General body repairs, exterior

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