General-body-repairs; Exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Tools
  1
• 1.2 Assembly overview - lock carrier > 03.05
  1
• 1.3 Lock carrier - service position > 03.05
  3
• 1.4 Removal and installation of lock carrier > 03.05
  4
• 1.5 Assembly overview - lock carrier 04.05 >
  6
• 1.6 Lock carrier - service position 04.05 >
  7
• 1.7 Removal and installation of lock carrier 04.05 >
  8
• 2 Wing
  11
• 2.1 Assembly overview - front wing
  11
• 2.2 Removal and installation of wing
  12
• 2.3 Removal and installation of closing piece
  14
• 2.4 Wing dimensions - Vehicles > 02.05
  14
• 2.5 Wing dimensions - Vehicles 03.05 >
  16
• 3 Noise insulation
  17
• 3.1 Assembly overview - noise insulation (petrol engine)
  17
• 3.2 Assembly overview - noise insulation (diesel engine)
  18
• 4 Cross panel
  19
• 4.1 Tools
  19
• 4.2 Materials
  19
• 4.3 Assembly overview - cross panel
  20
• Bonnet, rear lid
  21
• 1 Bonnet
  21
• 1.1 Tools
  21
• 1.2 Assembly overview - bonnet
  21
• 1.3 Removal and installation of bonnet
  23
• 1.4 Adjusting bonnet
  25
• 1.5 Removing gas-filled strut
  25
• 1.6 Removal and installation of Bowden cable
  26
• 1.7 Removal and installation of release lever
  29
• 1.8 Assembly overview - bonnet lock
  31
• 1.9 Removal and installation of lid lock
  31
• 2 Rear lid
  33
• 2.1 Tools
  33
• 2.2 Assembly overview
  33
• 2.3 Removing gas-filled strut
  35
• 2.4 Releasing gas from gas-filled strut
  35
• 2.5 Adjusting rear lid
  35
• 2.6 Removal and installation of lid lock
  37
• 3 Tank flap unit
  40
• 3.1 Removal and installation of tank flap unit
  40
• Front doors, door components, central locking
  42
• 1 Front door
  42
• 1.1 Tools
  42
• 1.2 Assembly overview
  42
• 1.3 Removal and installation of door
  45
• 1.4 Adjusting door
  45
• 1.5 Assembly overview - door handle and door lock
  46
• 1.6 Removal and installation of lock cylinder housing
  48
• 1.7 Removal and installation of door handle
  49
• 1.8 Removal and installation of door lock
  50
• 1.9 Removal and installation of locking knob for locking rod
  54
• 1.10 Door seals
  55
• 2 Central locking
  60
• 2.1 Location overview - central locking components
  60
• 2.2 Removal of control unit for convenience system
  63
• 2.3 Adapting keys with remote control
  63
• 2.4 Removal and installation of battery for folding key with remote control
  63
• Rear doors, door components
  66
• 1 Rear door
  66
• 1.1 Tools
  66
• 1.2 Assembly overview
  67
• 1.3 Removal and installation of door
  68
• 1.4 Adjusting door
  69
• 1.5 Assembly overview - door handle and door lock
  69
• 1.6 Removal and installation of door handle
  71
• 1.7 Removal and installation of door lock
  73
• 1.8 Door seals
  78
• Sunroof
  83
• 1 Sliding/tilting sunroof
  83
• 1.1 Function
  83
• 1.2 Assembly overview - sliding/tilting sunroof with glass panel
  83
• 1.3 Removal of sliding/tilting sunroof glass panel
  86
• 1.4 Installation of glass panel for sliding/tilting sunroof
  87
• 1.5 Adjusting sliding/tilting sunroof glass panel (height adjustment)
  87
• 1.6 Adjusting panel seal
  89
• 1.7 Renewing panel seal
  90
• 1.8 Removing wind deflector
  91
• 1.9 Removal and installation of sun blind
  91
• 1.10 Removing pre-selector switch for sliding/tilting sunroof (E 139)
  91
• 1.11 Removal of drive for sliding/tilting sunroof
