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General body repairs, exterior

For Polo A05

Original Volkswagen repair manual


33,78 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

37.194 KB

463 Sites

Detailed technical data

Immediately readable

This repair manual contains: Lock carrier, Wings, Plenum chamber bulkhead, Noise insulation, Underbody cladding, Tunnel cross-piece, Bonnet (hood), Rear lid, Door components, Panorama tilting sunroof, Front bumper cover, Flush bonded windows, Exterior mirror, Mouldings and trims and Special add-on parts. Show more
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Repair manual Polo A05 General body repairs, exterior PDF download has the following content:

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
    4
  • 1.4 Pressure hose with plug-in connector
    8
  • 2 Wings
    9
  • 2.1 Tools
    9
  • 2.2 Front wing
    9
  • 2.3 Insulation and foam elements for wing and web plate
    14
  • 2.4 Removing and installing wing bracket
    15
  • 3 Plenum chamber bulkhead
    16
  • 3.1 Tools
    16
  • 3.2 Assembly overview - plenum chamber bulkhead
    16
  • 4 Plenum chamber cover
    18
  • 4.1 Plenum chamber cover
    18
  • 5 Noise insulation
    22
  • 5.1 Tools
    22
  • 5.2 Assembly overview - diesel noise insulation
    22
  • 5.3 Assembly overview - long noise insulation
    24
  • 5.4 Assembly overview - short noise insulation
    25
  • 6 Underbody cladding
    26
  • 6.1 Tools
    26
  • 6.2 Assembly overview - underbody cladding
    26
  • 7 Bulkhead
    28
  • 7.1 Tools
    28
  • 7.2 Materials
    29
  • 7.3 Assembly overview - bulkhead
    29
  • 8 Tunnel cross-piece
    30
  • 8.1 Tools
    30
  • 8.2 Assembly overview - tunnel cross-piece
    30
  • Bonnet, rear lid
    31
  • 1 Bonnet (hood)
    31
  • 1.1 Tools
    31
  • 1.2 Assembly overview - bonnet
    31
  • 1.3 Removing and installing bonnet
    33
  • 1.4 Removing and installing bonnet hinge
    34
  • 1.5 Removing and installing insulation
    37
  • 1.6 Removing and installing support rod
    39
  • 1.7 Assembly overview - bonnet lock and release components
    40
  • 1.8 Removing and installing lid lock - LHD vehicle
    41
  • 1.9 Removing and installing lid lock - RHD vehicle
    43
  • 1.10 Detaching Bowden cable
    45
  • 1.11 Removing and installing striker pin
    46
  • 1.12 Removing and installing release lever
    47
  • 1.13 Adjusting bonnet
    49
  • 1.14 Adjusting striker pin
    51
  • 2 Rear lid
    52
  • 2.1 Tools
    52
  • 2.2 Assembly overview - rear lid
    52
  • 2.3 Removing and installing rear lid
    54
  • 2.4 Assembly overview - gas strut
    57
  • 2.5 Removing gas strut
    57
  • 2.6 Releasing gas from gas strut
    59
  • 2.7 Assembly overview - rear lid hinge
    59
  • 2.8 Removing and installing rear lid hinge
    61
  • 2.9 Removing and installing striker pin
    63
  • 2.10 Removing and installing stop buffer
    64
  • 2.11 Adjusting rear lid
    65
  • 2.12 Removing and installing bonnet lock
    68
  • 2.13 Removing and installing release element
    70
  • 2.14 Rear lid seal
    71
  • 2.15 Removing and installing rear lid seal
    72
  • 3 Tank flap unit
    74
  • 3.1 Tools
    74
  • 3.2 Assembly overview - tank flap unit and actuator
    74
  • 3.3 Removing and installing tank flap unit
    76
  • 3.4 Removing and installing actuator
    78
  • Front doors, door components, central locking
    80
  • 1 Rear door
    80
  • 1.1 Tools
