General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Tools
  1
• 1.2 Lock carrier - add-on parts
  2
• 1.3 Service position
  3
• 1.4 Removing and installing lock carrier with attachments
  5
• 1.5 Pressure hose with plug-in connector
  6
• 2 Wings
  8
• 2.1 Tools
  8
• 2.2 Front wing
  8
• 2.3 Insulation and foam elements for wing, web plate and A-pillar
  12
• 2.4 Removing and installing wing bracket
  12
• 3 Plenum chamber bulkhead
  14
• 3.1 Tools
  14
• 3.2 Assembly overview - plenum chamber bulkhead
  14
• 4 Plenum chamber cover
  15
• 4.1 Plenum chamber cover
  15
• 5 Noise insulation
  19
• 5.1 Tools
  19
• 5.2 Assembly overview - noise insulation
  19
• 6 Underbody cladding
  20
• 6.1 Tools
  20
• 6.2 Assembly overview - underbody cladding
  20
• 7 Bulkhead
  22
• 7.1 Tools
  22
• 7.2 Materials
  23
• 7.3 Assembly overview - bulkhead
  23
• 8 Tunnel cross-piece
  24
• 8.1 Tools
  24
• 8.2 Assembly overview - tunnel cross-piece
  24
• Bonnet, rear lid
  26
• 1 Bonnet (hood)
  26
• 1.1 Tools
  26
• 1.2 Assembly overview - bonnet
  26
• 1.3 Removing and installing bonnet
  28
• 1.4 Removing and installing bonnet hinge
  30
• 1.5 Removing and installing insulation
  32
• 1.6 Assembly overview - seals
  34
• 1.7 Removing gas strut
  35
• 1.8 Assembly overview - bonnet lock and release components
  38
• 1.9 Removing and installing lid lock - LHD vehicle
  39
• 1.10 Removing and installing lid lock - RHD vehicle
  41
• 1.11 Detaching Bowden cable
  43
• 1.12 Adjusting bonnet
  44
• 1.13 Removing and installing striker pin
  46
• 1.14 Adjusting striker pin
  47
• 1.15 Removing and installing release lever
  48
• 2 Rear lid
  50
• 2.1 Tools
  50
• 2.2 Assembly overview - rear lid
  50
• 2.3 Removing and installing rear lid
  52
• 2.4 Assembly overview - gas strut
  54
• 2.5 Removing gas strut
  54
• 2.6 Releasing gas from gas strut
  56
• 2.7 Assembly overview - rear lid hinge
  56
• 2.8 Removing and installing rear lid hinge
  58
• 2.9 Removing and installing striker pin
  60
• 2.10 Removing and installing stop buffer
  61
• 2.11 Adjusting rear lid
  62
• 2.12 Removing and installing bonnet lock
  65
• 2.13 Removing and installing release element
  68
• 2.14 Removing and installing release element with reversing camera
  70
• 2.15 Assembly overview - Bowden cable for manual release mechanism, LHD vehicles
  72
• 2.16 Assembly overview - emergency release cable RHD
  73
• 2.17 Opening and closing anti-theft protection using emergency release cable
  74
• 2.18 Rear lid seal
  75
• 2.19 Removing and installing rear lid seal
  76
• 3 Tank flap unit
  78
• 3.1 Assembly overview - tank flap unit and actuator
  78
• 3.2 Removing and installing tank flap unit
  79
• 3.3 Removing and installing actuator
  81
• Front doors, door components, central locking
  83
• 1 Rear door
  83
• 1.1 Tools
  83
• 1.2 Assembly overview - door hinges
  84
• 1.3 Greasing new door hinges
  86
• 1.4 Removing and installing door
  87
• 1.5 Door alignment
  89
• 2 Door components
  92
• 2.1 Tools
  92
• 2.2 Assembly overview - front door
  93
• 2.3 Removing and installing cover
  94
• 2.4 Assembly overview - door handle and door lock
  96
• 2.5 Removing and installing lock cylinder cover cap
  97
• 2.6 Removing and installing lock cylinder
  98
• 2.7 Removing and installing cover cap (without lock cylinder)
  100
• 2.8 Removing and installing door handle
