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  • Examplepage for repair manual 3 General body repairs, exterior

General body repairs, exterior

For Lupo / Lupo 3L

Original Volkswagen repair manual


10,89 €7% VAT incl.

  • Deutsch
  • English

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Language: English

Digital PDF file

3.408 KB

121 Sites

Detailed technical data

Immediately readable

This repair manual contains: Contact corrosion! Lupo 3L, FSI and GTI, Lock carrier, Wing, Noise insulation, Bonnet, Rear lid, Fuel tank flap, Sliding/tilting sunroof with glass panel (Webasto), Front bumper, Flush bonded windows, (aluminium/magnesium), Windows having threaded connections and Exterior mirror. Show more
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Repair manual Lupo / Lupo 3L General body repairs, exterior PDF download has the following content:

Chapter overview

  • Body - front
    1
  • 1 Contact corrosion! Lupo 3L, FSI and GTI
    1
  • 2 Lock carrier
    2
  • 2.1 Tools
    2
  • 2.2 Assembly overview - lock carrier
    2
  • 2.3 Removing and installing lock carrier with bolt-on parts
    4
  • 2.4 Service position
    5
  • 3 Wing
    7
  • 3.1 Tools
    7
  • 3.2 Removing and installing front wing for Lupo
    7
  • 3.3 Removing and installing front wing for Lupo 3L, FSI and GTI
    9
  • 4 Noise insulation
    11
  • 4.1 Tools
    11
  • 4.2 Assembly overview - noise insulation
    11
  • Bonnet, rear lid
    12
  • 1 Contact corrosion! Lupo 3L, FSI and GTI
    12
  • 2 Bonnet
    13
  • 2.1 Tools
    13
  • 2.2 Removing and installing bonnet
    13
  • 2.3 Bonnet striker pin fixing (Lupo 3L, FSI and GTI)
    14
  • 2.4 Attachment of gas-filled struts (Lupo 3L, FSI and GTI)
    14
  • 2.5 Bonnet hinge fixing (Lupo 3L, FSI and GTI)
    15
  • 2.6 Adjusting bonnet
    15
  • 2.7 Removing gas-filled strut
    15
  • 2.8 Removing and installing Bowden cable
    15
  • 2.9 Removing and installing release lever
    17
  • 2.10 Removing and installing bonnet lock
    18
  • 3 Rear lid
    20
  • 3.1 Note on magnesium components
    20
  • 3.2 Tools
    20
  • 3.3 Assembly overview - rear lid
    21
  • 3.4 Adjusting rear lid
    22
  • 3.5 Removing gas-filled strut
    23
  • 3.6 Releasing gas from gas strut
    24
  • 3.7 Removing and installing rear lid lock
    24
  • 3.8 Removing and installing lock cylinder housing
    26
  • 3.9 Lid seals
    26
  • 3.10 Removing and installing lid inner seal
    27
  • 4 Fuel tank flap
    28
  • 4.1 Tools
    28
  • 4.2 Assembly overview - tank flap unit
    28
  • Front doors, door components, central locking
    29
  • 1 Contact corrosion! Lupo 3L, FSI and GTI
    29
  • 2 Front door
    30
  • 2.1 Tools
    30
  • 2.2 Assembly overview - front door
    30
  • 2.3 Removing and installing door
    33
  • 2.4 Adjusting door
    33
  • 2.5 Assembly overview - door handle and door lock
    34
  • 2.6 Removing and installing lock cylinder housing
    35
  • 2.7 Removing and installing door handle
    36
  • 2.8 Removing and installing door lock
    37
  • 2.9 Removing and installing door arrester
    38
  • 2.10 Removing and installing locking knob for locking rod
    38
  • 2.11 Door seals
    40
  • 2.12 Removing and installing interior door seal
    40
  • 3 Central locking
    41
  • 3.1 Tools
    41
  • 3.2 Location overview - central locking components
    41
  • 3.3 Removing and installing battery for illuminated key
    43
  • 3.5 Adapting keys with remote control
    47
  • Sunroof
    48
  • 1 Sliding/tilting sunroof with glass panel (Webasto)
    48
  • 1.1 Function
    48
  • 1.2 Assembly overview- sliding/tilting sunroof with glass panel
    48
  • 1.3 Removing sunroof glass panel
    50
  • 1.4 Installing glass panel for sliding/tilting sunroof
    50
  • 1.5 Adjusting height of sliding/tilting sunroof glass panel
    51
  • 1.6 Renewing panel seal
    52
  • 1.7 Removing wind deflector
    52
  • 1.8 Removing and installing sliding headlining
    52
  • 1.9 Removing sliding/tilting sunroof preselector switch
    53