    80
  • 1.2 Assembly overview - door hinges
    81
  • 1.3 Removing and installing door
    82
  • 1.4 Installing after renewing A-pillar
    85
  • 1.5 Door alignment
    86
  • 2 Door components
    90
  • 2.1 Tools
    90
  • 2.2 Assembly overview - front door (2-door model)
    91
  • 2.3 Assembly overview - front door (4-door model)
    92
  • 2.4 Removing and installing cover (2-door model)
    93
  • 2.5 Removing and installing cover (4-door model)
    95
  • 2.6 Removing and installing door retaining strap
    97
  • 2.7 Removing and installing striker pin
    98
  • 2.8 Assembly overview - door handle and door lock
    98
  • 2.9 Removing and installing lock cylinder cover cap
    99
  • 2.10 Removing and installing lock cylinder
    100
  • 2.11 Removing and installing cover cap (without lock cylinder)
    103
  • 2.12 Removing and installing door handle
    106
  • 2.13 Removing and installing door lock
    108
  • 2.14 Removing and installing mounting bracket
    112
  • 2.15 Removing and installing window slot inner seal
    113
  • 2.16 Removing and installing outer window slot seal (2-door model)
    114
  • 2.17 Removing and installing outer window slot seal (4-door model)
    117
  • 2.18 Removing and installing inner door seal
    118
  • 2.19 Removing and installing door outer seal (2-door model)
    120
  • 2.20 Removing and installing door outer seal (4-door model)
    121
  • 2.21 Assembly overview - insulation (2-door model)
    122
  • 2.22 Assembly overview - insulation (4-door model)
    123
  • 3 Central locking
    124
  • 3.1 Fitting location overview - central locking components
    124
  • 3.2 Adapting keys with remote control
    125
  • 3.3 Assembly overview - battery for folding key with remote control
    126
  • 3.4 Removing and installing battery for folding key with remote control
    127
  • Rear doors, door components
    130
  • 1 Rear door
    130
  • 1.1 Tools
    130
  • 1.2 Assembly overview - door hinges
    131
  • 1.3 Removing and installing door
    132
  • 1.4 Installing after renewing B-pillar
    135
  • 1.5 Door alignment
    136
  • 2 Door components
    140
  • 2.1 Tools
    140
  • 2.2 Assembly overview - rear door
    141
  • 2.3 Removing and installing cover
    142
  • 2.4 Removing and installing door retaining strap
    143
  • 2.5 Removing and installing striker pin
    144
  • 2.6 Assembly overview - door handle and door lock
    144
  • 2.7 Removing and installing cap
    145
  • 2.8 Removing and installing door handle
    148
  • 2.9 Removing and installing door lock
    150
  • 2.10 Removing and installing mounting bracket
    154
  • 2.11 Removing and installing trim
    156
  • 2.12 Removing and installing window slot inner seal
    158
  • 2.13 Removing and installing window slot outer seal
    159
  • 2.14 Removing and installing inner door seal
    160
  • 2.15 Removing and installing outer door seal
    162
  • 2.16 Assembly overview - insulation
    163
  • Sunroof
    164
  • 1 Panorama tilting sunroof
    164
  • 1.1 Tools
    164
  • 1.2 Function
    164
  • 1.3 Panoramic sliding roof normalisation run
    166
  • 1.4 Assembly overview - panorama tilting sunroof
    167
  • 1.5 Removing glass panel for panorama tilting sunroof
    169
  • 1.6 Removing glass panel when drive is defective
    171
  • 1.7 Installing glass panel
    173
  • 1.8 Adjusting glass panel (height adjustment)
    175
  • 1.9 Removing and installing glass panel seal
