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 add-on parts
  4
• 1.5 Assembly overview - air deflector elements on lock carrier
  6
• 1.6 Removing and installing pressure hoses
  7
• 2 Wing
  9
• 2.1 Tools
  9
• 2.2 Assembly overview - front wing
  9
• 2.3 Removing and installing wing
  10
• 2.4 Removing and installing wing bracket
  12
• 3 Noise insulation
  14
• 3.1 Tools
  14
• 3.2 Assembly overview - noise insulation (long version)
  14
• 3.3 Assembly overview - noise insulation (short version)
  16
• 4 Underbody cladding
  17
• 4.1 Tools
  17
• 4.2 Assembly overview - underbody cladding
  17
• 4.3 Assembly overview - additional underbody covers (BlueMotion vehicles)
  19
• 5 Fuel tank covers (natural gas vehicles)
  20
• 6 Bulkhead
  21
• 6.1 Tools
  21
• 6.2 Materials
  21
• 6.3 Assembly overview - bulkhead
  22
• 7 Tunnel cross-piece
  23
• 7.1 Tools
  23
• 7.2 Assembly overview - tunnel cross-piece
  23
• Bonnet, rear lid
  25
• 1 Bonnet
  25
• 1.1 Tools
  25
• 1.2 Assembly overview - bonnet
  25
• 1.3 Removing and installing bonnet
  27
• 1.4 Removing gas strut
  29
• 1.5 Releasing gas from gas strut
  29
• 1.6 Assembly overview - bonnet hinge
  29
• 1.7 Removing and installing bonnet hinge
  30
• 1.8 Assembly overview - insulation
  33
• 1.9 Removing and installing insulation
  34
• 1.10 Assembly overview - bonnet lock and release components
  36
• 1.11 Removing and installing bonnet lock
  37
• 1.12 Disconnecting Bowden cable
  38
• 1.13 Adjusting bonnet
  38
• 1.14 Removing and installing release lever
  41
• 2 Rear lid (Saloon)
  42
• 2.1 Tools
  42
• 2.2 Assembly overview - rear lid
  42
• 2.3 Removing and installing rear lid
  43
• 2.4 Removing gas strut
  45
• 2.5 Installing gas strut
  46
• 2.6 Releasing gas from gas strut
  47
• 2.7 Assembly overview - rear lid hinge
  47
• 2.8 Removing and installing rear lid hinge
  48
• 2.9 Assembly overview - hinge seal
  51
• 2.10 Removing and installing hinge seal
  52
• 2.11 Removing and installing striker pin
  54
• 2.12 Adjusting rear lid
  54
• 2.13 Assembly overview - release element
  57
• 2.14 Removing and installing release element
  58
• 2.15 Removing and installing lid lock
  60
• 2.16 Rear lid seal
  61
• 2.17 Removing and installing rear lid seal
  62
• 3 Rear lid (Variant)
  64
• 3.1 Tools
  64
• 3.2 Assembly overview - rear lid
  64
• 3.3 Removing and installing rear lid
  65
• 3.4 Removing and installing rear lid hinge
  67
• 3.5 Removing and installing lid lock
  69
• 3.6 Removing and installing striker pin
  71
• 3.9 Adjusting rear lid
  76
• 3.10 Removing and installing gas strut
  80
• 3.11 Releasing gas from gas strut
  80
• 3.12 Removing and installing motor in control unit for electrically operated rear lid
  80
• 3.13 Rear lid seal
  84
• 3.14 Removing and installing rear lid seal
  84
• 3.15 Assembly overview - cover
  87
• 4 Tank flap unit
  88
• 4.1 Tools
  88
• 4.2 Assembly overview - tank flap unit and actuator
  88
• 4.3 Assembly overview - tank flap unit for natural gas vehicles
  90
• 4.4 Removing and installing tank flap unit
  91
• 4.5 Removing and installing actuator
  93
• Front doors, door components, central locking
  94
• 1 Front door
  94
• 1.1 Tools
  94
• 1.2 Assembly overview - front door
  95
• 1.3 Assembly overview - door hinges
  97
• 1.4 Removing and installing door
  98
• 1.5 Adjusting door
  100
• 2 Door components
  102
• 2.1 Tools
  102
• 2.2 Assembly overview - assembly carrier
  103
• 2.3 Removing and installing assembly carrier
  103
• 2.4 Assembly overview - door handle and door lock
  109
• 2.5 Removing and installing lock cylinder housing cover cap
