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General body repairs, exterior

For California / Multivan / Transporter / Transporter/Kombi LR

Original Volkswagen repair manual


32,88 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

13.879 KB

447 Sites

Detailed technical data

Immediately readable

This repair manual contains: Lock carrier to 2010, Wings, Bulkhead, Bonnet, Tank flap unit, Door, Central locking, Sliding door - high, Sliding/tilting sunroof with glass panel (Webasto), Repair instructions, Trim film and protective film, Exterior mirrors from 2010, Lettering and emblem, Load floor body and Spare wheel bracket. Show more
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Repair manual General body repairs, exterior PDF download has the following content:

Chapter overview

  • Body - front
    1
  • 1 Lock carrier to 2010
    1
  • 1.1 Assembly overview – lock carrier
    1
  • 1.3 Service position with front bumper cover installed
    4
  • 1.5 Removing and installing lock carrier with attachments
    7
  • 2 Lock carrier from 2010
    10
  • 2.1 Assembly overview – lock carrier
    10
  • 2.3 Service position with front bumper cover removed
    13
  • 2.4 Removing and installing front end with add-on parts
    13
  • 2.5 Removing and installing subframe
    15
  • 3 Wings
    18
  • 3.1 Assembly overview - wing
    18
  • 3.2 Removing and installing wing
    18
  • 4 Bulkhead
    21
  • 4.1 Assembly overview - plenum chamber bulkhead
    21
  • 4.2 Assembly overview - plenum chamber cover
    22
  • 4.3 Assembly overview - plenum chamber bulkhead
    24
  • 4.4 Assembly overview - battery housing cover
    25
  • 4.5 Removing and installing plenum chamber cover
    26
  • Bonnet, rear lid
    30
  • 1 Bonnet
    30
  • 1.1 Assembly overview - bonnet
    30
  • 1.2 Assembly overview - bonnet lock and release components
    32
  • 1.3 Assembly overview - bonnet stay
    33
  • 1.4 Removing and installing bonnet
    33
  • 1.5 Adjusting bonnet
    35
  • 1.6 Removing and installing rear lid lock
    36
  • 1.7 Removing and installing striker pin
    38
  • 1.8 Removing and installing bonnet release lever
    38
  • 1.9 Removing and installing hinges
    38
  • 1.10 Removing and installing insulation
    40
  • 1.11 Removing and installing gas strut
    41
  • 1.12 Releasing gas from gas strut
    42
  • 2 Rear lid
    43
  • 2.1 Assembly overview - rear lid
    43
  • 2.2 Assembly overview - guide wedge and centring lug
    45
  • 2.3 Assembly overview - locking and release components, rear lid
    46
  • 2.4 Assembly overview - interior operating mechanism
    50
  • 2.5 Assembly overview - light strip
    51
  • 2.6 Removing and installing rear lid
    51
  • 2.7 Adjusting rear lid
    53
  • 2.8 Removing and installing light strip
    57
  • 2.9 Removing and installing hinges
    58
  • 2.10 Removing and installing rear lid lock
    64
  • 2.11 Removing and installing childproof lock operating mechanism
    65
  • 2.12 Removing and installing lock carrier for rear lid
    65
  • 2.13 Removing lock cylinder from and installing in lock carrier
    69
  • 2.14 Removing and installing mechanical lock cylinder
    70
  • 2.15 Exterior handle without lock cylinder 2010, as of 2010
    72
  • 2.16 Removing and installing interior door handle
    77
  • 2.17 Removing and installing rear lid seal
    78
  • 2.18 Removing and installing gas strut
    78
  • 3 Tank flap unit
    80
  • 3.1 Assembly overview - fuel tank flap
    80
  • 3.2 Removing and installing fuel tank flap
    81
  • Front doors, door components, central locking
    84
  • 1 Door
    84
  • 1.1 Assembly overview - front door
    84
  • 1.2 Assembly overview - additional seals for postal and courier vehicles
    86
  • 1.3 Removing and installing inner door seals
    86
  • 1.4 Removing and installing door seal
    87
  • 1.5 Removing and installing door seal
    88