  • 1.10 Removing drive for sliding/tilting sunroof
    54
  • 1.11 Adjusting drive for sliding/tilting sunroof ("0" position)
    54
  • 1.12 Checking parallel running
    54
  • 1.13 Adjusting parallel running
    55
  • 1.14 Removing and installing carrier unit
    55
  • 1.15 Cleaning water drain hoses
    58
  • 2 Folding fabric sunroof
    60
  • 2.1 Assembly overview - folding fabric sunroof
    60
  • 2.2 Removing and installing complete folding fabric sunroof
    61
  • 2.3 Screw sequence
    62
  • 2.4 Removing and installing folding fabric sunroof with cover and trim
    63
  • 2.5 Renewing folding fabric sunroof cover and trim
    64
  • 2.6 Tightening folding fabric sunroof
    65
  • 2.7 Checking parallel running
    66
  • 2.8 Adjusting parallel running
    66
  • 2.9 Renewing roof spoiler
    66
  • Bumpers
    68
  • 1 Contact corrosion! Lupo 3L, FSI, GTI
    68
  • 2 Front bumper
    69
  • 2.1 Tools
    69
  • 2.2 Repairing bumper cover
    69
  • 2.3 Removing bumper, Lupo
    69
  • 2.4 Removing bumper Lupo 3L, FSI
    71
  • 2.5 Removing bumper, Lupo GTI
    72
  • 2.6 Removing and installing bumper cover insert
    74
  • 3 Rear bumper
    75
  • 3.1 Tools
    75
  • 3.2 Removing and installing bumper
    75
  • Glazing
    77
  • 1 Contact corrosion! Lupo 3L, FSI, GTI
    77
  • 2 Flush bonded windows
    78
  • 2.1 Tools
    78
  • 2.2 Materials
    79
  • 2.3 Repairing windscreen
    80
  • 2.4 Assembly overview - windscreen
    80
  • 2.5 Removing and installing plenum chamber cover
    81
  • 2.6 Removing windscreen
    83
  • 2.7 Installing windscreen
    84
  • 2.8 Assembly overview - rear window
    85
  • 2.9 Removing undamaged rear window
    85
  • 2.10 Removing broken rear window
    86
  • 2.11 Installing rear window
    87
  • 2.12 Assembly overview - side window
    87
  • 2.13 Removing undamaged side window
    87
  • 2.14 Removing broken side window
    88
  • 2.15 Installing side window
    88
  • 2.16 Preparing old undamaged window for glazing
    88
  • 2.17 Preparing new window for glazing
    89
  • 2.18 Preparing body flange for glazing
    90
  • 2.19 Installation instructions
    91
  • 2.20 Minimum curing time
    91
  • 2.21 Touching up paintwork damage
    92
  • 000 (aluminium/magnesium)
    92
  • 2.23 Cleaning off excess adhesive sealing material
    92
  • 3 Windows having threaded connections
    93
  • 3.1 Assembly overview - hinged window
    93
  • 3.2 Removing and installing hinged window
    94
  • 3.3 Installing sealing frame
    95
  • 4 Door windows
    96
  • 4.1 Assembly overview- front door window
    96
  • 4.2 Removing and installing door window
    96
  • 4.3 Adjusting door window
    97
  • 4.4 Removing and installing outer window channel
    97
  • 4.5 Removing and installing window regulator
    99
  • 4.6 Repairing electric window regulators
    99
  • Exterior equipment
    101
  • 1 Contact corrosion! Lupo 3L, FSI, GTI
    101
  • 2 Wheel housing liner
    102
  • 2.1 Removing and installing front wheel housing liner
    102
  • 2.2 Removing and installing rear wheel housing liner
    103
  • 3 Exterior mirror
    104
  • 3.1 Tools
    104
  • 3.2 Assembly overview
    104
  • 3.3 Removing mirror housing
    105
  • 4 Trim
    106
  • 4.1 Removing and installing radiator grille with trim frame
    106
  • 4.2 Removing trim frame
    106
  • 4.3 Removing radiator trim (Lupo 3L, FSI)
    107
  • 4.4 Assembly overview - plenum chamber cover
    107
  • 4.5 Removing and installing radiator grille, Lupo GTI
    108
  • 5 Mouldings
    109
  • 5.1 Tools
    109
  • 5.2 Removing and installing roof moulding
    109
  • 5.3 Protective side mouldings
    111
  • 6 Rear spoiler
    112
  • 6.1 Tools
    112
  • 6.4 Assembly overview - rear spoiler for Lupo FSI up to chassis number 6E-1-010 000
    114
Manufacturer's designation General body repairs, exterior
Manufacturer Volkswagen
Suitable for Lupo (1998 - 2006) / Lupo 3L (1999 - 2006)
Suitable car types 6X, 6E
Category Reparaturanleitung

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