General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Body - front end
  1
• 1.1 Front end with complementary parts - assembly overview
  1
• 1.2 Front end with complementary parts - remove and install
  2
• 1.3 Front end - service position
  3
• 1.4 Front wing - assembly overview
  4
• 2 Bulkhead
  7
• 2.1 Tools
  7
• 2.2 Auxiliary materials for Brazilian market
  7
• 2.3 Auxiliary materials for export market
  8
• 2.4 Matching table
  8
• 2.5 Engine compartment partition panel - assembly overview
  9
• 2.6 Minimum adhesive drying time
  9
• 3 Engine compartment upper partition panel
  10
• 3.1 Engine compartment upper partition panel - assembly overview
  10
• Bonnet, rear lid
  11
• 1 Bonnet
  11
• 1.1 Bonnet - assembly overview
  11
• 1.2 Operating cable - assembly overview
  12
• 1.3 Operating cable - remove and install
  13
• 1.4 Front bonnet latch and stop - assembly overview
  13
• 1.5 Bonnet - adjust
  14
• 1.6 Bonnet latch - remove and install
  15
• 1.7 Bonnet hinge - remove and install
  16
• 1.8 Bonnet striker - remove and install
  17
• 2 Rear lid (Fox)
  19
• 2.1 Rear lid - assembly overview
  19
• 2.2 Rear door shock absorber - remove and install
  21
• 2.3 Rear door shock absorber - replace
  21
• 2.4 Rear lid trim - remove and install
  21
• 2.5 Rear lid - remove and install
  23
• 2.6 Rear lid hinge - remove and install
  23
• 2.7 Rear lid - adjust
  24
• 2.8 Rear lid lock - remove and install
  25
• 2.9 Rear lid unlocking motor V139 - remove and install
  26
• 2.10 Latch cylinder - assembly overview
  28
• 2.11 Latch cylinder - remove and install
  29
• 2.12 Latch cylinder - disassemble
  29
• 3 Rear lid (Spacefox / Suran)
  30
• 3.1 Rear lid - assembly overview
  30
• 3.2 Rear door shock absorber - remove and install
  31
• 3.3 Rear door shock absorber - replace
  32
• 3.4 Rear lid trim - remove and install
  32
• 3.5 Rear lid - remove and install
  32
• 3.6 Rear lid hinge - remove and install
  33
• 3.7 Rear lid - adjust
  34
• 3.8 Rear lid lock - remove and install
  34
• 3.9 Rear lid unlocking motor V139 (version 1) - remove and install
  34
• 3.10 Rear lid unlocking motor V139 (version 2) - remove and install
  35
• 3.11 Lock cylinder - assembly overview
  35
• 3.12 Latch cylinder - remove and install
  36
• 3.13 Latch cylinder - disassemble
  37
• 3.14 Bonnet latch handle - remove and install
  37
• 3.15 Fastening of the rear license plate - install
  38
• 4 Fuel reservoir nozzle compartment and lid set
  39
• 4.1 Fuel tank nozzle compartment and lid set - remove and install
  39
• Front doors, door components, central locking
  40
• 1 Front door
  40
• 1.1 Front door - assembly overview
  40
• 1.2 Front door - remove and install
  41
• 1.3 Front door - adjust
  42
• 1.4 Front door - disassemble and assemble
  44
• 1.5 Front door - replace
  44
• 1.6 Door arrester - adjust
  45
• 1.7 Door limiter - remove and install
  45
• 1.8 Front door external handle and lock - Assembly overview
  46
• 1.9 Lock cylinder housing - remove and install
  48
• 1.10 Cylinder housing - disassemble and assemble
  49
• 1.11 Cylinders and keys (Specific information for Brazil) - request
  51
• 1.12 External door handle - remove and install
  51
• 1.13 External door handle - replace
  52
• 1.14 Door lock - remove and install
  53
• 1.15 Lock button (locking rod) - remove and install
  54
• 1.16 Lock Bowden cable - replace
  55
• 1.17 Door sealing membrane - remove and install
  55
• 1.18 Door sealing packings - Assembly overview
  57
• 1.19 External door packing - remove and install
  59
• 1.20 Internal door trim - remove and install
  60
• 1.21 Cylinders and keys (Specific information for Brazil) - request
  61
• 2 Central locking
  62
• 2.1 Central locking installation location overview - 2-door Fox
  62
• 2.2 Central locking installation location overview - 4-door Fox
  63
• 2.3 Central locking - Spacefox / Suran - assembly locations overview
  65
• 2.5 Battery of key with radio remote command (articulated) - assembly overview