  110
• 2.6 Removing and installing lock cylinder housing
  111
• 2.7 Removing and installing door handle
  112
• 2.8 Removing and installing door handle with access and start authorisation
  113
• 2.9 Removing and installing door lock
  115
• 2.10 Removing and installing bearing bracket
  119
• 2.11 Removing and installing retaining bracket
  122
• 2.12 Door inner seal
  123
• 2.13 Removing and installing door inner seal
  124
• 2.14 Removing and installing door outer seal
  125
• 2.15 Assembly overview - insulation
  129
• 3 Central locking
  130
• 3.1 Fitting location overview - central locking components
  130
• 3.2 Adapting remote control keys to remote control
  132
• 3.3 Adapting remote control keys to immobilizer
  132
• 3.4 Removing and installing remote control key battery
  132
• Rear doors, door components
  135
• 1 Rear door (Saloon)
  135
• 1.1 Tools
  135
• 1.2 Assembly overview - rear door
  136
• 1.3 Assembly overview - door hinges
  138
• 1.4 Removing and installing door
  139
• 1.5 Adjusting door
  141
• 2 Rear door (Variant)
  143
• 2.1 Tools
  143
• 2.2 Assembly overview - rear door
  144
• 2.3 Assembly overview - door hinges
  145
• 2.4 Removing and installing door
  147
• 2.5 Adjusting door
  149
• 3 Door components
  151
• 3.1 Tools
  151
• 3.2 Assembly overview - assembly carrier
  152
• 3.3 Removing and installing assembly carrier
  152
• 3.4 Assembly overview - door handle and door lock
  159
• 3.5 Removing and installing lock cylinder housing cover cap
  160
• 3.6 Removing and installing lock cylinder housing
  161
• 3.7 Removing and installing door handle
  162
• 3.8 Removing and installing door handle with access and start authorisation
  163
• 3.9 Removing and installing door lock
  165
• 3.10 Removing and installing bearing bracket
  168
• 3.11 Removing and installing retaining bracket
  171
• 3.12 Door inner seals
  172
• 3.13 Removing and installing door inner seal
  173
• 3.14 Removing and installing door outer seal
  174
• 3.15 Assembly overview - insulation
  178
• Sunroof
  179
• 1 Sliding/tilting sunroof with glass panel (Meritor)
  179
• 1.1 Tools
  179
• 1.2 Function
  179
• 1.3 Assembly overview - sliding/tilting sunroof with glass panel
  180
• 1.4 Removing and installing boot
  183
• 1.5 Removing sliding/tilting sunroof glass panel
  184
• 1.6 Installing sliding/tilting sunroof glass panel
  185
• 1.7 Adjusting height of sliding/tilting sunroof glass panel
  185
• 1.8 Adjusting panel seal
  186
• 1.9 Removing and installing panel seal
  187
• 1.10 Removing and installing wind deflector
  187
• 1.11 Removing and installing sliding headliner
  188
• 1.12 Removing and installing sliding/tilting sunroof glass panel drive
  189
• 1.13 Adjusting drive for sliding/tilting sunroof glass panel ("0" position)
  190
• 1.14 Removing and installing sliding/tilting sunroof glass panel automatic preselection switch
  191
• 1.15 Checking parallel running
  191
• 1.16 Adjusting parallel running
  191
• 1.17 Assembly overview - carrier unit
  192
• 1.18 Removing and installing carrier unit
  193
• 1.19 Operating without current
  198
• 1.20 Removing and installing guide plate
  198
• 1.21 Removing and installing guide plate
  199
• 1.22 Cleaning water drain hoses
  200
• 2 Sliding/tilting sunroof with solar panel (Webasto)
  204
• 2.1 Tools
  204
• 2.2 Function
  204
• 2.3 Assembly overview - sliding/tilting sunroof with solar panel
  205
• 2.4 Removing sliding/tilting sunroof solar panel
  206
• 2.5 Installing sliding/tilting sunroof solar panel
  207
• 2.6 Adjusting sliding/tilting sunroof solar panel height
  207
