General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Assembly overview – lock carrier
  1
• 1.2 Removing and installing lock carrier
  2
• 1.3 Moving to and back from service position
  7
• 2 Wings
  11
• 2.1 Assembly overview – wing
  11
• 2.2 Removing and installing wing
  15
• 2.3 Removing and installing wing bracket
  19
• 3 Plenum chamber bulkhead
  21
• 3.1 Assembly overview – bulkhead
  21
• 3.2 Assembly overview – plenum chamber cover
  22
• 3.3 Removing and installing plenum chamber cover
  23
• Body - rear
  28
• 1 Rear wing
  28
• 1.1 Assembly overview - rear wing
  28
• 1.2 Removing and installing rear wing
  28
• 1.3 Removing and installing anti-abrasion film
  31
• Bonnet, rear lid
  34
• 1 Bonnet
  34
• 1.1 Assembly overview – bonnet
  34
• 1.2 Assembly overview – Bowden cable
  35
• 1.3 Removing and installing bonnet
  37
• 1.4 Adjusting bonnet
  40
• 1.5 Removing and installing bonnet lock
  42
• 1.6 Removing and installing bonnet lock operating lever
  43
• 1.7 Removing and installing striker pin
  45
• 1.8 Removing and installing hinges
  46
• 1.9 Removing and installing insulation
  48
• 1.10 Removing and installing bonnet seals
  50
• 1.11 Separating and connecting Bowden cable coupling
  51
• 1.12 Removing and installing bonnet stay
  53
• 2 Rear lid
  56
• 2.1 Assembly overview – rear lid
  56
• 2.2 Removing and installing rear lid
  63
• 2.3 Adjusting rear lid
  68
• 2.4 Removing and installing bonnet lock
  81
• 2.5 Removing and installing operating mechanism
  84
• 2.6 Removing and installing striker pin
  86
• 2.7 Removing and installing hinges
  86
• 2.8 Removing and installing rear lid seal
  89
• 2.9 Removing and installing gas strut
  93
• 2.10 Releasing gas from gas strut
  95
• 3 Tank flap unit
  97
• 3.1 Assembly overview – tank flap unit
  97
• 3.2 Removing and installing tank flap unit
  97
• 3.3 Removing and installing actuator
  100
• Front doors, door components, central locking
  102
• 1 Door
  102
• 1.1 Assembly overview – door
  102
• 1.2 Removing and installing door
  104
• 1.3 Adjusting door
  106
• 1.4 Adjusting striker pin
  109
• 1.5 Removing and installing door arrester
  110
• 1.6 Removing and installing inner door seal
  112
• 1.7 Removing and installing outer door seal
  117
• 2 Door components
  120
• 2.1 Assembly overview – door components
  120
• 2.2 Assembly overview – door handle and door lock
  122
• 2.3 Removing and installing window regulator motor
  124
• 2.4 Removing and installing window regulator
  127
• 2.5 Removing and installing inner door cover
  129
• 2.6 Removing and installing striker pin
  131
• 2.7 Removing and installing cap on door handle
  133
• 2.8 Removing and installing lock cylinder
  137
• 2.9 Removing and installing door handle
  139
• 2.10 Removing and installing mounting bracket
  141
• 2.11 Removing and installing door lock
  143
• 2.12 Removing and installing window slot outer seal
  145
• 2.13 Removing and installing outer padding
  146
• 3 Central locking
  149
• 3.1 Overview of fitting locations – central locking system
  149
• 3.2 Assembly overview - ignition key
  153
• 3.3 Removing and installing ignition key battery
  154
• 3.4 Adapting ignition keys to remote control
  155
• Rear doors, door components
  157
• 1 Door components
  157
• 1.1 Removing and installing window regulator
  157
• 1.2 Removing and installing window regulator motor
  163
• Sunroof
  167
• 1 Sliding/tilting sunroof
  167
• 1.1 Assembly overview - panorama sliding/tilting glass roof
  167
• 1.2 Assembly overview – sunroof roller blind
  169
• 1.3 Function description
  171
• 1.4 Adapting sliding sunroof adjustment control unit J245
  171
• 1.5 Closing sunroof by hand
  172
• 1.6 Removing and installing glass panel
  173
• 1.7 Adjusting glass panel
  177
• 1.8 Removing and installing slotted guide
  179
• 1.9 Removing and installing sliding sunroof frame
  182
• 1.10 Removing and installing wind deflector
  192
• 1.11 Removing and installing sliding sunroof adjustment control unit J245
  194
• 1.12 Removing and installing sunroof sun blind cover
  197
• 1.13 Removing and installing transverse reinforcement
  198
• 1.14 Removing and installing sunroof roller blind
  199
• 1.15 Removing and installing interior seal
  203
• 1.16 Removing and installing trim
  206
• 1.17 Removing and installing tension bow
  214
• 2 Water drain hoses
  218
• 2.1 Assembly overview - water drain hoses
  218
• 2.2 Cleaning water drain hoses
  218
• Convertible roof, hardtop, canopy
  221
• 1 Convertible top
  221
• 1.1 Assembly overview - convertible top
  221
• 1.2 Assembly overview - convertible top frame
  223
• 1.3 Assembly overview - stop buffer
  225
• 1.4 Assembly overview - convertible top latch
  225
• 1.5 Assembly overview - control unit, microswitch for convertible top actuation
  226
• 1.6 Assembly overview - windscreen frame seal
  228
• 1.7 Removing and installing front trim
  228
• 1.8 Removing and installing side trim panels
  231
• 1.9 Removing and installing convertible top
  234
• 1.10 Removing and installing convertible roof headliner