  67
• 2.6 Battery of key with radio remote command (articulated) - remove and install
  68
• 2.8 Key - synchronize
  71
• Rear doors, door components
  72
• 1 Rear passenger doors
  72
• 1.1 Rear passenger doors - assembly overview
  72
• 1.2 Rear passenger door - remove and install
  73
• 1.3 Rear passenger door - adjust
  74
• 1.4 Rear passenger door - disassemble and assemble
  76
• 1.5 Rear door - replace
  76
• 1.6 Door arrester - adjust
  76
• 1.7 Door limiter - remove and install
  77
• 1.8 Rear door external handle and lock - assembly overview
  78
• 1.9 Cylinder housing without lock cylinder - remove and install
  79
• 1.10 External door handle - remove and install
  80
• 1.11 External door handle - replace
  81
• 1.12 Rear door lock - remove and install
  82
• 1.13 Lock Bowden cable - replace
  84
• 1.14 Lock button (locking rod) - remove and install
  84
• 1.15 Door sealing membrane - remove and install
  85
• 1.16 Door sealing packings - assembly overview
  87
• 1.17 External door packing - remove and install
  88
• 1.18 Internal door trim - remove and install
  90
• Sunroof
  92
• 1 Sliding / tilting sunroof (Fox)
  92
• 1.1 Operation
  92
• 1.2 Sliding/tilting sunroof with glass lid - assembly overview
  92
• 1.3 Sliding/tilting sunroof glass lid - remove
  94
• 1.4 Glass lid for sliding/tilting sunroof - install
  94
• 1.5 Glass lid for sliding/tilting sunroof (height adjustment) - adjust
  95
• 1.6 Lid trim - replace
  96
• 1.7 Air deflector - remove and install
  97
• 1.8 Sunroof lining - remove and install
  97
• 1.9 Sliding sunroof movement control unit J245 - remove and install
  98
• 1.10 Sliding/tilting sunroof selector key - remove and install
  99
• 1.11 Sliding sunroof activation motor V1 - remove and install
  99
• 1.12 Sliding sunroof motor V1 (zero position) - adjust
  100
• 1.13 Sliding sunroof activation motor V1 - program
  100
• 1.14 Parallelism - check
  101
• 1.15 Parallelism - adjust
  101
• 1.16 Sliding guide - remove and install
  102
• 1.17 Sunroof - remove and install
  102
• 1.18 Guide with steel cable - remove and install
  103
• 1.19 Drain hoses - clean
  104
• Bumpers
  106
• 1 Front bumper
  106
• 1.1 Front protector - assembly overview
  106
• 1.2 Front bumper protector - remove and install
  106
• 1.3 Front protector support - assembly overview
  107
• 1.4 Fastening of the front license number holder - install
  108
• 2 Rear bumper (Fox / Crossfox)
  110
• 2.1 Rear protector - assembly overview
  110
• 2.2 Rear protector (Crossfox) - assembly overview
  111
• 2.3 Rear protector (Fox) - remove and install
  111
• 2.4 Rear protector (Crossfox) - remove and install
  112
• 2.5 Rear protector support (Fox) - remove and install
  113
• 2.6 Rear protector support (Crossfox) - remove and install
  114
• 2.7 Fastening of the rear license plate - install
  116
• 3 Rear bumper (Spacefox / Suran)
  118
• 3.1 Rear bumper - assembly overview
  118
• 3.2 Rear protector - remove and install
  119
• 3.3 Rear bumper (Space Cross / Suran Cross) - assembly overview
  119
• 3.4 Rear protector (Space Cross / Suran Cross) - remove and install
  121
• 3.5 Rear protector support - assembly overview
  121
• Glazing
  123
• 1 Glasses glued with adhesive
  123
• 1.1 Tools
  123
• 1.2 Auxiliary materials for Brazilian market
  124
• 1.3 Auxiliary materials for export market
  125
• 1.4 Matching table
  125
• 1.5 Stickers for engraving the VIS number on the windows (only for Brazil) - supply
  126
• 1.6 Windscreen - Assembly overview
  126
• 1.7 Windscreen - remove and install
  127
• 1.8 Side glasses (Fox - 2-door) - assembly overview
  128
• 1.9 Undamaged side glass (Fox - 2-door) - remove
  129
• 1.10 Damaged side glass (Fox - 2-door) - remove
  130
• 1.11 Side glass internal trim (Fox - 2-door) - install
  130
• 1.12 Side glass (Fox - 2-door) - install
  131
• 1.13 Side glass (Spacefox / Suran) - assembly overview
  131
• 1.14 Undamaged side glass (Spacefox / Suran) - remove
