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
  2
• 1.4 Removing and installing lock carrier with attachments
  4
• 2 Wings
  6
• 2.1 Tools
  6
• 2.2 Assembly overview - front wing
  6
• 2.3 Removing and installing wing
  7
• 2.4 Removing and installing wing bracket
  8
• 3 Noise insulation
  10
• 3.1 Tools
  10
• 3.2 Assembly overview - noise insulation
  10
• 4 Underbody cladding
  12
• 4.1 Tools
  12
• 4.2 Assembly overview - underbody cladding
  12
• 4.3 Assembly overview - rear underbody cladding
  14
• 5 Plenum chamber bulkhead
  15
• 5.1 Tools
  15
• 5.2 Assembly overview - plenum chamber bulkhead
  15
• Bonnet, rear lid
  16
• 1 Bonnet
  16
• 1.1 Tools
  16
• 1.2 Assembly overview - bonnet
  16
• 1.3 Removing and installing bonnet
  17
• 1.4 Removing gas strut
  19
• 1.5 Releasing gas from gas strut
  19
• 1.6 Removing and installing bonnet hinge
  19
• 1.7 Removing and installing insulation
  20
• 1.8 Assembly overview - bonnet latch and release components
  23
• 1.9 Removing and installing bonnet lock
  23
• 1.10 Detaching Bowden cable
  24
• 1.11 Adjusting bonnet
  25
• 1.12 Removing and installing release lever
  27
• 2 Rear lid (saloon)
  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
  32
• 2.5 Releasing gas from gas strut
  33
• 2.6 Removing and installing bonnet hinge
  33
• 2.7 Removing and installing striker plate
  34
• 2.8 Adjusting rear lid
  34
• 2.9 Assembly overview - lid lock and lock cylinder carrier
  35
• 2.10 Removing and installing lock cylinder
  36
• 2.11 Removing and installing handle trim
  37
• 2.12 Removing and installing bonnet lock
  37
• 2.13 Rear lid seal
  38
• 2.14 Removing and installing rear lid seal
  39
• 3 Rear lid (Variant)
  40
• 3.1 Tools
  40
• 3.2 Assembly overview - rear lid
  40
• 3.3 Removing and installing rear lid
  41
• 3.4 Removing and installing gas strut
  42
• 3.5 Releasing gas from gas strut
  43
• 3.6 Removing and installing rear lid hinge
  43
• 3.7 Adjusting rear lid
  44
• 3.8 Removing and installing release button
  48
• 3.9 Removing and installing bonnet lock
  49
• 3.10 Rear lid seal
  51
• 3.11 Removing and installing rear lid seal
  52
• 3.12 Number plate carrier
  54
• 4 Fuel tank flap unit (saloon)
  55
• 4.1 Assembly overview - tank flap unit
  55
• 4.2 Removing and installing tank flap unit
  55
• 4.3 Removing and installing tank filler flap locking motor V155
  57
• 5 Fuel tank flap unit (Variant)
  59
• 5.1 Assembly overview - tank flap unit
  59
• 5.2 Removing and installing tank flap unit
  59
• 5.3 Removing and installing tank filler flap locking motor V155
  61
• Front doors, door components, central locking
  64
• 1 Rear door
  64
• 1.1 Tools
  64
• 1.2 Materials
  65
• 1.3 Assembly overview - door assembly
  66
• 1.4 Assembly overview - door hinges
  68
• 1.5 Removing and installing door
  69
• 1.6 Adjusting door
  71
• 1.7 Removing and installing outer panel on door
  73
• 1.8 Installing new outer panel on door
  77
• 1.9 Removing and installing retaining rail on outer door panel
  81
• 1.10 Installation notes for bonding a new outer panel on door
  83
• 1.11 Minimum curing period
  83
• 1.12 Cleaning in the event of dirt caused by adhesive sealant
  84
• 1.13 Assembly overview - door inner part
  84
• 1.14 Assembly overview - door handle and door lock
  86
• 1.15 Removing and installing housing
  87
• 1.16 Removing and installing door handle
  87
• 1.17 Removing and installing door handle bracket
  90
• 1.18 Removing and installing door lock
  91
• 1.19 Assembly overview - side impact protection
  93
• 1.20 Inner door seal
  93
• 1.21 Removing and installing inner door seal