  • 1.6 Removing and installing front door
    89
  • 1.7 Renewing front door
    91
  • 1.8 Removing and installing striker pin
    92
  • 1.9 Greasing new door hinges
    93
  • 1.10 Adjusting door
    93
  • 1.11 Adjusting striker pin
    97
  • 2 Door components
    98
  • 2.1 Assembly overview – subframe
    98
  • 2.2 Assembly overview - door handle and door lock
    99
  • 2.3 Assembly overview - window channels and window slot (aperture) seals
    100
  • 2.4 Removing and installing subframe
    101
  • 2.5 Removing and installing lock cylinder
    104
  • 2.6 Removing and installing door handle
    105
  • 2.7 Removing and installing door lock
    108
  • 2.8 Removing and installing mounting bracket
    110
  • 2.9 Removing and installing window regulator motor
    111
  • 3 Central locking
    114
  • 3.1 Overview of fitting locations - central locking
    114
  • 3.2 Assembly overview - key with illumination and battery
    117
  • 3.3 Assembly overview - ignition key to 2010
    118
  • 3.4 Assembly overview - ignition key from 2010
    119
  • 3.5 Removing and installing battery for illuminated key
    119
  • 3.6 Removing and installing ignition key battery to 2010
    121
  • 3.7 Removing and installing ignition key battery from 2010
    122
  • Rear doors, door components
    123
  • 1 Sliding door
    123
  • 1.1 Assembly overview - sliding door roller guides
    123
  • 1.2 Assembly overview - sliding door locking and release components
    125
  • 1.3 Assembly overview - sliding door remote release mechanism
    127
  • 1.4 Assembly overview - interior operating mechanism
    128
  • 1.5 Assembly overview - middle guide rail
    129
  • 1.6 Removing and installing inner door seals
    130
  • 1.7 Removing and installing seal
    131
  • 1.8 Removing and installing sliding door
    132
  • 1.9 Adjusting sliding door
    133
  • 1.10 Removing and installing striker pin
    138
  • 1.11 Removing and installing striker pin and power latching motor
    139
  • 1.12 Removing and installing lower roller guide
    141
  • 1.13 Removing and installing door arrester
    142
  • 1.14 Removing and installing hinge
    143
  • 1.15 Removing and installing door lock
    144
  • 1.16 Removing and installing sliding door remote release mechanism
    145
  • 1.17 Removing and installing contact module and contact strip
    147
  • 1.18 Removing and installing lock cylinder housing and exterior door handle
    149
  • 1.19 Removing and installing mounting bracket
    149
  • 1.20 Removing and installing interior door handle
    150
  • 1.21 Removing and installing upper guide rail
    152
  • 1.22 Removing and installing middle guide rail
    153
  • 2 Electrically operated sliding door
    157
  • 2.1 Assembly overview - electrical components of electrically operated sliding door
    157
  • 2.2 Assembly overview - guide rail with roller bearing
    159
  • 2.3 Assembly overview - upper roller guide with transponder
    160
  • 2.4 Assembly overview - lower roller guide
    160
  • 2.5 Assembly overview - wiring for electric sliding door operation
    162
  • 2.7 Removing and installing sliding door with electrical controls
    164
  • 2.8 Removing and installing striker pin with power latching motor
    165
  • 2.9 Removing and installing door arrester
    167
  • 2.10 Removing and installing motor to open right sliding door V323
    168
  • 2.11 Removing and installing guide rail with roller bearing
    169
  • 2.12 Removing and installing upper guide rail with reader coil
    172
  • 2.13 Removing and installing upper roller guide with transponder
    174
  • 2.14 Removing and installing lower roller guide
    175
  • 2.15 Removing and installing right electric sliding door sender unit G481
    176
  • 3 Sliding door - high
    178
  • 3.1 Assembly overview - locking and release components for high sliding door
    178
  • 3.2 Assembly overview - emergency release
    180
