General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Tools
  1
• 1.2 Assembly overview - lock carrier, service position
  2
• 1.3 Service position
  3
• 1.4 Removing and installing lock carrier with attachments
  4
• 2 Wing
  7
• 2.1 Tools
  7
• 2.2 Assembly overview - front wing
  7
• 2.3 Removing and installing wing
  8
• 2.4 Removing and installing wing brace
  10
• 3 Noise insulation
  12
• 3.1 Tools
  12
• 3.2 Assembly overview - noise insulation
  12
• 4 Underbody cladding
  14
• 4.1 Tools
  14
• 4.2 Assembly overview - underbody cladding
  14
• 5 Plenum chamber bulkhead
  16
• 5.1 Tools
  16
• 5.2 Assembly overview - plenum chamber bulkhead
  16
• Bonnet, rear lid
  17
• 1 Bonnet
  17
• 1.1 Tools
  17
• 1.2 Assembly overview - bonnet
  17
• 1.3 Removing and installing bonnet
  19
• 1.4 Removing gas strut
  20
• 1.5 Releasing gas from gas strut
  20
• 1.6 Removing and installing lid hinge
  20
• 1.7 Removing and installing insulation
  21
• 1.8 Assembly overview - bonnet latch and release components
  24
• 1.9 Removing and installing bonnet lock
  25
• 1.10 Separating Bowden cable
  26
• 1.11 Adjusting bonnet
  26
• 1.12 Removing and installing release lever
  28
• 2 Rear lid
  29
• 2.1 Tools
  29
• 2.2 Assembly overview - rear lid
  29
• 2.3 Removing and installing rear lid
  30
• 2.4 Removing gas strut
  31
• 2.5 Releasing gas from gas strut
  31
• 2.6 Removing and installing rear lid hinges
  31
• 2.7 Removing and installing striker pin
  34
• 2.8 Adjusting rear lid
  34
• 2.9 Assembly overview - rear lid latch and release components
  36
• 2.10 Removing and installing release element
  37
• 2.11 Removing and installing rear lid lock
  39
• 2.12 Rear lid seal
  39
• 2.13 Removing and installing rear lid seal
  40
• 3 Tank flap unit
  41
• 3.1 Tools
  41
• 3.2 Assembly overview - tank flap unit
  41
• Front doors, door components, central locking
  45
• 1 Front door
  45
• 1.1 Tools
  45
• 1.2 Materials
  46
• 1.3 Assembly overview - door assembly
  46
• 1.4 Assembly overview - door hinges
  49
• 1.5 Removing and installing door
  50
• 1.6 Adjusting door
  52
• 1.7 Removing and installing outer door panel
  55
• 1.8 Installing new outer door panel
  58
• 1.9 Removing and installing retaining rail on outer door panel
  62
• 1.10 Installation instructions for bonding in new outer door panel
  63
• 1.11 Minimum curing period
  64
• 1.12 Cleaning off excess adhesive sealing material
  64
• 1.13 Assembly overview - door inner part
  65
• 1.14 Assembly overview - door handle and door lock
  66
• 1.15 Removing and installing housing
  67
• 1.16 Removing and installing door handle
  68
• 1.17 Removing and installing mounting bracket
  70
• 1.18 Removing and installing door lock
  72
• 1.19 Assembly overview - side impact protection
  74
• 1.20 Door inner seal
  74
• 1.21 Removing and installing door inner seal
  75
• 1.22 Removing and installing door outer seal
  77
• 2 Central locking
  80
• 2.1 Fitting location overview - central locking components
  80
• 2.2 Adapting keys with remote control
  81
• 2.3 Assembly overview - battery for folding key with remote control
  82
• 2.4 Removing and installing battery for folding key with remote control
  83
• Rear doors, door components
  85
• 1 Rear door
  85
• 1.1 Tools
  85
• 1.2 Materials
  86
• 1.3 Assembly overview - door assembly
  86
• 1.4 Assembly overview - door hinges
  89
• 1.5 Removing and installing door
  90
• 1.6 Adjusting door
  92
• 1.7 Removing and installing outer door panel
  95
• 1.8 Installing new outer door panel
  98
• 1.9 Removing and installing retaining rail on outer door panel
  102
• 1.10 Installation instructions for bonding in new outer door panel
  103
• 1.11 Minimum curing period
  104
• 1.12 Cleaning off excess adhesive sealing material
  104
• 1.13 Assembly overview - door inner part
  105
• 1.14 Assembly overview - door handle and door lock
  106
• 1.15 Removing and installing housing
  107
• 1.16 Removing and installing door handle
  107
• 1.17 Removing mounting bracket
  109
• 1.18 Removing and installing door lock