  94
• 1.22 Removing and installing outer door seal
  95
• 2 Central locking
  99
• 2.1 Fitting location overview - central locking components
  99
• 2.2 Adapting keys with remote control
  101
• 2.3 Assembly overview - battery for folding key with remote control
  101
• 2.4 Removing and installing battery for folding key with remote control
  102
• Rear doors, door components
  103
• 1 Rear door (saloon)
  103
• 1.1 Tools
  103
• 1.2 Materials
  104
• 1.3 Assembly overview - door assembly
  105
• 1.4 Assembly overview - door hinges
  106
• 1.5 Removing and installing door
  108
• 1.6 Adjusting door
  110
• 1.7 Removing and installing outer panel on door
  112
• 1.8 Installing new outer panel on door
  115
• 1.9 Removing and installing retaining rail on outer door panel
  119
• 1.10 Installation notes for bonding a new outer panel on door
  121
• 1.11 Minimum curing period
  121
• 1.12 Cleaning in the event of dirt caused by adhesive sealant
  122
• 1.13 Assembly overview - door inner part
  122
• 1.14 Assembly overview - door handle and door lock
  124
• 1.15 Removing and installing housing
  124
• 1.16 Removing and installing door handle
  125
• 1.17 Removing mounting bracket
  128
• 1.18 Removing and installing door lock
  129
• 1.19 Assembly overview - side impact protection
  130
• 1.20 Door inner seals
  131
• 1.21 Removing and installing inner door seal
  132
• 1.22 Removing and installing outer door seal
  133
• 2 Rear door (Variant)
  137
• 2.1 Tools
  137
• 2.2 Assembly overview - rear door
  138
• 2.3 Assembly overview - door hinges
  138
• 2.4 Removing and installing door
  140
• 2.5 Adjusting door
  142
• 2.6 Assembly overview - assembly carrier
  144
• 2.7 Removing and installing subframe
  145
• 2.8 Assembly overview - door handle and door lock
  149
• 2.9 Removing and installing housing
  150
• 2.10 Removing and installing door handle
  150
• 2.11 Removing and installing door handle bracket
  153
• 2.12 Removing and installing door lock
  154
• 2.13 Door inner seals
  154
• 2.14 Removing and installing inner door seal
  155
• 2.15 Removing and installing outer door seal
  156
• Sunroof
  160
• 1 Sliding/tilting sunroof with glass panel (Meritor)
  160
• 1.1 Tools
  160
• 1.2 Function
  160
• 1.3 Assembly overview - sliding/tilting sunroof with glass panel
  161
• 1.4 Removing and installing boot
  163
• 1.5 Removing and installing sliding/tilting sunroof glass panel
  165
• 1.6 Adjusting height of sliding/tilting sunroof glass panel
  166
• 1.7 Adjusting panel seal
  167
• 1.8 Renew panel seal
  168
• 1.9 Removing and installing wind deflector
  168
• 1.10 Removing and installing sliding headliner
  169
• 1.11 Removing and installing sliding/tilting sunroof glass panel drive
  170
• 1.12 Adjusting drive for sliding/tilting sunroof glass panel ("0" position)
  171
• 1.13 Removing and installing sliding/tilting sunroof glass panel automatic preselection switch
  171
• 1.14 Checking parallel running
  171
• 1.15 Adjusting parallel running
  172
• 1.16 Assembly overview - carrier unit
  172
• 1.17 Removing and installing carrier unit
  173
• 1.18 Operating without current
  175
• 1.19 Removing and installing guide plate
  176
• 1.20 Removing and installing guide plate
  177
• 1.21 Cleaning water drainage hoses
  178
• 2 Panorama sliding sunroof (Arvin-Meritor)
  180
• 2.1 Tools
  180
• 2.2 Function
  180
• 2.3 Establishing reference points of panorama sliding roof
  181
• 2.4 Assembly overview - panorama sliding roof
  182
• 2.5 Removing and installing front glass panel
  183
• 2.6 Removing and installing rear glass panel
