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  • Examplepage for repair manual General body repairs, exterior
  • Examplepage for repair manual 2 General body repairs, exterior
  • Examplepage for repair manual 3 General body repairs, exterior

General body repairs, exterior

For Caddy Kasten/Kombi / Polo Classic / Polo Variant

Original Volkswagen repair manual


16,48 €7% VAT incl.

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Language: English

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3.503 KB

198 Sites

Detailed technical data

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This repair manual contains: Body - front, Rear boot lid/tailgate (Polo Classic, Polo Estate), Tank flap unit, Central locking, Rear door (Caddy), Front bumper, Flush bonded windows, Windows secured by threaded fasteners, Roof moulding, Trim and Protective strips. Show more
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Repair manual Caddy Kasten/Kombi / Polo Classic / Polo Variant General body repairs, exterior PDF download has the following content:

Chapter overview

  • Body front
    1
  • 1 Body - front
    1
  • 1.1 Body - front
    1
  • 1.2 Removing and installing lock carrier with attachments
    1
  • 1.3 Removing and installing front wing
    3
  • 1.4 Removing sealing piece
    5
  • Bonnet, Flaps
    6
  • 1 Bonnet
    6
  • 1.1 Bonnet
    6
  • 1.2 Removing and installing bonnet
    6
  • 1.3 Removing and installing bonnet lock cable
    8
  • 2 Rear boot lid/tailgate (Polo Classic, Polo Estate)
    10
  • 2.1 Rear boot lid/tailgate (Polo Classic, Polo Estate)
    10
  • 2.2 Tools
    10
  • 2.3 Removing gas strut
    10
  • 2.4 Removing gas strut (Polo Estate)
    11
  • 2.5 Releasing gas from strut
    12
  • 2.6 Adjusting tailgate (Estate)
    12
  • 2.7 Removing and installing tailgate/boot lid lock
    15
  • 2.8 Removing and installing lock cylinder
    17
  • 2.9 Maintaining common key locking
    18
  • 3 Tank flap unit
    19
  • 3.1 Tank flap unit
    19
  • 3.2 Assembly overview (Caddy)
    19
  • 3.3 Tools
    20
  • 3.4 Removing and installing tank flap unit (Caddy)
    20
  • 3.5 Dismantling and assembling tank flap unit (Caddy)
    21
  • Front doors/Door components/Central locking system
    23
  • 1 Front door
    23
  • 1.1 Front door
    23
  • 1.2 Front door - assembly overview
    23
  • 1.3 Tools
    25
  • 1.4 Removing and installing door
    25
  • 1.5 Adjusting door
    26
  • 1.6 Door handle - Assembly overview
    28
  • 1.7 Removing and installing door handle
    30
  • 1.8 Removing inner release handle
    31
  • 1.9 Maintaining common key locking
    31
  • 1.10 Door lock - Assembly overview
    32
  • 1.11 Removing and installing door lock
    33
  • 2 Central locking
    35
  • 2.1 Central locking
    35
  • 2.2 Central locking - Assembly overview (Caddy)
    35
  • 2.3 Central locking - Assembly overview (Polo Classic)
    38
  • 2.4 Central locking - Assembly overview (Polo Estate)
    42
  • 2.5 New coupling and junction piece for pipe connector
    46
  • 2.6 Removing and installing bi-pressure pump (Caddy)
    46
  • 2.7 Removing and installing bi-pressure pump (Polo Classic)
    47
  • 2.8 Removing and installing bi-pressure pump (Polo Estate)
    48
  • 2.9 Removing and installing tank flap positioning element (Polo Classic)
    48
  • 2.10 Removing and installing tank flap positioning element (Polo Estate)
    49
  • 2.11 Removing and installing front door positioning element
    50
  • 2.12 Removing and installing rear door lock positioning element (Caddy)
    52
