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General-body-repairs; Exterior

For Polo

Original Volkswagen repair manual


19,15 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

5.573 KB

235 Sites

Detailed technical data

Immediately readable

This repair manual contains: Lock carrier, Wing, Noise insulation, Bonnet, Rear lid, Sliding/tilting sunroof, Front bumper, Flush bonded windows, Removal and installation of wheel housing liner, Exterior mirror, Roof edge spoiler and Special body kit, Polo Fun. Show more
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Repair manual Polo General-body-repairs; Exterior PDF download has the following content:

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
Manufacturer's designation General-body-repairs; Exterior
Manufacturer Volkswagen
Suitable for Polo (2005 - 2007)
Suitable car types 9N4
Category Reparaturanleitung

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