  111
• 1.19 Assembly overview - side impact protection
  112
• 1.20 Door inner seals
  113
• 1.21 Removing and installing door inner seal
  114
• 1.22 Removing and installing door outer seal
  115
• Sunroof
  119
• 1 Sliding/tilting sunroof with glass panel (Meritor)
  119
• 1.1 Tools
  119
• 1.2 Function
  120
• 1.3 Assembly overview - sliding/tilting sunroof with glass panel
  120
• 1.4 Removing and installing boot
  123
• 1.5 Removing sliding/tilting sunroof glass panel
  124
• 1.6 Installing sliding/tilting sunroof glass panel
  125
• 1.7 Adjusting height of sliding/tilting sunroof glass panel
  125
• 1.8 Adjusting panel seal
  126
• 1.9 Renewing panel seal
  127
• 1.10 Removing and installing wind deflector
  127
• 1.11 Removing and installing sliding headliner
  128
• 1.12 Removing and installing sliding/tilting sunroof glass panel drive
  129
• 1.13 Adjusting drive for sliding/tilting sunroof glass panel ("0" position)
  130
• 1.14 Removing and installing sliding/tilting sunroof glass panel automatic preselection switch
  131
• 1.15 Checking parallel running
  131
• 1.16 Adjusting parallel running
  131
• 1.17 Assembly overview - carrier unit
  132
• 1.18 Removing and installing carrier unit
  133
• 1.19 Operating without current
  135
• 1.20 Removing and installing guide plate
  135
• 1.21 Removing and installing guide plate
  136
• 1.22 Cleaning water drain hoses
  137
• Bumpers
  140
• 1 Front bumper
  140
• 1.1 Tools
  140
• 1.2 Repairing bumper cover
  140
• 1.3 Assembly overview - bumper cover
  140
• 1.4 Removing and installing front bumper cover
  141
• 1.5 Front bumper attachments
  143
• 1.6 Front bumper substructure
  144
• 1.7 Assembly overview - bumper carrier
  145
• 1.8 Assembly overview - number plate carrier
  146
• 2 Front bumper for GTI, GTI special models, GT, R32
  147
• 2.1 Tools
  147
• 2.2 Repairing bumper cover
  147
• 2.3 Assembly overview - bumper cover for GTI, GT
  147
• 2.4 Removing and installing front bumper cover for GT, GTI
  148
• 2.5 Front bumper attachments for GT, GTI
  150
• 2.6 Assembly overview - bumper cover for R32
  152
• 2.7 Removing and installing front bumper cover for R32
  152
• 2.8 Front bumper attachments for R32
  154
• 2.9 Assembly overview - front bumper cover for GTI special models
  155
• 2.10 Removing and installing front bumper cover for GTI special models
  155
• 2.11 Front bumper attachments for GTI special models
  157
• 2.12 Front bumper substructure
  158
• 2.13 Assembly overview - bumper carrier
  159
• 3 Rear bumper
  160
• 3.1 Tools
  160
• 3.2 Repairing bumper cover
  160
• 3.3 Assembly overview - bumper cover
  160
• 3.4 Removing and installing bumper cover
  161
• 3.5 Rear bumper attachments
  163
• 3.6 Rear bumper substructure
  164
• 3.7 Assembly overview - bumper carrier
  165
• 3.8 Assembly overview - towing bracket
  165
• 4 Rear bumper for R32 and GTI special models
  167
• 4.1 Tools
  167
• 4.2 Repairing bumper cover
  167
• 4.3 Assembly overview - bumper cover for R32
  167
• 4.4 Removing and installing bumper cover for R32
  168
• 4.5 Rear bumper attachments for R32
  170
• 4.6 Assembly overview - rear bumper cover for GTI special models
  171
• 4.7 Removing and installing rear bumper cover for GTI special models
  171
• 4.8 Rear bumper attachments for GTI special models
  173
• 4.9 Rear bumper substructure
  174
• 4.10 Assembly overview - bumper carrier
  175
• Glazing
  176
• 1 Flush bonded windows
  176
• 1.1 Tools
  176
• 1.2 Materials
  178
• 1.3 Repairing windscreen
  178
• 1.4 Assembly overview - windscreen
  178
• 1.5 Assembly overview - plenum chamber cover
  180
• 1.6 Removing windscreen
  183
• 1.7 Installing windscreen
  183
• 1.8 Assembly overview - rear window
  184
• 1.9 Removing undamaged rear window
  184
• 1.10 Removing broken rear window
  185
• 1.11 Installing rear window
  186
• 1.12 Assembly overview - rear side window
  186
• 1.13 Removing undamaged rear side window
  187
• 1.14 Removing broken rear side window
  188
• 1.15 Installing rear side window
  188