    176
  • 1.10 Removing and installing cover
    177
  • 1.11 Removing and installing drive for panorama tilting sunroof glass panel
    178
  • 1.12 Removing and installing panorama tilting sunroof switch
    180
  • 1.13 Operating without current
    181
  • 1.14 Removing and installing wind deflector
    182
  • 1.15 Removing and installing interior seal
    184
  • 1.16 Sun blind
    185
  • 1.17 Removing and installing guide rails
    193
  • 1.18 Cleaning water drainage hoses
    196
  • 1.19 Assembly overview – assembly frame and trim
    199
  • 1.20 Removing and installing assembly frame
    200
  • 1.21 Removing and installing trim
    208
  • 1.22 Installing trim panel
    216
  • Bumpers
    218
  • 1 Front bumper cover
    218
  • 1.1 Tools
    218
  • 1.2 Repairing front bumper cover
    218
  • 1.3 Number plate carrier
    219
  • 1.4 Front bumper carrier and lateral guides
    220
  • 2 Front bumper cover, Polo
    221
  • 2.1 Front bumper cover
    221
  • 2.2 Front bumper cover, Polo Blue Motion
    227
  • 2.3 Front bumper cover, Cross Polo
    233
  • 2.4 Front bumper cover, Polo »GTI«
    239
  • 2.5 Front bumper cover, Polo »R-Line«
    246
  • 3 Rear bumper cover
    251
  • 3.1 Tools
    251
  • 3.2 Repairing rear bumper cover
    251
  • 3.3 Installing brackets for parking aid system
    251
  • 3.4 Number plate carrier
    257
  • 3.5 Rear bumper carrier and subassemblies
    258
  • 4 Rear bumper cover, Polo
    259
  • 4.1 Rear bumper cover
    259
  • 4.2 Rear bumper cover, Polo Blue Motion
    262
  • 4.3 Rear bumper cover, Cross Polo
    266
  • 4.4 Rear bumper cover, Polo GTI, Blue GT
    270
  • 4.5 Rear bumper cover - Polo »R-Line«
    273
  • 5 Towing bracket
    278
  • 5.1 Assembly overview - towing bracket
    278
  • Glazing
    279
  • 1 Flush bonded windows
    279
  • 1.1 Tools
    279
  • 1.2 Materials
    280
  • 1.3 Assembly overview - windscreen
    281
  • 1.4 Removing windscreen
    282
  • 1.5 Installing windscreen
    283
  • 1.6 Assembly overview - rear window
    283
  • 1.7 Removing undamaged rear window
    285
  • 1.8 Removing broken rear window
    286
  • 1.9 Installing rear window
    287
  • 1.10 Assembly overview - side window (2-door model)
    287
  • 1.11 Removing undamaged side window (2-door model)
    288
  • 1.12 Assembly overview - side window (4-door model)
    289
  • 1.13 Removing undamaged side window (4-door model)
    291
  • 1.14 Removing broken side window
    292
  • 1.15 Installing side window
    292
  • 1.16 Preparing old undamaged window for glazing
    293
  • 1.17 Preparing new window without precoating for glazing
    293
  • 1.18 Preparing body flange for glazing
    294
  • 1.19 Fitting instructions
    295
  • 1.20 Minimum curing period
    295
  • 1.21 Touching up paint damage
    296
  • 1.22 Cleaning in the event of dirt caused by adhesive sealant
    296
  • 2 Front door window
    297
  • 2.1 Tools
    297
  • 2.2 Assembly overview - front door window
    298
  • 2.3 Removing and installing door window
    298
  • 2.4 Removing and installing window regulator motor
    303
  • 2.5 Installing and removing window regulators
    305
  • 2.6 Removing and installing window channel
    307
  • 3 Rear door window
    310
  • 3.1 Tools
    310
  • 3.2 Assembly overview - rear door window
    311
  • 3.3 Removing and installing door window
    311
  • 3.4 Removing and installing window regulator motor
    315
  • 3.5 Removing and installing manual drive
