General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Body - front
  1
• 1.1 Tools
  1
• 1.2 Removing and installing lock carrier with attachments
  1
• 1.3 Lock carrier - service position
  3
• 1.4 Assembly overview - front wing
  4
• 1.5 Wing dimensions
  5
• 1.6 Assembly overview - noise insulation (petrol engine)
  6
• 1.7 Assembly overview - noise insulation (diesel engine)
  7
• Bonnet, rear lid
  8
• 1 Bonnet
  8
• 1.1 Assembly overview
  8
• 1.2 Adjusting bonnet
  9
• 1.3 Removing gas strut
  9
• 1.4 Removing and installing Bowden cable
  9
• 1.5 Removing and installing release lever
  11
• 1.6 Assembly overview - bonnet lock
  12
• 1.7 Removing and installing bonnet lock
  12
• 2 Rear lid, Golf
  14
• 2.1 Tools
  14
• 2.2 Assembly overview
  14
• 2.3 Removing gas strut
  16
• 2.4 Releasing gas from gas strut
  16
• 2.5 Adjusting bonnet
  16
• 2.6 Removing and installing rear lid lock
  18
• 2.7 Removing and installing lock cylinder housing
  20
• 3 Rear lid, Bora
  21
• 3.1 Tools
  21
• 3.2 Assembly overview
  21
• 3.3 Removing and installing rear lid lock
  23
• 3.4 Removing and installing lock cylinder housing
  24
• 3.5 Removing and installing microswitch
  25
• 4 Rear lid, estate
  27
• 4.1 Assembly overview
  27
• 4.2 Removing and installing rear lid lock
  28
• 4.3 Removing and installing lock cylinder housing
  29
• 4.4 Removing and installing microswitch
  30
• 5 Tank flap unit
  32
• 5.1 Removing and installing tank flap unit (Golf)
  32
• 5.2 Removing and installing tank flap unit (Bora)
  33
• Front doors, door components, central locking
  34
• 1 Front door
  34
• 1.1 Tools
  34
• 1.2 Assembly overview
  35
• 1.3 Removing and installing door
  37
• 1.4 Adjusting door
  38
• 1.5 Assembly overview - door handle and door lock
  38
• 1.6 Removing and installing lock cylinder housing
  39
• 1.7 Removing and installing door handle
  40
• 1.8 Removing and installing door lock
  42
• 1.9 Removing and installing locking button for locking rod
  46
• 1.10 Door seals
  48
• 1.11 Removing and installing additional seal
  50
• 2 Central locking
  53
• 2.1 Assembly overview for central locking and convenience system
  53
• 2.5 Adapting keys with remote control
  60
• Rear doors, door components
  61
• 1 Rear door
  61
• 1.1 Tools
  61
• 1.2 Assembly overview
  62
• 1.3 Removing and installing door
  63
• 1.4 Adjusting door
  63
• 1.5 Assembly overview - door handle and door lock
  64
• 1.6 Removing and installing door handle
  65
• 1.7 Removing and installing door lock
  67
• 1.8 Fitting door window to window regulator
  73
• 1.9 Door seals
  73
• Sunroof
  76
• 1 Sliding/tilting sunroof
  76
• 1.1 Tools
  76
• 1.2 General
  76
• 1.3 Function
  76
• 2 Sliding/tilting sunroof with glass panel (Webasto)
  79
• 2.1 Assembly overview - sliding/tilting sunroof with glass panel
  79
• 2.2 Removing sliding/tilting sunroof glass panel
  80
• 2.3 Installing glass panel for sliding/tilting sunroof
  81
• 2.4 Adjusting glass panel for sliding/tilting sunroof (height adjustment)
  82
• 2.5 Renewing panel seal
  84
• 2.6 Removing wind deflector
  84
• 2.7 Removing sliding headlining
  85
• 2.8 Removing drive mechanism for sliding/tilting sunroof
  85
• 2.9 Adjusting drive mechanism for sliding/tilting sunroof (zero position)
  86
• 2.10 Removing pre-selector control for sliding/tilting sunroof
  87
• 2.11 Checking parallel running
  87
• 2.12 Adjusting parallel running
  88
• 2.13 Removing and installing carrier unit
  88
• 2.14 Removing coulisse guide rail
  90
• 2.15 Cleaning water drain hoses
  90
• 3 Sliding/tilting sunroof with glass panel (Meritor)
  93
• 3.1 Assembly overview - sliding/tilting sunroof with glass panel
  93
• 3.2 Removing sliding/tilting sunroof glass panel
  94
• 3.3 Installing glass panel for sliding/tilting sunroof
  95
• 3.4 Adjusting glass panel for sliding/tilting sunroof (height adjustment)
  96
• 3.5 Adjusting panel seal
  98
• 3.6 Renewing panel seal
  98
• 3.7 Removing wind deflector
  99
• 3.8 Removing sliding headlining
  99
• 3.9 Removing drive mechanism for sliding/tilting sunroof
  100
• 3.10 Adjusting drive mechanism for sliding/tilting sunroof (zero position)
  100
• 3.11 Removing pre-selector control for sliding/tilting sunroof