  133
• 1.15 Damaged side glass (Spacefox / Suran) - remove
  133
• 1.16 Side glass (Spacefox / Suran) - install
  133
• 1.17 Rear window (Fox) - assembly overview
  134
• 1.18 Undamaged rear window (Fox) - remove
  134
• 1.19 Damaged rear window (Fox) - remove
  135
• 1.20 Rear window (Fox) - install
  136
• 1.21 Rear glass (Spacefox / Suran) - assembly overview
  136
• 1.22 Undamaged rear glass (Spacefox / Suran) - remove
  136
• 1.23 Damaged rear glass (Spacefox / Suran) - remove
  138
• 1.24 Undamaged glass - prepare for install
  139
• 1.25 New glass - prepare for install
  139
• 1.26 Body flange - prepare to install the window
  140
• 1.27 Assembly instructions
  141
• 1.28 Minimum adhesive drying time
  142
• 1.29 Paint damage - repair
  143
• 1.30 Cleaning in case of resulting adhesive residues
  144
• 1.31 Data stickers
  144
• 2 Door window glass
  146
• 2.1 Front door window glass (2-door) - assembly overview
  146
• 2.2 Front door window glass (4-door) - Assembly overview
  147
• 2.3 Front door window glass - remove and install
  147
• 2.5 Electrical window drive mechanism - remove and install
  151
• 2.6 Window drive motor - remove and install
  151
• 2.7 Front door window winder - remove and install
  152
• 2.8 Front door window channel - remove and install
  153
• 2.9 Front door window internal trim - remove and install
  153
• 2.10 Front door window external trim - replace
  153
• 2.11 Rear door window glass - assembly overview
  153
• 2.12 Rear door window glass - remove and install
  155
• 2.13 Rear door window power activation mechanism - remove and install
  155
• 2.14 Rear door window drive motor - remove and install
  156
• 2.15 Rear door window drive mechanism - remove and install
  156
• 2.16 Door window activation crank - remove and install
  157
• 2.17 Rear door glass rear guide rail - remove and install
  158
• 2.18 Rear door window channel - remove and install
  158
• 2.19 Rear door window internal trim - remove and install
  158
• 2.20 Rear door window external trim - replace
  159
• 2.21 Rear door fixed glass - replace
  159
• Exterior equipment
  160
• 1 Materials used and operational care required
  160
• 1.1 Auxiliary materials for Brazilian market
  160
• 1.2 Auxiliary materials for export market
  160
• 1.3 Matching table
  161
• 1.4 Paint damage - repair
  161
• 1.6 Minimum adhesive drying time
  162
• 2 Spoiler
  163
• 2.1 Roof spoiler (Fox) - Assembly overview
  163
• 2.2 Spoiler (Spacefox / Suran) - remove and install
  169
• 2.3 Assembly overview
  170
• 2.5 Remove
  171
• 2.6 Install
  173
• 3 Roof Rack
  177
• 3.1 Roof rack (Crossfox) - Assembly overview
  177
• 3.2 Roof rack (Crossfox) - remove and install
  177
• 3.3 Roof rack fastening support (Crossfox) - Assembly overview
  178
• 3.4 Roof rack fastening support (Crossfox) - replace
  179
• 3.5 Roof rack (Spacefox / Suran) - remove and install
  181
• 3.6 Roof rack fastening support (Spacefox / Suran) - Assembly overview
  185
• 3.7 Roof rack fastening support (Spacefox / Suran) - replace
  185
• 4 Inscriptions
  187
• 4.1 Volkswagen Badge - replace
  187
• 4.2 Model lettering (Fox) - replace
  188
• 4.3 Version lettering (Fox) - replace
  189
• 4.4 Version lettering (Fox - iMotion) - replace
  190
• 4.5 “Total Flex” badge - replace
  190
• 4.6 Version lettering (Bluemotion) - replace
  191
• 4.7 “Spacefox / Suran” lettering on rear lid - replace
  192
• 4.8 “1.6” lettering on rear lid (Spacefox / Suran) - replace
  193
• 4.9 Version lettering (Spacefox / Suran - Imotion) - replace
  194
• 4.10 Badge “Rock in Rio” (Gol Rock in Rio MY 12 ►) - replace
  195
• 4.11 Badge “Rock in Rio” (Gol Rock in Rio MY 14 ►) - replace
  196
• 4.12 “Brazilian Soccer Team” Badge (Fox Seleção MY 14 ►) - remove and install
  198
• 4.13 “Brazilian Flag” Badge (Fox Seleção MY 14 ►) - remove and install
  199
• 4.14 Model lettering (Fox) - replace
  200
• 4.15 Model lettering (Crossfox) - replace
  201
• 4.16 “Fox-shape” badge on door (Crossfox) - replace