    317
  • 3.6 Removing and installing window crank
    318
  • 3.7 Installing and removing window regulators
    319
  • 3.8 Removing and installing window channel
    320
  • Exterior equipment
    323
  • 1 Wheel housing liner
    323
  • 1.1 Tools
    323
  • 1.2 Front wheel housing liner
    323
  • 1.3 Rear wheel housing liner
    326
  • 2 Exterior mirror
    331
  • 2.1 Tools
    331
  • 2.2 Assembly overview - exterior mirror
    331
  • 2.3 Removing and installing mirror glass
    332
  • 2.4 Removing and installing adjustment unit with motor
    334
  • 2.5 Removing and installing mirror housing
    335
  • 2.6 Removing and installing trim
    336
  • 2.7 Removing and installing assembly bracket with side turn signal repeater
    337
  • 2.8 Removing and installing exterior mirror (manual operation)
    338
  • 2.9 Removing and installing exterior mirror (electric operation)
    342
  • 3 Radiator grille
    347
  • 3.1 Tools
    347
  • 3.2 Removing and installing radiator grille
    347
  • 3.3 Removing and installing emblem
    350
  • 3.4 Removing and installing emblem on Polo Blue Motion
    354
  • 3.5 Assembly overview - radiator grille, Polo »GTI«
    358
  • 4 Mouldings and trims
    359
  • 4.1 Tool
    359
  • 4.2 Removing and installing A-pillar trim
    359
  • 4.3 B-pillar trim
    361
  • 4.4 Wing trim panel
    364
  • 4.5 Water deflector, Polo Blue Motion, Blue GT
    365
  • 4.6 Removing and installing cover strip
    368
  • 5 Removing and installing roof railing
    370
  • 5.1 Tools
    370
  • 5.2 Roof railing
    370
  • 6 Roof spoiler
    373
  • 6.1 Tools
    373
  • 6.2 Materials
    374
  • 6.3 Roof spoiler, Polo Blue Motion
    374
  • 6.4 Roof spoiler, Polo »GTI«
    383
  • 6.5 Roof spoiler, Polo Blue GT
    388
  • 6.6 Roof spoiler, Polo “WRC”
    392
  • 7 Special add-on parts
    397
  • 7.1 Assembly overview - Polo Blue Motion
    397
  • 7.2 Assembly overview - Cross Polo
    399
  • 7.3 Assembly overview - Polo »GTI«
    400
  • 7.4 Assembly overview - Polo »R-Line«
    401
  • 7.5 Assembly overview - Polo »WRC«
    402
  • 7.6 Safety requirements
    402
  • 7.7 Tools
    403
  • 7.8 Materials
    404
  • 7.9 Side member extension, Polo Blue Motion, Blue GT
    404
  • 7.10 Side member extension, Cross Polo
    411
  • 7.11 Side member extension, Polo »GTI«
    419
  • 7.12 Front wheel housing trim, Cross Polo
    423
  • 7.13 Rear wheel housing trim, Cross Polo
    426
  • 7.14 Front door cover, Cross Polo
    428
  • 7.15 Rear door cover, Cross Polo
    431
  • 7.16 Wheel arch trim, rear door, Cross Polo
    434
  • 7.17 Preparing attachment for bonding
    435
  • 7.18 Preparing body component for bonding
    435
  • 7.19 Fitting instructions
    436
  • 7.20 Minimum curing period
    436
  • 7.21 Touching up paint damage
    437
  • 7.22 Cleaning in the event of dirt caused by adhesive sealant
    437
  • 7.23 Cleaning guidelines
    437
  • 8 Lettering and emblems
    438
  • 8.1 Fitting instructions
    438
  • 8.2 Dimensions - lettering and emblems on rear lid
    439
  • 8.3 Removing and installing emblems
    446
  • 8.4 Side lettering
    448
  • 9 Scuff protection film
    452
  • 9.1 Renewing scuff protection film, Polo »GTI«
    452
Manufacturer's designation General body repairs, exterior
Manufacturer Volkswagen
Suitable for Polo A05 (2010)
Suitable car types 6R1
Category Reparaturanleitung

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