• 1.16 Preparing old undamaged window for glazing
  189
• 1.17 Preparing new window without precoating for glazing
  189
• 1.18 Preparing new window with precoating for glazing
  190
• 1.19 Preparing body flange for glazing
  191
• 1.20 Installation instructions
  192
• 1.21 Minimum curing period
  192
• 1.22 Touching up paint damage
  193
• 1.23 Cleaning off excess adhesive sealing material
  193
• 2 Front door windows
  194
• 2.1 Tools
  194
• 2.2 Assembly overview- front door window
  194
• 2.3 Removing and installing door window
  195
• 2.4 Adjusting door window
  197
• 2.5 Assembly overview - window regulator motor
  199
• 2.6 Removing and installing window regulator motor
  200
• 2.7 Assembly overview - window channel
  202
• 2.8 Removing and installing window channel
  202
• 2.9 Assembly overview - window regulator
  204
• 2.10 Removing and installing window regulator
  204
• 3 Rear door windows
  206
• 3.1 Tools
  206
• 3.2 Assembly overview - rear door windows
  206
• 3.3 Removing and installing door window
  207
• 3.4 Assembly overview - fixed door window with window channel
  209
• 3.5 Removing and installing fixed door window with window channel
  210
• 3.6 Assembly overview - window regulator motor
  213
• 3.7 Removing and installing window regulator motor
  213
• 3.8 Assembly overview - window regulator
  216
• 3.9 Removing and installing window regulator
  216
• Exterior equipment
  218
• 1 Wheel housing liner
  218
• 1.1 Tools
  218
• 1.2 Assembly overview - front wheel housing liner
  218
• 1.3 Removing and installing front wheel housing liner
  219
• 1.4 Assembly overview - rear wheel housing liner
  221
• 1.5 Removing and installing rear wheel housing liner
  221
• 2 Exterior mirror
  223
• 2.1 Tools
  223
• 2.2 Assembly overview - rear view mirror
  223
• 2.3 Removing and installing mirror glass
  224
• 2.4 Removing and installing mirror housing
  225
• 2.5 Removing and installing trim
  227
• 2.6 Removing and installing side turn signal repeaters
  227
• 2.7 Removing and installing rear view mirror
  228
• 3 Radiator grille
  230
• 3.1 Tools
  230
• 3.2 Assembly overview - radiator grille
  230
• 3.3 Removing and installing radiator grille
  231
• 3.4 Assembly overview - radiator grille for GTI, GTI special models and GT
  232
• 3.5 Removing and installing radiator grille for GT, GTI special models and GT
  234
• 3.6 Radiator grille for GTI, GTI special models, GT and R32 - number plate carrier
  236
• 3.7 Assembly overview - radiator grille for R32
  237
• 3.8 Removing and installing radiator grille for R32
  238
• 3.9 R32 radiator grille - company emblem
  240
• 4 Mouldings and trims
  241
• 4.1 Tools
  241
• 4.2 Assembly overview - water deflector
  241
• 4.3 Removing and installing water deflector
  243
• 4.4 Assembly overview - protective side strip
  245
• 4.5 Renewing protective side strips
  246
• 4.6 Removing and installing stone-chip protection trim
  247
• 4.7 Assembly overview - side member extension for GTI, GTI special models and R32
  251
• 4.9 Retaining strip for side member extension
  254
• 5 Roof spoiler
  258
• 5.1 Tools
  258
• 5.2 Materials
  258
• 5.3 Assembly overview - roof spoiler for GTI, GTI special models and R32
  259
• 5.4 Removing and installing roof spoiler for GTI, GTI special models and R32
  260
• 5.5 Retaining strip
  263
• 5.6 Preparing body kit component for bonding
  264
• 5.7 Installation instructions
  265
• 5.8 Minimum curing period
  265
• 5.9 Touching up paint damage
  265
• 5.10 Cleaning off excess adhesive sealing material
  266
• 6 Protective backing
  267
• 6.1 Attachment notes for protective foil
  267
• 6.2 Renewing scuff protection film
  267
• 7 Lettering
  269
• 7.1 Tools
  269
• 7.2 Installation instructions for lettering and emblems
  269
• 7.3 Rear lettering dimensions
  269
• 7.4 Rear lettering dimensions for GTI and R32
  271
• 7.5 Rear lettering dimensions - USA
  273
• 7.6 Dimensions for lettering on side - Volkswagen R GmbH
  274
• 8 Vermin repellent system
  277
• 8.1 Assembly overview - vermin repellent system
  277