• 2.11 Removing and installing trim
  156
• 2.12 Removing and installing window slot inner seal
  158
• 2.13 Removing and installing window slot outer seal
  159
• 2.14 Removing and installing inner door seal
  160
• 2.15 Removing and installing outer door seal
  162
• 2.16 Assembly overview - insulation
  163
• Sunroof
  164
• 1 Panorama tilting sunroof
  164
• 1.1 Tools
  164
• 1.2 Function
  164
• 1.3 Panoramic sliding roof normalisation run
  166
• 1.4 Assembly overview - panorama tilting sunroof
  167
• 1.5 Removing glass panel for panorama tilting sunroof
  169
• 1.6 Removing glass panel when drive is defective
  171
• 1.7 Installing glass panel
  173
• 1.8 Adjusting glass panel (height adjustment)
  175
• 1.9 Removing and installing glass panel seal
  176
• 1.10 Removing and installing cover
  177
• 1.11 Removing and installing drive for panorama tilting sunroof glass panel
  178
• 1.12 Removing and installing panorama tilting sunroof switch
  180
• 1.13 Operating without current
  181
• 1.14 Removing and installing wind deflector
  182
• 1.15 Removing and installing interior seal
  184
• 1.16 Sun blind
  185
• 1.17 Removing and installing guide rails
  193
• 1.18 Cleaning water drainage hoses
  196
• 1.19 Assembly overview – assembly frame and trim
  199
• 1.20 Removing and installing assembly frame
  200
• 1.21 Removing and installing trim
  208
• 1.22 Installing trim panel
  216
• Bumpers
  218
• 1 Front bumper cover
  218
• 1.1 Tools
  218
• 1.2 Repairing front bumper cover
  218
• 1.3 Number plate carrier
  219
• 1.4 Front bumper carrier and lateral guides
  220
• 2 Front bumper cover, Polo
  221
• 2.1 Front bumper cover
  221
• 2.2 Front bumper cover, Polo Blue Motion
  227
• 2.3 Front bumper cover, Cross Polo
  233
• 2.4 Front bumper cover, Polo »GTI«
  239
• 2.5 Front bumper cover, Polo »R-Line«
  246
• 3 Rear bumper cover
  251
• 3.1 Tools
  251
• 3.2 Repairing rear bumper cover
  251
• 3.3 Installing brackets for parking aid system
  251
• 3.4 Number plate carrier
  257
• 3.5 Rear bumper carrier and subassemblies
  258
• 4 Rear bumper cover, Polo
  259
• 4.1 Rear bumper cover
  259
• 4.2 Rear bumper cover, Polo Blue Motion
  262
• 4.3 Rear bumper cover, Cross Polo
  266
• 4.4 Rear bumper cover, Polo GTI, Blue GT
  270
• 4.5 Rear bumper cover - Polo »R-Line«
  273
• 5 Towing bracket
  278
• 5.1 Assembly overview - towing bracket
  278
• Glazing
  279
• 1 Flush bonded windows
  279
• 1.1 Tools
  279
• 1.2 Materials
  280
• 1.3 Assembly overview - windscreen
  281
• 1.4 Removing windscreen
  282
• 1.5 Installing windscreen
  283
• 1.6 Assembly overview - rear window
  283
• 1.7 Removing undamaged rear window
  285
• 1.8 Removing broken rear window
  286
• 1.9 Installing rear window
  287
• 1.10 Assembly overview - side window (2-door model)
  287
• 1.11 Removing undamaged side window (2-door model)
  288
• 1.12 Assembly overview - side window (4-door model)
  289
• 1.13 Removing undamaged side window (4-door model)
  291
• 1.14 Removing broken side window
  292
• 1.15 Installing side window
  292
• 1.16 Preparing old undamaged window for glazing
  293
• 1.17 Preparing new window without precoating for glazing
  293
• 1.18 Preparing body flange for glazing
  294
• 1.19 Fitting instructions
  295
• 1.20 Minimum curing period
  295
• 1.21 Touching up paint damage
  296
• 1.22 Cleaning in the event of dirt caused by adhesive sealant
  296
• 2 Front door window
  297
• 2.1 Tools
  297