  • 2.13 Removing and installing boot lid/tailgate lock positioning element (Polo Classic, Polo Estate)
    52
  • 2.14 Removing and installing boot lid positioning element (Polo Classic)
    54
  • 2.15 Removing and installing tailgate positioning element (Polo Estate)
    54
  • 2.16 Activating individual door opening of central locking system
    55
  • 2.17 Functional check of central locking
    55
  • 2.18 Functional check of central locking with radio remote control
    55
  • 2.19 Synchronising keys with radio remote control > 09.99
    56
  • Rear doors/Door components
    58
  • 1 Rear door (Caddy)
    58
  • 1.1 Rear door (Caddy)
    58
  • 1.2 Servicing rear wing doors
    58
  • 1.3 Adjusting rear wing door locks
    63
  • 1.4 Servicing left door lock operating mechanism
    64
  • 1.5 Servicing right door lock operating mechanism
    66
  • 2 Rear door (Polo Classic, Polo Estate)
    68
  • 2.1 Rear door (Polo Classic, Polo Estate)
    68
  • 2.2 Rear door - Assembly overview
    68
  • 2.3 Removing and installing door
    72
  • 2.4 Adjusting door
    72
  • 2.5 Door handle - Assembly overview
    73
  • 2.6 Removing and installing door handle
    74
  • 2.7 Removing inner release handle
    75
  • 2.8 Servicing door lock with operating mechanism
    76
  • 2.9 Removing and installing door lock
    78
  • Sliding/tilting roof
    79
  • 1 Sliding/tilting roof with glass panel >09.99
    79
  • 1.1 Sliding/tilting roof with glass panel >09.99
    79
  • 1.2 Sliding/tilting roof with glass panel - Assembly overview
    79
  • 1.3 Removing sliding/tilting roof glass panel
    83
  • 1.4 Installing sliding/tilting roof glass panel
    83
  • 1.5 Sliding/tilting roof glass panel (height adjustment)
    84
  • 1.6 Adjusting panel seal
    85
  • 1.7 Checking and adjusting parallel running
    85
  • 1.8 Removing sliding headlining
    87
  • 1.9 Installing sliding headlining
    87
  • 1.10 Removing and installing carrier unit
    88
  • 1.11 Cleaning water drain hoses (Polo Classic)
    90
  • 1.12 Cleaning water drain hoses (Polo Estate)
    91
  • 1.13 Sliding/tilting sunroof with glass panel 10.99 >
    92
  • 1.14 Function
    92
  • 1.15 Sliding/tilting roof with glass panel - Assembly overview
    93
  • 1.16 Removing sliding/tilting sunroof glass panel
    97
  • 1.17 Installing sliding/tilting sunroof glass panel
    97
  • 1.18 Adjusting sliding/tilting roof glass panel (height adjustment)
    98
  • 1.19 Adjusting panel seal
    99
  • 1.20 Renewing panel seal
    100
  • 1.21 Removing wind deflector
    101
  • 1.22 Removing and installing sliding headlining
    101
  • 1.23 Removing sliding/tilting sunroof preselector switch
    102
  • 1.24 Removing drive for sliding/tilting sunroof
    103
  • 1.25 Adjusting drive for sliding/tilting sunroof ("0" position)
    103
  • 1.26 Checking parallel running
    103
  • 1.27 Adjusting parallel running
    104
  • 1.28 Removing coulisse guide
    105
  • 1.29 Removing and installing carrier unit
    106
  • 1.30 Removing guide and cable
    108
  • 1.31 Cleaning water drain hoses (Polo Classic)
    110
  • 1.32 Cleaning water drain hoses (Polo Estate)
    111
  • Bumpers
    112
  • 1 Front bumper
    112
  • 1.1 Front bumper
    112
  • 1.2 Assembly overview
    112
  • 2 Rear bumper
    115
  • 2.1 Rear bumper
    115
  • 2.2 Assembly overview (Caddy)
    115
  • 2.3 Assembly overview (Polo Classic)
    117
  • 2.4 Assembly overview (Polo Estate)
    120
  • Glazing
    123
  • 1 Flush bonded windows
    123
  • 1.1 Flush bonded windows
    123
  • 1.2 Tools
    123
  • 1.3 Materials
    124
  • 1.4 Windscreen - Assembly overview