  185
• 2.7 Adjusting height of front and rear glass panel
  186
• 2.8 Renewing seals for rear glass panel
  188
• 2.9 Renewing outer seal
  189
• 2.10 Renewing inner seal
  191
• 2.11 Removing and installing wind deflector
  191
• 2.12 Removing and installing wind deflector bracket
  193
• 2.13 Removing and installing preselector for glass panel and sunroof sun blind
  194
• 2.14 Removing and installing sliding sunroof motor
  194
• 2.15 Removing and installing sun blind motor
  196
• 2.16 Removing and installing sun blind
  197
• 2.17 Assembly overview - assembly frame
  201
• 2.18 Installing and removing motor plate and sun blind cable
  202
• 2.19 Removing and installing assembly frame
  205
• 2.20 Removing and installing rear part
  208
• 2.21 Removing and installing front motor plate
  210
• 2.22 Removing and installing tilting mechanism and front glass panel cable
  214
• 2.23 Maintenance and care
  216
• 2.24 Operating without current
  216
• 2.25 Cleaning water drainage hoses
  218
• Bumpers
  221
• 1 Bumper, front
  221
• 1.1 Tools
  221
• 1.2 Repairing bumper cover
  221
• 1.3 Installing parking aid holder
  221
• 1.4 Assembly overview - bumper cover
  228
• 1.5 Removing and installing front bumper cover
  228
• 1.6 Front bumper cover add-on parts
  230
• 1.7 Front bumper cover substructure parts
  231
• 1.8 Assembly overview - bumper carrier
  233
• 1.9 Installing small registration plate carrier
  233
• 2 Front bumper, Cup Edition
  234
• 2.1 Front bumper cover
  234
• 3 Rear bumper (saloon)
  241
• 3.1 Tools
  241
• 3.2 Repairing bumper cover
  241
• 3.3 Installing brackets for parking aid system
  241
• 3.4 Assembly overview - bumper cover
  248
• 3.5 Removing and installing bumper cover
  248
• 3.6 Rear bumper cover with add-on parts
  250
• 3.7 Rear bumper cover substructure parts
  251
• 3.8 Assembly overview - bumper carrier
  252
• 4 Rear bumper, saloon, Cup Edition
  253
• 4.1 Rear bumper cover, saloon
  253
• 5 Rear bumper (Variant)
  260
• 5.1 Tools
  260
• 5.2 Repairing bumper cover
  260
• 5.3 Installing brackets for parking aid system
  260
• 5.4 Assembly overview - bumper cover
  267
• 5.5 Removing and installing bumper cover
  267
• 5.6 Rear bumper cover with add-on parts
  270
• 5.7 Rear bumper cover substructure parts
  271
• 5.8 Assembly overview - bumper carrier
  272
• 5.9 Assembly overview - towing bracket
  273
• 5.10 Removing and installing towing bracket
  273
• Glazing
  276
• 1 Flush bonded windows
  276
• 1.1 Tools
  276
• 1.2 Materials
  278
• 1.3 Assembly overview - windscreen
  278
• 1.4 Assembly overview - plenum chamber cover
  280
• 1.5 Removing and installing plenum chamber cover
  280
• 1.6 Removing and installing windscreen
  282
• 1.7 Assembly overview - rear window (saloon)
  283
• 1.8 Removing and installing rear window (saloon)
  284
• 1.9 Assembly overview - rear window (Variant)
  286
• 1.10 Removing and installing rear window (Variant)
  287
• 1.11 Assembly overview - side window (Variant)
  289
• 1.12 Removing undamaged side window (Variant)
  290
• 1.13 Removing broken side window (Variant)
  291
• 1.14 Installing side window (Variant)
  291
• 1.15 Preparing old undamaged window for glazing
  292
• 1.16 Preparing new window for glazing
  292
• 1.17 Touching up paint damage
  293
• 1.18 Preparing body flange for glazing
  293
• 1.19 Fitting instructions
  294
• 1.20 Minimum curing period
  294
• 1.21 Touching up paint damage
  294
• 1.22 Cleaning in the event of dirt caused by adhesive sealant
  295
• 2 Front door windows
  296
• 2.1 Tools
  296
• 2.2 Assembly overview- front door window