• 2.2 Assembly overview - front door window
  298
• 2.3 Removing and installing door window
  298
• 2.4 Removing and installing window regulator motor
  303
• 2.5 Installing and removing window regulators
  305
• 2.6 Removing and installing window channel
  307
• 3 Rear door window
  310
• 3.1 Tools
  310
• 3.2 Assembly overview - rear door window
  311
• 3.3 Removing and installing door window
  311
• 3.4 Removing and installing window regulator motor
  315
• 3.5 Removing and installing manual drive
  317
• 3.6 Removing and installing window crank
  318
• 3.7 Installing and removing window regulators
  319
• 3.8 Removing and installing window channel
  320
• Exterior equipment
  323
• 1 Wheel housing liner
  323
• 1.1 Tools
  323
• 1.2 Front wheel housing liner
  323
• 1.3 Rear wheel housing liner
  326
• 2 Exterior mirror
  331
• 2.1 Tools
  331
• 2.2 Assembly overview - exterior mirror
  331
• 2.3 Removing and installing mirror glass
  332
• 2.4 Removing and installing adjustment unit with motor
  334
• 2.5 Removing and installing mirror housing
  335
• 2.6 Removing and installing trim
  336
• 2.7 Removing and installing assembly bracket with side turn signal repeater
  337
• 2.8 Removing and installing exterior mirror (manual operation)
  338
• 2.9 Removing and installing exterior mirror (electric operation)
  342
• 3 Radiator grille
  347
• 3.1 Tools
  347
• 3.2 Removing and installing radiator grille
  347
• 3.3 Removing and installing emblem
  350
• 3.4 Removing and installing emblem on Polo Blue Motion
  354
• 3.5 Assembly overview - radiator grille, Polo »GTI«
  358
• 4 Mouldings and trims
  359
• 4.1 Tool
  359
• 4.2 Removing and installing A-pillar trim
  359
• 4.3 B-pillar trim
  361
• 4.4 Wing trim panel
  364
• 4.5 Water deflector, Polo Blue Motion, Blue GT
  365
• 4.6 Removing and installing cover strip
  368
• 5 Removing and installing roof railing
  370
• 5.1 Tools
  370
• 5.2 Roof railing
  370
• 6 Roof spoiler
  373
• 6.1 Tools
  373
• 6.2 Materials
  374
• 6.3 Roof spoiler, Polo Blue Motion
  374
• 6.4 Roof spoiler, Polo »GTI«
  383
• 6.5 Roof spoiler, Polo Blue GT
  388
• 6.6 Roof spoiler, Polo “WRC”
  392
• 7 Special add-on parts
  397
• 7.1 Assembly overview - Polo Blue Motion
  397
• 7.2 Assembly overview - Cross Polo
  399
• 7.3 Assembly overview - Polo »GTI«
  400
• 7.4 Assembly overview - Polo »R-Line«
  401
• 7.5 Assembly overview - Polo »WRC«
  402
• 7.6 Safety requirements
  402
• 7.7 Tools
  403
• 7.8 Materials
  404
• 7.9 Side member extension, Polo Blue Motion, Blue GT
  404
• 7.10 Side member extension, Cross Polo
  411
• 7.11 Side member extension, Polo »GTI«
  419
• 7.12 Front wheel housing trim, Cross Polo
  423
• 7.13 Rear wheel housing trim, Cross Polo
  426
• 7.14 Front door cover, Cross Polo
  428
• 7.15 Rear door cover, Cross Polo
  431
• 7.16 Wheel arch trim, rear door, Cross Polo
  434
• 7.17 Preparing attachment for bonding
  435
• 7.18 Preparing body component for bonding
  435
• 7.19 Fitting instructions
  436
• 7.20 Minimum curing period
  436
• 7.21 Touching up paint damage
  437
• 7.22 Cleaning in the event of dirt caused by adhesive sealant
  437
• 7.23 Cleaning guidelines
  437
• 8 Lettering and emblems
  438
• 8.1 Fitting instructions
  438
• 8.2 Dimensions - lettering and emblems on rear lid
  439
• 8.3 Removing and installing emblems
  446
• 8.4 Side lettering
  448
• 9 Scuff protection film
  452
• 9.1 Renewing scuff protection film, Polo »GTI«
  452