  • 3.3 Removing and installing inner door seals
    180
  • 3.4 Renewing pre-seal
    181
  • 3.5 Removing and installing additional lock
    181
  • 3.6 Removing and installing manual release mechanism
    182
  • 3.7 Removing and installing centre stop
    183
  • 3.8 Removing and installing guide wedge - wedge guide
    184
  • 4 Cab door - double cab
    186
  • 4.1 Assembly overview - cab door
    186
  • 4.2 Assembly overview - door handle and door lock
    187
  • 4.3 Removing and installing inner door seals
    188
  • 4.4 Removing and installing cab door
    189
  • 4.5 Adjusting cab door
    191
  • 4.6 Removing and installing striker pin
    192
  • 4.7 Removing and installing door hinge
    193
  • 4.8 Removing and installing door arrester
    194
  • 4.9 Removing and installing impact bar
    194
  • 4.10 Removing and installing lock cylinder housing
    195
  • 4.11 Removing and installing door handle
    196
  • 4.12 Removing and installing mounting bracket
    199
  • 4.13 Removing and installing door lock
    199
  • 5 Wing doors
    203
  • 5.1 Assembly overview - wing door
    203
  • 5.2 Assembly overview - wing door hinges
    205
  • 5.3 Assembly overview - door arrester with opening angle of 250°
    206
  • 5.5 Assembly overview - locking and release components, wing doors, high roof
    208
  • 5.6 Assembly overview – subframe
    209
  • 5.7 Removing and installing wing door seal
    209
  • 5.8 Removing and installing inner seal of wing door
    211
  • 5.9 Removing and installing wing door
    211
  • 5.10 Adjusting wing door
    213
  • 5.11 Removing and installing upper striker pin
    219
  • 5.12 Removing and installing lower striker pin
    220
  • 5.13 Replacing wing door
    221
  • 5.14 Removing and installing wing door hinges
    221
  • 5.15 Removing and installing door arrester
    223
  • 5.16 Installing stop in wing door for door arrester with opening angle of 250°
    224
  • 5.17 Removing and installing upper right wing door lock
    226
  • 5.18 Removing and installing release lever
    227
  • 5.19 Removing and installing lower right wing door lock
    229
  • 5.20 Removing and installing lower left wing door lock
    229
  • 5.21 Removing and installing childproof lock
    230
  • 5.22 Removing and installing latch carrier
    230
  • 5.23 Removing and installing interior door handle
    232
  • 5.24 Removing and installing exterior door handle
    232
  • 5.25 Removing and installing subframe
    233
  • 5.26 Removing and installing light strip
    235
  • 5.27 Removing and installing upper left wing door lock
    235
  • 5.28 Removing and installing lock cylinder
    236
  • Sunroof
    238
  • 1 Sliding/tilting sunroof with glass panel (Webasto)
    238
  • 1.1 Assembly overview - sliding sunroof
    238
  • 1.2 Function
    240
  • 1.3 Removing and installing sliding/tilting sunroof glass panel
    241
  • 1.4 Adjusting height of sliding/tilting sunroof glass panel
    242
  • 1.5 Checking parallel running of glass panel
    243
  • 1.6 Adjusting parallel running of glass panel
    244
  • 1.7 Renewing panel seal
    244
  • 1.8 Removing wind deflector
    244
  • 1.9 Removing and installing sliding headliner
    245
  • 1.10 Removing and installing sliding/tilting sunroof drive
    245
  • 1.11 Adjusting drive for sliding/tilting sunroof (zero position)
    246
  • 1.12 Removing pre-selector control for sliding/tilting sunroof
    248
  • 1.13 Removing and installing carrier unit
    249
  • 1.14 Operating without current
    250
  • 1.15 Cleaning water drain hoses
    250
  • Convertible roof, hardtop, canopy
    253
  • 1 Convertible roof frame and soft top canopy
    253
  • 1.1 Assembly overview - canopy frame with canopy
    253
  • 1.2 Contact corrosion
    255
  • Bumpers
    257
  • 1 Front bumper cover to 2010
    257
  • 1.1 Assembly overview - front bumper cover
    257
  • 1.2 Assembly overview - front bumper cover, add-on parts