  101
• 3.12 Checking parallel running
  101
• 3.13 Adjusting parallel running
  101
• 3.14 Removing and installing carrier unit
  102
• 3.15 Removing coulisse guide rail
  103
• 3.16 Cleaning water drain hoses
  104
• Bumpers
  106
• 1 Front bumper
  106
• 1.1 Assembly overview - bumper cover
  106
• 1.2 Removing and installing bumper cover
  107
• 1.3 Removing release lever
  108
• 1.4 Assembly overview - bumper carrier
  108
• 1.5 Assembly overview - bumper cover, Golf R32
  109
• 1.6 Removing and installing bumper cover, Golf R32
  110
• 1.7 Removing and installing adapter, Golf R32
  111
• 1.8 Assembly overview - centre air intake and air guide, Golf R32
  112
• 1.9 Assembly overview - bumper carrier, Golf R32
  112
• 2 Rear bumper
  113
• 2.1 Assembly overview - bumper cover
  113
• 2.2 Removing and installing bumper cover
  114
• 2.3 Assembly overview - bumper carrier
  115
• 2.4 Assembly overview - towing bracket
  116
• 2.5 Removing and installing towing bracket
  117
• 2.6 Assembly overview - bumper cover, Golf R32
  118
• 2.7 Removing and installing bumper cover, Golf R32
  119
• 2.8 Removing and installing adapter, Golf R32
  120
• 2.9 Assembly overview - bumper carrier, R32
  121
• Glazing
  122
• 1 Flush bonded windows
  122
• 1.1 Tools
  122
• 1.2 Materials
  124
• 1.3 Assembly overview - windscreen
  124
• 1.4 Removing and installing plenum chamber cover
  125
• 1.5 Removing windscreen
  127
• 1.6 Installing windscreen
  129
• 1.7 Assembly overview - side window, Golf
  129
• 1.8 Removing undamaged side window
  130
• 1.9 Removing damaged side window
  131
• 1.10 Installing side window
  131
• 1.11 Assembly overview - side window, estate
  131
• 1.12 Removing undamaged side window
  132
• 1.13 Removing damaged side window
  133
• 1.14 Installing side window
  133
• 1.15 Assembly overview - rear window, Golf
  133
• 1.16 Removing undamaged rear window
  134
• 1.17 Removing damaged rear window
  135
• 1.18 Installing rear window
  136
• 1.19 Assembly overview - rear window, Bora
  136
• 1.20 Removing undamaged rear window
  137
• 1.21 Removing damaged rear window
  138
• 1.22 Installing rear window
  138
• 1.23 Preparing undamaged window for glazing
  139
• 1.24 Preparing new window for glazing
  139
• 1.25 Preparing new window without precoating for glazing
  140
• 1.26 Preparing body flange for glazing
  141
• 1.27 Installation instructions
  142
• 1.28 Minimum curing time
  142
• 1.29 Touching up paint damage
  143
• 1.30 Cleaning off excess adhesive sealing material
  143
• 2 Door window
  144
• 2.1 Tools
  144
• 2.2 Assembly overview - front door window
  145
• 2.3 Removing front door window
  145
• 2.4 Adjusting door window
  146
• 2.5 Removing and installing assembly carrier
  146
• 2.6 Assembly overview - rear door window
  150
• 2.8 Fitting door window to window regulator
  158
• 2.10 Overriding resistance in event of force limitation intervention
  160
• 2.11 Removing and installing window regulator motor or assembly carrier with window regulator
  161
• 2.12 Assembly overview - assembly carrier with window regulator
  162
• 2.13 Repairing window regulator
  163
• Exterior equipment
  168
• 1 Removing and installing wheel housing liner
  168
• 1.1 Front wheel housing liner
  168
• 1.2 Rear wheel housing liner
  169
• 2 Exterior mirror
  170
• 2.1 Tools
  170
• 2.2 Assembly overview
  170
• 2.3 Removing mirror housing
  171
• 2.4 Removing exterior mirror (mechanical type)
  171
• 3 Roof mouldings
  173
• 3.1 Roof moulding
  173
• 4 Roof rail
  174
• 4.1 Assembly overview
  174
• 4.2 Installing retaining bracket
  174
• 5 Trim
  176
• 5.1 Removing and installing radiator grille
  176
• 6 Bump strips
  178
• 6.1 Renewing side bump strips
  178
• 7 Special body parts, Golf GTI (132 kW) and Golf R32
  179
• 7.1 Safety requirements
  179
• 7.2 Tools
  179
• 7.3 Materials
  179
• 7.4 Assembly overview
  180
• 7.5 Front and rear spoiler (Golf GTI)
  180
• 7.6 Side skirt (Golf GTI, Golf R32)
  182
• 7.7 Roof spoiler (Golf GTI, Golf R32)
  186
• 7.8 Preparing body kit component for bonding
  188
• 7.9 Installation instructions
  189
• 7.10 Minimum curing time
  189
• 7.11 Touching up paint damage
  189
• 7.12 Cleaning off excess adhesive sealing material
  190