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 Skid plate
  21
• 6.1 Tools
  21
• 6.2 Assembly overview - skid plate
  21
• 7 Underbody cladding
  23
• 7.1 Tools
  23
• 7.2 Assembly overview - underbody cladding in the middle
  23
• 7.3 Assembly overview - rear underbody cladding
  25
• 8 Bulkhead
  26
• 8.1 Tools
  26
• 8.2 Materials
  27
• 8.3 Assembly overview - bulkhead
  27
• 9 Tunnel cross-piece
  28
• 9.1 Tools
  28
• 9.2 Assembly overview - tunnel cross-piece
  28
• Bonnet, rear lid
  30
• 1 Bonnet
  30
• 1.1 Tools
  30
• 1.2 Assembly overview - bonnet
  30
• 1.3 Removing and installing bonnet
  32
• 1.4 Removing and installing bonnet hinge
  34
• 1.5 Removing and installing insulation
  36
• 1.6 Assembly overview - seals
  38
• 1.7 Removing gas strut
  39
• 1.8 Assembly overview - bonnet lock and release components
  42
• 1.9 Removing and installing lid lock - LHD vehicle
  43
• 1.10 Removing and installing lid lock - RHD vehicle
  45
• 1.11 Detaching Bowden cable
  47
• 1.12 Adjusting bonnet
  48
• 1.13 Removing and installing striker pin
  50
• 1.14 Adjusting striker pin
  51
• 1.15 Removing and installing release lever
  52
• 2 Rear lid
  54
• 2.1 Tools
  54
• 2.2 Assembly overview - rear lid
  54
• 2.3 Removing and installing rear lid
  56
• 2.4 Assembly overview - gas strut
  59
• 2.5 Removing gas strut
  59
• 2.6 Releasing gas from gas strut
  61
• 2.7 Assembly overview - rear lid hinge
  61
• 2.8 Removing and installing rear lid hinge
  63
• 2.9 Removing and installing striker pin
  65
• 2.10 Removing and installing stop buffer
  66
• 2.11 Adjusting rear lid
  67
• 2.12 Removing and installing rear lid lock
  70
• 2.13 Removing and installing release element
  72
• 2.14 Removing and installing release element with reversing camera system
  74
• 2.15 Rear lid seal
  75
• 2.16 Removing and installing rear lid seal
  76
• 3 Tank flap unit
  78
• 3.1 Tools
  78
• 3.2 Assembly overview - tank flap unit and actuator
  78
• 3.3 Removing and installing tank flap unit
  80
• 3.4 Removing and installing actuator
  82
• Front doors, door components, central locking
  84
• 1 Rear door
  84
• 1.1 Tools
  84
• 1.2 Assembly overview - door hinges
  85
• 1.3 Greasing new door hinges
  87
• 1.4 Removing and installing door
  88
• 1.5 Door alignment
  89
• 2 Door components
  94
• 2.1 Tools
  94
• 2.2 Assembly overview - front door
  95
• 2.3 Removing and installing subframe
  96
• 2.4 Removing and installing cover, 2-door model
  102
• 2.5 Assembly overview - door handle and door lock
  104
• 2.6 Removing and installing lock cylinder cover cap
  105
• 2.7 Removing and installing lock cylinder
  106
• 2.8 Removing and installing cover cap (without lock cylinder)
  108
• 2.9 Removing and installing door handle
  110
• 2.10 Removing and installing door lock
  112
• 2.11 Removing and installing mounting bracket
  114
• 2.12 Removing and installing trim
  114
• 2.13 Removing and installing inner window slot seal
  116
• 2.14 Removing and installing outer window slot seal
  117
• 2.15 Removing and installing inner door seal
  118
• 2.16 Removing and installing door outer seal, 2-door model
  120
• 2.17 Removing and installing door outer seal, 4-door model
  121
• 2.18 Assembly overview - insulation (2-door model)
  123
• 2.19 Assembly overview - insulation (4-door model)
  124
• 3 Central locking
  125
• 3.1 Fitting location overview - central locking components
  125
• 3.2 Adapting keys with remote control
  126
• 3.3 Assembly overview - battery for folding key with remote control
  127
• 3.4 Removing and installing battery for folding key with remote control
  128
• Rear doors, door components
  130
• 1 Rear door
  130
• 1.1 Tools
  130
• 1.2 Assembly overview - door hinges
  131
• 1.3 Greasing new door hinges
  133
• 1.4 Removing and installing door
  134
• 1.5 Door alignment
  135
• 2 Door components
  140
• 2.1 Tools
  140
• 2.2 Assembly overview - rear door
  141
• 2.3 Removing and installing subframe
  142
• 2.4 Assembly overview - door handle and door lock
  148
• 2.5 Removing and installing cap
  148
• 2.6 Removing and installing door handle
  151
• 2.7 Removing and installing door lock
  153
• 2.8 Removing and installing mounting bracket
  155
• 2.9 Removing and installing trim
  157
• 2.10 Removing and installing inner window slot seal
  159
• 2.11 Removing and installing outer window slot seal
  159
• 2.12 Removing and installing inner door seal
  160
• 2.13 Removing and installing outer door seal
  162
• 2.14 Assembly overview - insulation
  164
• Sunroof
  165
• 1 Sliding/tilting sunroof with glass panel (Meritor)
  165
• 1.1 Tools
  165
• 1.2 Function
  166
• 1.3 Assembly overview - sliding/tilting sunroof with glass panel
  166
• 1.4 Removing and installing bellows
  169
• 1.5 Removing sliding/tilting sunroof glass panel
  170
• 1.6 Installing sliding/tilting sunroof glass panel
  171