  102
• 2.9 Removing and installing door lock
  104
• 2.10 Removing and installing door handle bracket
  106
• 2.11 Removing and installing outer window slot seal
  108
• 2.12 Removing and installing inner door seal
  109
• 2.13 Removing and installing outer door seal
  112
• 2.14 Assembly overview - insulation
  113
• 3 Central locking
  114
• 3.1 Fitting location overview - central locking components
  114
• 3.2 Adapting keys with remote control
  115
• 3.3 Assembly overview - battery for folding key with remote control
  116
• 3.4 Removing and installing battery for folding key with remote control
  117
• Convertible roof, hardtop, canopy
  120
• 1 Convertible roof
  120
• 1.1 Assembly overview - convertible roof
  120
• 1.2 Removing convertible roof
  121
• 1.3 Installing convertible roof
  125
• 1.4 Adjusting top
  127
• 1.5 Convertible roof frame - component designation
  128
• 1.6 Removing headliner
  128
• 1.7 Installing headliner
  133
• 1.8 Removing convertible roof cover
  140
• 1.9 Installing convertible roof cover
  152
• 1.10 Removing and installing tensioning belt with bracket
  164
• 1.11 Adjusting tensioning belt
  166
• 1.12 Repairing tensioning cords
  166
• 1.13 Removing and installing tensioning bar
  168
• 1.14 Windscreen frame seal
  169
• 1.15 Convertible roof locking mechanism
  173
• 1.16 Removing and installing front bow trim
  179
• 1.17 Seals on convertible roof frame
  180
• 1.18 Assembly overview - water trap moulding
  186
• 1.19 Removing and installing water deflector
  188
• 1.20 Removing and installing convertible roof rest
  189
• 1.21 Removing and installing convertible roof rest stop buffer
  190
• 2 Hydraulic system
  191
• 2.1 Safety information
  191
• 2.2 Rules for cleanliness
  191
• 2.3 Filling and bleeding the hydraulic system
  192
• 2.4 Assembly overview - hydraulic system
  194
• 2.5 Removing hydraulic cylinder
  194
• 2.6 Installing hydraulic cylinder
  197
• 2.7 Assembly overview - hydraulic pump
  199
• 2.8 Removing hydraulic pump
  200
• 2.9 Installing hydraulic pump
  202
• 2.10 Removing and installing pump motor
  204
• 2.11 Removing and installing oil reservoir
  205
• 3 Electrical and electronic components
  207
• 3.1 Overview of fitting locations - electrical and electronic components
  207
• 3.5 Removing and installing convertible roof actuation control unit J256
  212
• Bumpers
  213
• 1 Front bumper cover
  213
• 1.1 Assembly overview - front bumper cover
  213
• 1.2 Assembly overview - front bumper cover, add-on parts
  217
• 1.3 Assembly overview - front bumper carrier
  221
• 1.4 Assembly overview - side guide
  223
• 1.5 Removing and installing front bumper cover
  223
• 1.6 Removing and installing front bumper cover, GTI
  227
• 1.7 Removing and installing front spoiler, GTI
  230
• 1.8 Removing and installing assembly parts
  231
• 1.9 Number plate carrier
  233
• 1.10 Installing brackets for parking aid system
  236
• 1.11 Repairing front bumper cover
  241
• 2 Rear bumper cover
  242
• 2.1 Assembly overview - rear bumper cover
  242
• 2.2 Assembly overview - rear bumper cover, add-on parts
  244
• 2.3 Assembly overview - rear bumper cover, substructure parts
  247
• 2.4 Assembly overview - rear bumper carrier
  248
• 2.5 Assembly overview - towing bracket
  249
• 2.6 Removing and installing rear bumper cover
  249
• 2.7 Installing number plate carrier
  252