    259
  • 1.3 Assembly overview - front bumper cover, add-on parts, commercial vehicles
    260
  • 1.4 Assembly overview - bumper carrier
    261
  • 1.5 Removing and installing front bumper cover
    261
  • 1.6 Removing and installing bumper carrier
    264
  • 1.7 Repairing front bumper cover
    265
  • 2 Front bumper cover from 2010
    267
  • 2.1 Assembly overview - front bumper cover
    267
  • 2.2 Assembly overview - front bumper cover, add-on parts
    269
  • 2.3 Assembly overview - parking aid and brackets in front bumper cover
    270
  • 2.4 Assembly overview - bumper carrier
    271
  • 2.5 Removing and installing front bumper cover
    271
  • 2.6 Removing and installing front bumper carrier
    273
  • 2.7 Repairing front bumper cover
    276
  • 2.8 Installing brackets for parking aid system
    276
  • 3 Rear bumper cover to 2010
    281
  • 3.1 Assembly overview - rear bumper cover
    281
  • 3.2 Assembly overview - rear bumper cover, add-on parts
    282
  • 3.3 Assembly overview - parking aid and brackets in rear bumper cover
    283
  • 3.4 Assembly overview - rear bumper cover, substructure parts
    283
  • 3.5 Assembly overview - rear bumper carrier
    285
  • 3.6 Removing and installing rear bumper cover
    285
  • 3.7 Repairing rear bumper cover
    287
  • 3.8 Installing brackets for parking aid system
    287
  • 4 Rear bumper cover from 2010
    292
  • 4.1 Assembly overview - rear bumper cover
    292
  • 4.2 Removing and installing rear bumper cover
    293
  • Glazing
    296
  • 1 Repair instructions
    296
  • 1.1 Minimum curing periods for bonded windows
    296
  • 1.2 Window repair
    297
  • 1.3 Fitting instructions
    298
  • 1.4 Preparing old undamaged window for glazing
    299
  • 1.5 Preparing new window for glazing
    300
  • 1.6 Preparing body flange for glazing
    300
  • 1.7 Touching up paint damage
    301
  • 1.8 Cleaning off excess adhesive
    301
  • 2 Windscreen
    302
  • 2.1 Assembly overview - windscreen
    302
  • 2.2 Windscreen spacings
    302
  • 2.3 Removing and installing windscreen
    305
  • 3 Side window
    310
  • 3.1 Assembly overview - side windows
    310
  • 3.2 Removing and installing rear side window
    313
  • 4 Sliding window
    319
  • 4.1 Assembly overview - sliding window
    319
  • 4.2 Removing sliding window for sliding door
    319
  • 4.3 Removing and installing sliding window in side panel
    321
  • 5 Rear windscreen
    328
  • 5.1 Assembly overview - rear window
    328
  • 5.2 Assembly overview - rear window, double cab and dropside
    330
  • 5.3 Assembly overview - rear window, wing door
    331
  • 5.4 Assembly overview - sliding window and rear window for partition
    332
  • 5.5 Removing undamaged double cab and dropside rear window
    332
  • 5.6 Removing broken double cab and dropside rear window
    332
  • 5.7 Installing rear window for double cab and dropside
    332
  • 5.8 Removing undamaged rear window
    333
  • 5.9 Removing broken rear window
    334
  • 5.10 Installing rear window
    334
  • 5.11 Removing undamaged wing door window
    334
  • 5.12 Removing damaged wing door window
    335
  • 5.13 Installing rear wing door window
    335
  • 5.14 Removing and installing sliding window and rear window for partition
    335
  • 6 Front door windows
    338
  • 6.1 Removing and installing door window
    338
  • 6.2 Adjusting door window
    338
  • Exterior equipment
    340
  • 1 Radiator grille to 2010
    340
  • 1.1 Assembly overview - radiator grille
    340
  • 1.2 Removing and installing radiator grille
    340
  • 1.3 Removing and installing radiator grille trim and strip
    342
  • 2 Radiator grille from 2010
    344
  • 2.1 Assembly overview - radiator grille and emblem
    344
  • 2.2 Removing and installing radiator grille and emblem
    345
  • 3 Mouldings, trims, extensions
    346
  • 3.1 Assembly overview - B-pillar trim