  202
• 4.17 “Silverfox” (Fox BlackFox) lettering on rear lid - replace
  203
• 4.18 “BlackFox” (Fox BlackFox) Badge on rear door - replace
  203
• 4.19 “VW Tag” (Rear window - Fox Seleção MY 14 ►) - remove and install
  204
• 4.20 Side badge (Trend) - replace
  205
• 4.21 Side lettering - “Silverfox”, side (Fox Silverfox) - replace
  206
• 4.22 Side badge - BlackFox version (Fox BlackFox) - replace
  207
• 4.23 Side version lettering “ITREND” - replace
  208
• 4.26 Decorative strip on the front and rear door (Fox Rock in Rio MY 12 ►) - replace
  210
• 4.27 Decorative strip on the front and rear door (Fox Rock in Rio MY 14 ►) - replace
  212
• 4.28 Decorative strip on the rear door (Fox Rock in Rio MY 12 ►) - replace
  213
• 4.29 Decorative strip on the rear door (Fox Rock in Rio MY 14 ►) - replace
  215
• 4.30 Decorative stripe on bumper rear protector (Fox) - replace
  217
• 4.31 Side badge (Crossfox) - replace
  219
• 5 Side footboard (Crossfox)
  222
• 5.1 Rear side panel trim (Crossfox and Space Cross / Suran Cross) - replace
  222
• 5.2 Front wing trim (Crossfox and Space Cross / Suran Cross) - replace
  224
• 5.3 Side footboard (CrossFox and Space Cross / Suran Cross)- Assembly overview
  225
• 5.5 Side footboard (Crossfox) - replace
  226
• 5.7 Rear footboard lining (Crossfox and Space Cross / Suran Cross) - replace
  231
• 5.8 Upper footboard lining (Crossfox and Space Cross / Suran Cross) - replace
  232
• 6 External rear-view mirror
  233
• 6.1 External rear-view mirror - assembly overview
  233
• 6.2 Exterior rear-view mirror - remove and install
  234
• 6.3 Mirror covering - remove
  234
• 6.4 Mirror glass - remove and install
  235
• 7 Side trims
  236
• 7.1 Side trims (Fox - 2-door) - replace
  236
• 7.2 Side trims - replace
  238
• 7.3 Side trims (Fox Prime) - replace
  240
• 7.4 Side trims - replace
  242
• 7.5 Door trims (Space Cross / Suran Cross) - Assembly overview
  244
• 7.6 Front door trim (Space Cross / Suran Cross) - replace
  246
• 7.7 Rear door trim (Space Cross / Suran Cross and Crossfox 2013►) - replace
  251
• 8 Front grid
  257
• 8.1 Front bonnet - remove and install
  257
• 8.2 Front grid (Bluemotion) - remove and install
  258
• 8.3 Radiator grille (Crossfox and Space Cross / Suran Cross) - remove and install . . .
  261
• 9 Wheel arch protector
  263
• 9.1 Front wheel arch protector - remove and install
  263
• 9.2 Rear wheel arch protector (Fox) - remove and install
  264
• 9.3 Rear wheel arch protector (Spacefox / Suran) - remove and install
  265
• 10 External linings
  266
• 10.1 Lower windscreen covering - Assembly overview
  266
• 10.2 Windscreen lower trim - remove and install
  266
• 10.3 Floor lower lining - assembly overview
  267
• 10.4 Lower longitudinal member external lining - replace
  268
• 10.5 Pillar and door external lining - replace
  269
• 11 Spoiler grids and bumper protector trims
  272
• 11.1 Front protector grilles - assembly overview
  272
• 11.3 Rear protector trim, spoiler (Crossfox) - assembly overview
  275
• 12 Spare wheel support (CrossFox)
  278
• 12.1 Spare wheel support - remove and install
  278
• 12.2 Spare wheel support internal lining - remove and install
  278
• 12.3 Spare wheel support external lining - remove and install
  279
• 12.4 Knob internal lining - remove and install
  280
• 12.5 Puller external lining - remove and install
  281
• 12.6 Spare wheel support shock absorber - remove and install
  282
• 12.7 Spare wheel support shock absorber - replace
  282
• 12.8 Spare wheel lock motor V340 - remove and install
  283
• 12.9 Spare wheel latch buffer - remove and install
  284
• 12.10 Spare wheel latch buffer - adjust
  284
• 12.11 Spare wheel support latch - remove and install
  284
• 12.12 Spare wheel support latch - adjust
  285
• 12.13 Spare wheel support bearing - remove and install
  286
• 13 Crossfox components
  287
• 13.1 Assembly overview
  287
• 14 Space Cross / Suran Cross components
  288
• 14.1 Assembly overview
  288