  247
• 1.11 Removing and installing convertible top cover
  258
• 1.12 Repairing water trap channel
  277
• 1.13 Removing and installing rear window control link
  278
• 1.14 Removing and installing tensioning cord for convertible top
  280
• 1.15 Repairing tensioning cords
  280
• 1.16 Removing and installing tensioning strap
  281
• 1.17 Removing and installing bolted retaining strips
  284
• 1.18 Removing and installing riveted retaining strip
  286
• 1.19 Removing and installing convertible top motor
  288
• 1.20 Removing and installing toothed segment
  291
• 1.21 Removing and installing convertible top latch
  292
• 1.22 Removing and installing convertible top latch motor
  293
• 1.23 Removing and installing convertible top lock
  295
• 1.24 Removing and installing striker pin
  297
• 1.25 Removing and installing windscreen frame seal
  299
• 1.26 Removing and installing convertible top seals
  303
• 1.27 Removing and installing water drip tray
  303
• 1.28 Checking water drainage from convertible top
  305
• 1.29 Removing and installing retaining plate
  306
• Bumpers
  308
• 1 Bumper, front
  308
• 1.1 Assembly overview – bumper cover
  308
• 1.2 Assembly overview - attachments
  309
• 1.3 Assembly overview - guides and brackets
  311
• 1.4 Assembly overview – bumper carrier
  312
• 1.5 Removing and installing bumper cover
  314
• 1.6 Removing and installing attachments
  317
• 1.7 Repairing bumper cover
  318
• 1.8 Installing holder for parking aid sender
  318
• 1.9 Installing brackets for park assist steering
  323
• 2 Bumper, rear
  328
• 2.1 Assembly overview – bumper cover
  328
• 2.2 Assembly overview - attachments
  329
• 2.3 Assembly overview - guides and brackets
  331
• 2.4 Assembly overview – bumper carrier
  332
• 2.5 Removing and installing bumper cover
  333
• 2.6 Repairing bumper cover
  336
• 2.7 Installing holder for parking aid sender
  336
• 2.8 Installing brackets for park assist steering
  341
• Glazing
  346
• 1 Repair notes
  346
• 1.1 Minimum drying times for bonded windows
  346
• 1.2 Window repair
  346
• 1.3 Installation instructions for bonded windows
  347
• 1.4 Removing broken window
  348
• 1.5 Preparing old undamaged windows for installing
  349
• 1.6 Preparing new windows for installing
  349
• 1.7 Preparing body flange for installing
  350
• 1.8 Cleaning off excess adhesive
  351
• 2 Windscreen
  352
• 2.1 Assembly overview – windscreen
  352
• 2.2 Removing and installing windscreen
  353
• 3 Rear windscreen
  359
• 3.1 Assembly overview – rear window
  359
• 3.2 Removing and installing rear window
  359
• 4 Side windows
  364
• 4.1 Assembly overview - rear side windows
  364
• 4.2 Removing and installing rear side window
  365
• 4.3 Adjusting rear door window
  372
• 5 Door windows
  378
• 5.1 Assembly overview - front door window
  378
• 5.2 Removing and installing front door window
  378
• 5.3 Adjusting front door window
  382
• Exterior equipment
  395
• 1 Radiator grille and front trim
  395
• 1.1 Removing and installing front trim
  395
• 2 Spoiler
  398
• 2.1 Assembly overview – spoiler
  398
• 2.2 Removing and installing spoiler
  399
• 3 Mouldings, trims, extensions
  413
• 3.1 Assembly overview - side member trim, Dune
  413
• 3.2 Assembly overview - trim strip and covers
  414
• 3.3 Removing and installing trim strip
  415
• 3.4 Removing and installing step moulding
  422
• 3.5 Removing and installing retaining strip for side member extension, Dune
  425
• 3.6 Removing and installing side member trim, Dune
  428
• 3.7 Removing and installing wheel arch covers
  432
• 4 Noise insulation
  440
• 4.1 Assembly overview - noise insulation
  440
• 4.2 Removing and installing noise insulation
  443
• 5 Underbody cladding
  447
• 5.1 Assembly overview – underbody cladding
  447
• 5.2 Removing and installing tunnel cross-piece
  448
• 6 Exterior mirror
  450
• 6.1 Assembly overview – exterior mirror
  450
• 6.2 Removing and installing exterior mirror
  452
• 6.3 Removing and installing mirror glass
  455
• 6.4 Removing and installing mirror adjustment unit
  457
• 6.5 Removing and installing mirror frame
  460
• 6.6 Removing and installing mirror cover
  463
• 6.7 Removing and installing assembly bracket
  466
• 7 Wheel housing liner
  468
• 7.1 Assembly overview – front wheel housing liner
  468
• 7.2 Assembly overview – rear wheel housing liner
  469
• 7.3 Removing and installing front wheel housing liner
  470
• 7.4 Removing and installing rear wheel housing liner
  473
• 8 Lettering, emblems and decorative films
  475
• 8.1 Instructions for affixing the lettering
  475
• 8.2 Dimensions - lettering and emblems on rear lid
  476
• 8.3 Dimensions - lettering and emblems on wing
  477
• 8.4 Removing and installing front badge
  482
• 8.5 Instructions for affixing decorative films and protective films
  483
• 8.6 Protective film on rear wing
  485
• 8.7 Decorative film, door and side panel
  486
• 8.8 Decorative films, Beetle »Herbie«
  487
• 9 Special add-on parts
  500
• 9.1 Overview of fitting locations - special add-on parts, Dune
  500