• 2.8 Installing brackets for parking aid system
  253
• 2.9 Repairing rear bumper cover
  259
• 2.10 Add-on element, rear bumper cover
  259
• Glazing
  264
• 1 Flush bonded windows
  264
• 1.1 Tools
  264
• 1.2 Materials
  265
• 1.3 Assembly overview - windscreen
  266
• 1.4 Removing windscreen
  267
• 1.5 Installing windscreen
  269
• 1.6 Assembly overview - rear window
  269
• 1.7 Preparing old undamaged window for glazing
  270
• 1.8 Preparing new window for glazing
  271
• 1.9 Preparing body flange for glazing
  272
• 1.10 Fitting instructions
  273
• 1.11 Minimum curing period
  273
• 1.12 Touching up paint damage
  274
• 1.13 Cleaning in the event of dirt caused by adhesive sealant
  274
• 2 Front door window
  275
• 2.1 Tools
  275
• 2.2 Removing and installing door window
  276
• 2.3 Adjusting door window
  280
• 2.4 Removing and installing window regulator motor
  285
• 2.5 Installing and removing window regulators
  287
• 2.6 Removing and installing window channel
  289
• 3 Rear side window
  291
• 3.1 Tools
  291
• 3.2 Assembly overview - side window
  291
• 3.3 Removing side window
  292
• 3.4 Installing side window
  294
• 3.5 Adjusting side window
  294
• 3.6 Removing and installing seal
  300
• 3.7 Assembly overview - window regulator
  301
• 3.8 Removing window lifters
  302
• 3.9 Installing window lifters
  304
• 3.10 Removing side window from window regulator
  305
• 3.11 Installing side window on window regulator
  306
• 3.12 Removing and installing cover for window regulator motor
  306
• 3.13 Removing and installing window regulator motor
  311
• 3.14 Assembly overview - inner and outer window slot seal
  314
• 3.15 Removing and installing inner window slot seal
  315
• 3.16 Removing and installing outer window slot seals
  317
• 3.17 Assembly overview - intermediate plate
  319
• Exterior equipment
  320
• 1 Wheel housing liner
  320
• 1.1 Tools
  320
• 1.2 Front wheel housing liner
  320
• 1.3 Rear wheel housing liner
  323
• 2 Exterior mirror
  327
• 2.1 Tools
  327
• 2.2 Assembly overview - exterior mirror
  327
• 2.3 Removing and installing mirror glass
  328
• 2.4 Removing and installing adjustment unit with motor
  331
• 2.5 Removing and installing mirror frame
  332
• 2.6 Removing and installing mirror housing
  333
• 2.7 Removing and installing side turn signal and entry light in exterior mirror
  334
• 2.8 Removing and installing exterior mirror
  336
• 3 Radiator grille
  338
• 3.1 Tools
  338
• 3.2 Removing and installing radiator grille
  338
• 4 Spoiler
  341
• 4.1 Repair instructions
  341
• 4.2 Assembly overview - spoiler
  343
• 4.3 Removing and installing spoiler
  344
• 5 Mouldings and trims
  347
• 5.1 Tools
  347
• 5.2 Water deflector
  348
• 5.3 Trim strips on window slot seal
  352
• 5.4 Side member cover
  355
• 5.5 Side member extension »GTI«
  358
• 5.6 Side member extension
  364
• 5.7 Wheel arch trim, »R«
  370
• 5.8 Removing and installing cover strip
  371
• 6 Heat shields, underbody
  373
• 6.1 Assembly overview - heat shields, tunnel
  373
• 6.2 Assembly overview - heat shields at centre and at rear
  374
• 7 Lettering and emblems
  375
• 7.1 Tools
  375
• 7.2 Fitting instructions
  375
• 7.3 Rear lettering - dimensions
  375
• 7.4 Removing and installing »R« emblem on radiator grille
  379
• 8 Special add-on parts
  380
• 8.1 Assembly overview – special add-on parts
  380