• 2.7 Checking parallel running of solar panel
  208
• 2.8 Adjusting parallel running of solar panel
  209
• 2.9 Renewing panel seal
  209
• 2.10 Removing wind deflector
  209
• 2.11 Removing solar panel trim
  210
• 2.12 Removing sliding/tilting sunroof drive
  210
• 2.13 Adjusting drive for sliding/tilting sunroof (zero position)
  211
• 2.14 Removing pre-selector control for sliding/tilting sunroof
  212
• 2.15 Removing electrical contact in solar roof
  212
• 2.17 Removing and installing carrier unit
  213
• 2.18 Operating without current
  217
• 2.19 Cleaning water drain hoses
  218
• Bumpers
  222
• 1 Front bumper cover
  222
• 1.1 Tools
  222
• 1.2 Repairing front bumper cover
  222
• 1.3 Installing bracket for parking aid system
  222
• 1.4 Assembly overview - front bumper cover
  227
• 1.5 Assembly overview - front bumper cover »R36«
  227
• 1.6 Removing and installing front bumper cover
  228
• 1.7 Front bumper cover add-on parts
  230
• 1.8 Add-on parts for front bumper cover »R36«
  231
• 1.9 Front bumper cover substructure parts
  232
• 1.10 Assembly overview - front bumper carrier
  233
• 1.11 Assembly overview - front bumper carrier (USA)
  234
• 1.12 Assembly overview - front bumper bracket »R36« and »R-Line«
  234
• 2 Rear bumper cover (Saloon)
  236
• 2.1 Tools
  236
• 2.2 Repairing rear bumper cover
  236
• 2.3 Installing bracket for parking aid system
  236
• 2.4 Assembly overview - rear bumper cover
  241
• 2.5 Removing and installing rear bumper cover
  242
• 2.6 Rear bumper cover add-on parts
  244
• 2.7 Rear bumper cover substructure parts
  247
• 2.8 Assembly overview - rear bumper carrier
  248
• 2.9 Assembly overview - towing bracket
  249
• 3 Rear bumper cover (Variant)
  251
• 3.1 Tools
  251
• 3.2 Repairing rear bumper cover
  251
• 3.3 Installing bracket for parking aid system
  251
• 3.4 Assembly overview - rear bumper cover
  256
• 3.5 Removing and installing rear bumper cover
  257
• 3.6 Rear bumper cover add-on parts
  259
• 3.7 Rear bumper cover substructure parts
  262
• 3.8 Assembly overview - rear bumper carrier
  263
• 3.9 Assembly overview - towing bracket
  264
• Glazing
  266
• 1 Flush bonded windows
  266
• 1.1 Tools
  266
• 1.2 Materials
  267
• 1.3 Repairing windscreen
  268
• 1.4 Assembly overview - windscreen
  268
• 1.5 Assembly overview - plenum chamber cover
  270
• 1.6 Removing windscreen
  273
• 1.7 Installing windscreen
  275
• 1.8 Assemble overview - rear window (Saloon)
  275
• 1.9 Removing undamaged rear window (Saloon)
  277
• 1.10 Removing broken rear window (Saloon)
  278
• 1.11 Installing rear window (Saloon)
  278
• 1.12 Assembly overview - rear window (Variant)
  278
• 1.13 Removing undamaged rear window (Variant)
  279
• 1.14 Removing broken rear window (Variant)
  280
• 1.15 Installing rear window (Variant)
  281
• 1.16 Assembly overview - side window (Variant)
  281
• 1.17 Removing undamaged side window (Variant)
  282
• 1.18 Removing broken side window (Variant)
  283
• 1.19 Installing side window (Variant)
  283
• 1.20 Preparing old undamaged window for glazing
  284
• 1.21 Preparing new window without precoating for glazing
  284
• 1.22 Preparing body flange for glazing
  285
• 1.23 Installation instructions
  287
• 1.24 Minimum curing period
  289
• 1.25 Touching up paint damage
  290
• 1.26 Cleaning off excess adhesive sealing material
  290
• 2 Front door window
  291
• 2.1 Tools
  291
• 2.2 Assembly overview
  292
• 2.3 Removing and installing door window
  293
• 2.4 Removing and installing window regulator motor
  297
• 2.5 Removing and installing window channel
  298
• 2.6 Removing and installing window channel trim strip