    346
  • 3.2 Assembly overview - guide rail
    347
  • 3.3 Removing and installing trim strip
    347
  • 3.4 Removing and installing roller guide trim
    354
  • 3.5 Removing and installing wing cover
    356
  • 3.6 Removing and installing guide rail
    356
  • 3.7 Renewing roof strip
    359
  • 3.8 Renewing protective films
    359
  • 4 Noise insulation
    361
  • 4.1 Assembly overview - noise insulation
    361
  • 4.2 Removing and installing noise insulation
    361
  • 5 Underbody cladding
    364
  • 5.1 Assembly overviews
    364
  • 6 Trim film and protective film
    379
  • 6.1 Removing and installing trim film for fog light trim
    379
  • 6.2 Fitting instructions
    382
  • 7 Exterior mirror to 2010
    383
  • 7.1 Assembly overview – exterior mirror, up to 2010
    383
  • 7.2 Removing and installing mirror housing
    383
  • 7.3 Removing and installing mirror glass
    386
  • 7.4 Removing and installing exterior mirror
    386
  • 8 Exterior mirrors from 2010
    388
  • 8.1 Assembly overview - exterior mirror
    388
  • 8.2 Removing and installing mirror glass
    389
  • 8.3 Removing and installing housing frame
    391
  • 8.4 Removing and installing mirror housing
    393
  • 8.5 Removing and installing exterior mirror
    394
  • 9 Exterior mirror, double cab and dropside
    396
  • 9.1 Assembly overview - exterior mirror, double cab and dropside
    396
  • 9.2 Removing and installing double cab and dropside exterior mirror
    397
  • 10 Wheel housing liner
    398
  • 10.1 Assembly overview - front wheel housing liner
    398
  • 10.2 Assembly overview - rear wheel housing liner
    399
  • 10.3 Removing and installing front wheel housing liner
    399
  • 10.4 Removing and installing rear wheel housing liner
    401
  • 11 Lettering and emblem
    403
  • 11.1 Assembly overview - lettering on rear lid
    403
  • 11.2 Assembly overview - lettering on rear wing doors
    404
  • 11.3 Assembly overview - lettering on rear lid, dropside
    405
  • 11.4 Dimensions - lettering and emblems on rear lid
    407
  • 11.5 Dimensions – lettering on rear, wing doors
    408
  • 11.6 Dimensions – lettering on rear, dropside
    410
  • 11.7 Removing and installing rear emblem
    411
  • 11.8 Removing and installing “BLUEMOTION” lettering on radiator grille
    413
  • 11.9 Removing and installing lettering or emblem
    414
  • 12 Load floor body
    415
  • 12.1 Contact corrosion
    415
  • 12.2 Assembly overview - dropside body
    415
  • 12.3 Load floor and tailboard
    416
  • 12.4 Assembly overview – tailboard, add-on parts
    419
  • 12.5 Assembly overview - skid plate for short wheelbase
    420
  • 12.6 Assembly overview - skid plate for long wheelbase
    421
  • 12.7 Assembly overview - rear wheel housing
    422
  • 12.8 Assembly overview - tank trim
    423
  • 13 Towing bracket
    424
  • 13.1 Assembly overview - rigid towing bracket
    424
  • 13.2 Assembly overview - towing bracket, double cab and dropside
    426
  • 13.3 Assembly overview - towing eye
    427
  • 13.4 Removing and installing rigid towing bracket
    427
  • 13.5 Removing and installing towing bracket, double cab and dropside
    429
  • 13.6 Removing and installing towing eye
    431
  • 14 Spare wheel bracket
    433
  • 14.1 Assembly overview - closed bodies
    433
  • 14.2 Assembly overview - open bodies
    433
  • 15 Mudflap
    435
  • 15.1 Assembly overview - front mud flaps
    435
  • 15.2 Assembly overview - rear mud flaps
    436
  • 15.3 Assembly overview - rear mud flaps, double cab and dropside
    437
Manufacturer's designation General body repairs, exterior
Manufacturer Volkswagen
Suitable for California / Multivan / Transporter / Transporter/Kombi LR (2003 - 2007) / Transporter (2003 - 2007) / Transporter (2010)
Suitable car types 7H, 7F, 7E
Category Reparaturanleitung

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