• 1.7 Adjusting height of sliding/tilting sunroof glass panel
  171
• 1.8 Adjusting panel seal
  172
• 1.9 Renewing panel seal
  173
• 1.10 Removing and installing wind deflector
  173
• 1.11 Removing and installing sliding headliner
  174
• 1.12 Removing and installing sliding/tilting sunroof glass panel drive
  175
• 1.13 Adjusting drive for sliding/tilting sunroof glass panel ("0" position)
  176
• 1.14 Removing and installing sliding/tilting sunroof glass panel automatic preselection switch
  177
• 1.15 Checking parallel running
  177
• 1.16 Adjusting parallel running
  177
• 1.17 Assembly overview - carrier unit
  178
• 1.18 Removing and installing carrier unit
  179
• 1.19 Operating without current
  181
• 1.20 Removing and installing guide plate
  181
• 1.21 Removing and installing guide plate
  182
• 1.22 Cleaning water drain hoses
  183
• Bumpers
  186
• 1 Front bumper cover
  186
• 1.1 Tools
  186
• 1.2 Repairing front bumper cover
  186
• 1.3 Installing brackets for parking aid system
  186
• 1.4 Front bumper cover
  191
• 1.5 Front bumper cover - GTI, GTD
  197
• 1.6 Front bumper cover - »R«
  205
• 1.7 Front bumper cover - »R-Line«
  210
• 1.8 Front bumper carrier
  215
• 1.9 Assembly overview - side guide
  217
• 2 Rear bumper cover
  218
• 2.1 Tools
  218
• 2.2 Repairing rear bumper cover
  218
• 2.3 Installing brackets for parking aid system
  218
• 2.4 Rear bumper cover
  223
• 2.5 Rear bumper cover - GTI, GTD
  227
• 2.6 Rear bumper cover »R«
  231
• 2.7 Rear bumper cover - »R-Line«
  235
• 2.8 Installing number plate carrier
  239
• 2.9 Rear bumper cover substructure parts
  240
• 2.10 Rear bumper carrier
  241
• 2.11 Assembly overview - towing bracket
  243
• Glazing
  244
• 1 Flush bonded windows
  244
• 1.1 Tools
  244
• 1.2 Materials
  245
• 1.3 Assembly overview - windscreen
  246
• 1.4 Removing windscreen
  247
• 1.5 Installing windscreen
  249
• 1.6 Assembly overview - rear window
  249
• 1.7 Removing undamaged rear window
  251
• 1.8 Removing broken rear window
  252
• 1.9 Installing rear window
  252
• 1.10 Assembly overview - side window
  252
• 1.11 Removing undamaged side window
  253
• 1.12 Removing broken side window
  254
• 1.13 Installing side window
  254
• 1.14 Preparing old undamaged window for glazing
  255
• 1.15 Preparing new window without precoating for glazing
  256
• 1.16 Preparing body flange for glazing
  257
• 1.17 Fitting instructions
  259
• 1.18 Minimum curing period
  259
• 1.19 Touching up paint damage
  259
• 1.20 Cleaning in the event of dirt caused by adhesive sealant
  259
• 2 Front door window
  261
• 2.1 Tools
  261
• 2.2 Removing and installing door window
  262
• 2.3 Removing and installing window regulator motor
  266
• 2.4 Removing and installing window channel
  268
• 3 Rear door window
  270
• 3.1 Tools
  270
• 3.2 Removing and installing door window
  270
• 3.3 Removing and installing window regulator motor
  273
• 3.4 Removing and installing window crank
  276
• 3.5 Removing and installing window channel
  276
• 3.6 Removing and installing fixed door-window
  279
• Exterior equipment
  282
• 1 Wheel housing liner
  282
• 1.1 Tools
  282
• 1.2 Front wheel housing liner
  282
• 1.3 Rear wheel housing liner
  285
• 2 Exterior mirror
  289
• 2.1 Tools
  289
• 2.2 Assembly overview - exterior mirror
  289
• 2.3 Removing and installing mirror glass
  290
• 2.4 Removing and installing adjustment unit with motor
  293
• 2.5 Removing and installing frame
  294
• 2.6 Removing and installing mirror housing
  295
• 2.7 Removing and installing side turn signal and entry light in exterior mirror
  296
• 2.8 Removing and installing exterior mirror
  298
• 3 Radiator grille
  300
• 3.1 Tools
  300
• 3.2 Removing and installing radiator grille
  300
• 4 Mouldings and trims
  303
• 4.1 Tools
  303
• 4.2 Water deflector
  303
• 4.3 Side member cover
  307
• 4.4 Stone-chip protection trim
  310
• 4.5 Side member extension »GTI« and »GTD«
  314
• 4.6 Side member extension »GTI Edition 35«, »R« and »R Line«
  320
• 4.7 Cover strip
  326
• 4.8 Wheel arch trim
  328
• 5 Roof spoiler
  330
• 5.1 Tools
  330
• 5.2 Materials
  330
• 5.3 Assembly overview - roof spoiler
  331
• 5.4 Removing and installing roof spoiler
  332
• 5.5 Retaining strip
  335
• 5.6 Preparing body component for bonding
  336
• 5.7 Fitting instructions
  337
• 5.8 Minimum curing period
  337
• 5.9 Touching up paint damage
  338
• 5.10 Cleaning in the event of dirt caused by adhesive sealant
  338
• 6 Special add-on parts
  339
• 6.1 Assembly overview - special add-on parts, »R« and »R-Line«
  339
• 7 Lettering and emblems
  340
• 7.1 Tools
  340
• 7.2 Fitting instructions
  340
• 7.3 »R« emblem on radiator grille
  340
• 7.4 Rear lettering - dimensions
  342
• 7.5 Dimensions - lettering and emblems on sides
  345
• 8 Vermin repellent system
  348
• 8.1 Assembly overview - vermin repellent system
  348