  301
• 3 Rear door window (Saloon)
  303
• 3.1 Tools
  303
• 3.2 Assembly overview
  304
• 3.3 Removing and installing door window
  305
• 3.4 Removing and installing window regulator motor
  309
• 3.5 Removing and installing window channel
  310
• 3.6 Removing and installing window channel trim strip
  312
• 4 Rear door window (Variant)
  314
• 4.1 Tools
  314
• 4.2 Assembly overview
  315
• 4.3 Removing and installing door window
  316
• 4.4 Removing and installing window regulator motor
  321
• 4.5 Removing and installing window channel
  322
• 4.6 Removing and installing guide rails
  323
• 4.7 Removing and installing window channel trim strip
  324
• Exterior equipment
  326
• 1 Wheel housing liner
  326
• 1.1 Tools
  326
• 1.2 Assembly overview - front wheel housing liner
  326
• 1.3 Removing and installing front wheel housing liner
  327
• 1.4 Assembly overview - rear wheel housing liner
  329
• 1.5 Removing and installing rear wheel housing liner
  330
• 2 Exterior mirror
  332
• 2.1 Tools
  332
• 2.2 Assembly overview - exterior mirror
  332
• 2.3 Removing and installing mirror glass
  333
• 2.4 Removing and installing mirror housing
  334
• 2.5 Removing and installing trim
  335
• 2.6 Removing and installing turn signal repeater
  335
• 2.7 Removing and installing exterior mirror
  336
• 3 Radiator grille
  338
• 3.1 Tools
  338
• 3.2 Radiator grille
  338
• 3.3 Radiator grille »R36«
  342
• 3.4 Removing and installing VW emblem
  344
• 3.5 Removing and installing VW emblem on vehicles with adaptive cruise control
  346
• 3.6 Assembly overview - number plate carrier
  347
• 3.7 Removing and installing number plate carrier
  348
• 4 Roof railing
  350
• 4.1 Tools
  350
• 4.2 Assembly overview - roof railing
  350
• 4.3 Removing and installing roof railing
  351
• 4.4 Assembly overview - roof railing retaining bracket
  354
• 4.5 Removing and installing roof railing retaining bracket
  355
• 5 Mouldings and trims
  358
• 5.1 Tools
  358
• 5.2 Assembly overview - water deflector
  359
• 5.3 Removing and installing water deflector
  359
• 5.4 Assembly overview - protective side strip
  362
• 5.5 Removing protective side moulding
  362
• 5.6 Installing protective side moulding
  364
• 5.7 Front and rear door mouldings, vehicles up to 05.2007
  365
• 5.8 Front and rear door mouldings - vehicles from 06.2007
  368
• 5.9 Assembly overview - side member extension
  372
• 5.10 Assembly overview - rear lid trim strip (Variant)
  373
• 5.11 Wheel arch trim
  374
• 5.12 »R-Line« and »Exclusive« cover strip
  376
• 6 Special add-on parts
  378
• 6.1 Safety requirements
  378
• 6.2 Tools
  378
• 6.3 Materials
  380
• 6.4 Special add-on parts for Passat »R36« and »R-Line«
  381
• 6.5 Removing and installing front wheel housing extension
  382
• 6.6 Removing and installing rear wheel housing extension
  385
• 6.7 Assembly overview - side member extension
  387
• 6.8 Roof edge spoiler (Variant)
  388
• 6.9 Rear lid spoiler, Saloon
  392
• 6.10 Fitting notes
  396
• 6.11 Preparing add-on parts for bonding
  396
• 6.12 Preparing new add-on part for bonding
  396
• 6.13 Preparing body kit component for bonding
  397
• 6.14 Installation instructions
  397
• 6.15 Minimum curing period
  398
• 6.16 Touching up paint damage
  398
• 6.17 Cleaning off excess adhesive sealing material
  398
• 6.18 Cleaning guidelines
  398
• 7 Lettering
  399
• 7.1 Tools
  399
• 7.2 Fitting notes
  399
• 7.3 Rear lettering - dimensions
  400
• 7.4 Lettering on wing
  404
• 8 Scuff protection film »R36« and »R-Line«
  409
• 8.1 Scuff protection film at front and rear
  409