    125
  • 1.5 Removing windscreen
    126
  • 1.6 Installing windscreen
    127
  • 1.7 Side window (Polo Classic) - Assembly overview
    128
  • 1.8 Removing undamaged side window (Polo Classic)
    128
  • 1.9 Removing broken side window (Polo Classic)
    129
  • 1.10 Installing side window (Polo Classic)
    129
  • 1.11 Side window (Polo Estate) - Assembly overview
    130
  • 1.12 Removing undamaged side window (Polo Estate)
    130
  • 1.13 Removing broken side window (Polo Estate)
    132
  • 1.14 Installing side window (Polo Estate)
    132
  • 1.15 Rear window (Polo Classic) - Assembly overview
    133
  • 1.16 Removing undamaged rear window (Polo Classic)
    134
  • 1.17 Removing broken rear window (Polo Classic)
    135
  • 1.18 Installing rear window (Polo Classic)
    135
  • 1.19 Rear window (Polo Estate) - Assembly overview
    136
  • 1.20 Removing undamaged rear window (Polo Estate)
    136
  • 1.21 Removing broken rear window (Polo Estate)
    138
  • 1.22 Installing rear window (Polo Estate)
    138
  • 1.23 Preparing old undamaged window for glazing
    139
  • 1.24 Preparing new window for glazing
    140
  • 1.25 Preparing new window for glazing (Polo Estate)
    141
  • 1.26 Preparing body flange for glazing
    142
  • 1.27 Installation instructions
    143
  • 1.28 Curing time
    143
  • 1.29 Touching up paint damage
    144
  • 1.30 Cleaning off surplus adhesive sealing material
    144
  • 2 Windows secured by threaded fasteners
    145
  • 2.1 Windows secured by threaded fasteners
    145
  • 2.2 Removing and installing side window (Caddy)
    145
  • 3 Door windows
    147
  • 3.1 Door windows
    147
  • 3.2 Front door window - Assembly overview
    147
  • 3.3 Removing front door window
    148
  • 3.4 Adjusting front door window
    148
  • 3.5 Removing and installing front window lifter
    149
  • 3.6 Rear door window - Assembly overview
    150
  • 3.7 Removing and installing rear door window (Polo Classic)
    152
  • 3.8 Removing and installing rear door window (Polo Estate)
    153
  • 3.9 Removing rear window lifters
    155
  • Exterior equipment
    156
  • 1 Roof moulding
    156
  • 1.1 Roof moulding
    156
  • 1.2 Removing and installing roof moulding (Caddy)
    156
  • 1.3 Removing and installing roof moulding (Polo Classic, Polo Estate)
    160
  • 2 Roof railing
    162
  • 2.1 Roof railing
    162
  • 2.2 Removing and installing roof railing
    162
  • 3 Trim
    165
  • 3.1 Trim
    165
  • 3.2 Removing and installing radiator grille with trim frame
    165
  • 3.3 Removing and installing plenum chamber cover
    167
  • 3.4 Removing and installing underbody cover (Polo Classic)
    169
  • 4 Wheel housing liner
    170
  • 4.1 Wheel housing liner
    170
  • 4.2 Removing and installing front wheel housing liner
    170
  • 5 Protective strips
    173
  • 5.1 Protective strips
    173
  • 5.2 Renewing side protective strips (Caddy)
    173
  • 5.3 Renewing side protective strips (Polo Classic, Polo Estate)
    176
  • 5.4 Renewing roof protective strips (Polo Estate)
    179
  • 6 Rear view mirror
    182
  • 6.1 Rear view mirror
    182
  • 6.2 Tools
    182
  • 6.3 Exterior mirror (Caddy)
    183
  • 6.4 Exterior mirror (Polo Classic, Polo Estate)
    185
  • 6.5 Removing mirror housing (Polo Classic, Polo Estate) 10.99 >
    192
Manufacturer's designation General body repairs, exterior
Manufacturer Volkswagen
Suitable for Caddy Kasten/Kombi (1996 - 2003) / Polo Classic / Polo Variant (1996 - 2002)
Suitable car types 9K, 6V
Category Reparaturanleitung

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