  92
• 1.12 Adjusting drive for sliding/tilting sunroof (zero position)
  92
• 1.13 Checking parallel running
  92
• 1.14 Adjusting parallel running
  93
• 1.15 Removing guide plate
  93
• 1.16 Removal and installation of assembly unit
  94
• 1.17 Removal of guide with cable
  96
• 1.18 Cleaning water drain hoses
  97
• Bumpers
  99
• 1 Front bumper
  99
• 1.1 Tools
  99
• 1.2 Repairing front bumper cover
  99
• 2 Front bumper > 03.05
  100
• 2.1 Assembly overview - bumper cover > 03.05
  100
• 2.2 Removal and installation of bumper cover > 03.05
  101
• 2.3 Assembly overview - bumper carrier > 03.05
  102
• 3 Front bumper 04.05 >
  103
• 3.1 Assembly overview - front bumper 04.05 >
  103
• 3.2 Removal and installation of front bumper cover 04.05 >
  104
• 3.3 Front bumper attachments 04.05 >
  106
• 3.4 Assembly overview - front bumper carrier 04.05 >
  107
• 4 Front bumper, Polo Fun
  108
• 4.1 Assembly overview - bumper cover, Polo Fun
  108
• 4.2 Removal and installation of front bumper cover, Polo Fun
  109
• 4.3 Assembly overview - bumper carrier, Polo Fun
  110
• 5 Front bumper, Cross Polo
  111
• 5.1 Assembly overview - bumper cover, Cross Polo
  111
• 5.2 Removal and installation of bumper cover, Cross Polo
  112
• 5.3 Assembly overview - bumper carrier, Cross Polo
  113
• 6 Rear bumper
  114
• 6.1 Tools
  114
• 6.2 Repairing rear bumper cover
  114
• 7 Rear bumper
  115
• 7.1 Assembly overview - rear bumper cover
  115
• 7.2 Removal and installation of rear bumper cover
  116
• 7.3 Assembly overview - bumper carrier
  117
• 8 Rear bumper, Polo Fun
  118
• 8.1 Assembly overview - bumper cover, Polo Fun
  118
• 8.2 Removal and installation of bumper cover, Polo Fun
  119
• 8.3 Assembly overview - bumper carrier, Polo Fun
  120
• 9 Rear bumper, Cross Polo
  121
• 9.1 Assembly overview - bumper cover, Cross Polo
  121
• 9.2 Removal and installation of bumper cover, Cross Polo
  121
• 9.3 Assembly overview - bumper carrier, Cross Polo
  123
• 10 Towing bracket
  124
• 10.1 Assembly overview - towing bracket
  124
• Glazing
  125
• 1 Flush bonded windows
  125
• 1.1 Tools
  125
• 1.2 Materials
  126
• 1.3 Repairing windscreen
  127
• 1.4 Assembly overview - windscreen
  127
• 1.5 Removal and installation of plenum chamber cover
  128
• 1.6 Removing windscreen
  130
• 1.7 Installing windscreen
  131
• 1.9 Assembly overview - side window (2-door)
  132
• 1.10 Removal of undamaged side window (2-door)
  132
• 1.11 Removal of damaged side window (2-door)
  133
• 1.12 Installation of side window (2-door)
  133
• 1.13 Assembly overview - side window (4-door)
  134
• 1.14 Removal of undamaged side window (4-door)
  134
• 1.15 Removal of damaged side window (4-door)
  135
• 1.16 Installation of side window (4-door)
  135
• 1.17 Assembly overview - rear window
  136
• 1.18 Removal of undamaged rear window
  136
• 1.19 Removal of broken rear window
  138
• 1.20 Installation of rear window
  138
• 1.21 Preparing old undamaged window for glazing
  138
• 1.22 Preparing new window with precoating for glazing
  139
• 1.23 Preparing new window without precoating for glazing
  139
• 1.24 Preparing body flange for glazing
  144
• 1.25 Installation instructions
  145
• 1.26 Minimum curing period
  145
• 1.27 Touching up paint damage
  146
• 1.28 Cleaning off excess adhesive sealing material
  146