  296
• 2.3 Removing and installing door window
  297
• 2.4 Adjusting door window
  299
• 2.5 Assembly overview - window regulator motor
  301
• 2.6 Removing and installing window regulator motor
  301
• 2.7 Assembly overview - window channel
  304
• 2.8 Removing and installing window channel
  304
• 2.9 Removing and installing window channel trim strip
  306
• 2.10 Assembly overview - window regulator
  307
• 2.11 Removing and installing window regulator
  308
• 3 Rear door window (saloon)
  310
• 3.1 Tools
  310
• 3.2 Assembly overview - rear door windows
  311
• 3.3 Removing and installing door window
  311
• 3.4 Assembly overview - door with fixed window with window channel
  313
• 3.5 Removing and installing fixed door window with window channel
  314
• 3.6 Removing and installing window channel trim strip
  317
• 3.7 Assembly overview - window regulator motor
  318
• 3.8 Removing and installing window regulator motor
  319
• 3.9 Assembly overview - window regulator
  322
• 3.10 Removing and installing window regulator
  322
• 4 Rear door window (Variant)
  324
• 4.1 Tools
  324
• 4.2 Assembly overview - rear door window
  324
• 4.3 Removing and installing door window
  325
• 4.4 Removing and installing outer window slot seal
  327
• 4.5 Assembly overview - door with fixed window with window channel
  328
• 4.6 Removing and installing fixed door window with window channel
  328
• 4.7 Removing and installing window channel trim strip
  332
• 4.8 Assembly overview - window regulator motor
  332
• 4.9 Removing and installing window regulator motor
  333
• Exterior equipment
  336
• 1 Wheel housing liner
  336
• 1.1 Tools
  336
• 1.2 Assembly overview - front wheel housing liner
  336
• 1.3 Removing and installing front wheel housing liner
  337
• 1.4 Assembly overview - rear wheel housing liner
  339
• 1.5 Removing and installing rear wheel housing liner
  339
• 1.6 Installing protective cover for wheel housing
  340
• 2 Exterior mirror
  342
• 2.1 Tools
  342
• 2.2 Assembly overview - rear view mirror
  342
• 2.3 Removing and installing mirror glass
  343
• 2.4 Removing and installing mirror housing
  344
• 2.5 Removing and installing trim
  345
• 2.6 Removing and installing side turn signal repeaters
  345
• 2.7 Removing and installing entry light
  346
• 2.8 Removing and installing adjustment unit with motor for rear view mirror
  347
• 2.9 Removing and installing rear view mirror
  347
• 3 Roof railing
  349
• 3.1 Tools
  349
• 3.2 Assembly overview - roof railing
  349
• 3.3 Removing and installing roof railing
  350
• 4 Radiator grille
  352
• 4.1 Tools
  352
• 4.2 Radiator grille
  352
• 4.3 Radiator grille, Cup Edition
  356
• 5 Mouldings and trims
  360
• 5.1 Tools
  360
• 5.2 Removing and installing side panel trim strips on GLI vehicles
  361
• 5.3 Side member extension, Jetta Cup Edition
  362
• 6 Special add-on parts
  367
• 6.1 Safety requirements
  367
• 6.2 Fitting notes for extensions
  367
• 6.3 Materials
  367
• 6.4 Special add-on parts, Jetta Cup Edition
  368
• 6.5 Preparing body component for bonding
  368
• 6.6 Preparing new add-on part for bonding
  369
• 6.7 Fitting instructions
  369
• 6.8 Minimum curing period
  369
• 6.9 Touching up paint damage
  370
• 6.10 Cleaning in the event of dirt caused by adhesive sealant
  370
• 7 Protective backing
  371
• 7.1 Scuff protection film
  371
• 8 Lettering
  373
• 8.1 Tools
  373
• 8.2 Installation instructions for lettering and emblems
  373
• 8.3 Rear lettering dimensions (saloon)
  373
• 8.4 Rear lettering dimensions (Variant)
  375
• 8.5 Side lettering dimensions - Individual
  377