• 2 Screw-fastened windows
  147
• 2.1 Removal and installation of vent wing
  147
• 2.2 Window seal
  148
• 2.3 Adjusting vent wing
  148
• 3 Door windows
  150
• 3.1 Tools
  150
• 3.2 Assembly overview - front door window
  151
• 3.3 Removing front door window
  152
• 3.4 Adjusting front door window
  153
• 3.5 Removal and installation of front and rear assembly carriers
  153
• 3.6 Assembly overview - rear door window
  156
• 3.7 Removing rear door window
  159
• 3.8 Fitting rear door window to window lifter
  160
• 3.9 Removal and installation of assembly carrier
  160
• 3.11 Overcoming resistance with excess force limitation
  166
• 3.12 Removal and installation of window lifter motor in assembly carrier
  166
• Exterior equipment
  169
• 1 Removal and installation of wheel housing liner
  169
• 1.1 Front wheel housing liner
  169
• 1.2 Rear wheel housing liner
  170
• 2 Exterior mirror
  171
• 2.1 Tools
  171
• 2.2 Assembly overview - exterior mirror (with electric actuation) > 02.05
  171
• 2.3 Assembly overview - exterior mirror (with manual actuation) > 02.05
  173
• 2.4 Removing mirror housing > 02.05
  173
• 2.5 Assembly overview - exterior mirror 03.05 >
  174
• 2.6 Removal and installation of mirror glass 03.05 >
  175
• 2.7 Removal and installation of mirror housing 03.05 >
  176
• 2.8 Removal and installation of cover with side turn signal repeaters 03.05 >
  177
• 2.9 Removal and installation of exterior mirror 03.05 >
  177
• 3 Mouldings and trims
  179
• 3.1 Assembly overview - radiator grille > 03.50
  179
• 3.2 Removal and installation of radiator grille > 03.05
  180
• 3.3 Assembly overview - radiator grille 04.05 >
  181
• 3.4 Removal and installation of radiator grille 04.05 >
  182
• 3.5 Renewal of side protective mouldings
  184
• 3.6 Assembly overview - sill extension, Polo GTI
  185
• 3.7 Assembly overview - lettering > 03.05
  190
• 3.8 Assembly overview - lettering 04.05 >
  191
• 3.9 Side lettering, Cross Polo
  192
• 4 Roof edge spoiler
  193
• 4.1 Tools
  193
• 4.2 Materials
  193
• 4.3 Roof edge spoiler
  194
• 4.4 Preparing body kit component for bonding
  197
• 4.5 Installation instructions
  197
• 4.6 Minimum curing period
  198
• 4.7 Touching up paint damage
  198
• 4.8 Cleaning off excess adhesive sealing material
  198
• 5 Special body kit, Polo Fun
  199
• 5.1 Safety requirements
  199
• 5.2 Tools
  199
• 5.3 Materials
  199
• 5.4 Assembly overview
  199
• 5.5 Roof railing
  201
• 5.6 Sill extension and wheel arch trim
  203
• 5.7 Protective side mouldings
  205
• 5.8 Preparing body kit component for bonding
  207
• 5.9 Preparing body kit component for bonding
  207
• 5.10 Installation instructions
  207
• 5.11 Minimum curing period
  208
• 5.12 Touching up paint damage
  208
• 5.13 Cleaning off excess adhesive sealing material
  208
• 6 Special body kit, Cross Polo
  209
• 6.1 Safety requirements
  209
• 6.2 Tools
  209
• 6.3 Materials
  209
• 6.4 Assembly overview
  209
• 6.5 Roof railing
  211
• 6.6 Sill extension and wheel arch trim
  214
• 6.7 Protective side mouldings
  223
• 6.8 Preparing body kit component for bonding
  225
• 6.9 Preparing body kit component for bonding
  226
• 6.10 Installation instructions
  226
• 6.11 Minimum curing period
  226
• 6.12 Touching up paint damage
  227
• 6.13 Cleaning off excess adhesive sealing material
  227