General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Tools
  1
• 1.2 Assembly overview - lock carrier > 03.05
  1
• 1.3 Lock carrier - service position > 03.05
  3
• 1.4 Removal and installation of lock carrier > 03.05
  4
• 1.5 Assembly overview - lock carrier 04.05 >
  6
• 1.6 Lock carrier - service position 04.05 >
  7
• 1.7 Removal and installation of lock carrier 04.05 >
  8
• 2 Wing
  11
• 2.1 Assembly overview - front wing
  11
• 2.2 Removal and installation of wing
  12
• 2.3 Removal and installation of closing piece
  14
• 2.4 Wing dimensions - Vehicles > 02.05
  14
• 2.5 Wing dimensions - Vehicles 03.05 >
  16
• 3 Noise insulation
  17
• 3.1 Assembly overview - noise insulation (petrol engine)
  17
• 3.2 Assembly overview - noise insulation (diesel engine)
  18
• 4 Cross panel
  19
• 4.1 Tools
  19
• 4.2 Materials
  19
• 4.3 Assembly overview - cross panel
  20
• Bonnet, rear lid
  21
• 1 Bonnet
  21
• 1.1 Tools
  21
• 1.2 Assembly overview - bonnet
  21
• 1.3 Removal and installation of bonnet
  23
• 1.4 Adjusting bonnet
  25
• 1.5 Removing gas-filled strut
  25
• 1.6 Removal and installation of Bowden cable
  26
• 1.7 Removal and installation of release lever
  29
• 1.8 Assembly overview - bonnet lock
  31
• 1.9 Removal and installation of lid lock
  31
• 2 Rear lid
  33
• 2.1 Tools
  33
• 2.2 Assembly overview
  33
• 2.3 Removing gas-filled strut
  35
• 2.4 Releasing gas from gas-filled strut
  35
• 2.5 Adjusting rear lid
  35
• 2.6 Removal and installation of lid lock
  37
• 3 Tank flap unit
  41
• 3.1 Removal and installation of tank flap unit
  41
• Front doors, door components, central locking
  43
• 1 Front door
  43
• 1.1 Tools
  43
• 1.2 Assembly overview
  43
• 1.3 Removal and installation of door
  46
• 1.4 Adjusting door
  46
• 1.5 Assembly overview - door handle and door lock
  47
• 1.6 Removal and installation of lock cylinder housing
  49
• 1.7 Removal and installation of door handle
  50
• 1.8 Removal and installation of door lock
  51
• 1.9 Removal and installation of locking knob for locking rod
  55
• 1.10 Door seals
  57
• 2 Central locking
  63
• 2.1 Location overview - central locking components
  63
• 2.2 Removal of control unit for convenience system
  66
• 2.3 Adapting keys with remote control
  66
• 2.4 Removal and installation of battery for folding key with remote control
  66
• Rear doors, door components
  69
• 1 Rear door
  69
• 1.1 Tools
  69
• 1.2 Assembly overview
  70
• 1.3 Removal and installation of door
  71
• 1.4 Adjusting door
  72
• 1.5 Assembly overview - door handle and door lock
  72
• 1.6 Removal and installation of door handle
  74
• 1.7 Removal and installation of door lock
  76
• 1.8 Door seals
  82
• Sunroof
  88
• 1 Sliding/tilting sunroof
  88
• 1.1 Function
  88
• 1.2 Assembly overview - sliding/tilting sunroof with glass panel
  88
• 1.3 Removal of sliding/tilting sunroof glass panel
  91
• 1.4 Installation of glass panel for sliding/tilting sunroof
  92
• 1.5 Adjusting sliding/tilting sunroof glass panel (height adjustment)
  92
• 1.6 Adjusting panel seal
  94
• 1.7 Renewing panel seal
  95
• 1.8 Removing wind deflector
  96
• 1.9 Removal and installation of sun blind
  96
• 1.10 Removing pre-selector switch for sliding/tilting sunroof (E 139)
  96
• 1.11 Removal of drive for sliding/tilting sunroof
  97
• 1.12 Adjusting drive for sliding/tilting sunroof (zero position)
  97
• 1.13 Checking parallel running
  97
• 1.14 Adjusting parallel running
  98
• 1.15 Removing guide plate
  98
• 1.16 Removal and installation of assembly unit
  99
• 1.17 Removal of guide with cable
  101
• 1.18 Cleaning water drain hoses
  102
• Bumpers
  104
• 1 Front bumper
  104
• 1.1 Tools
  104
• 1.2 Repairing front bumper cover
  104
• 2 Front bumper > 03.05
  106
• 2.1 Assembly overview - bumper cover > 03.05
  106
• 2.2 Removal and installation of bumper cover > 03.05
  107
• 2.3 Assembly overview - bumper carrier > 03.05
  108
• 3 Front bumper 04.05 >
  109
• 3.1 Assembly overview - front bumper 04.05 >
  109
• 3.2 Removal and installation of front bumper cover 04.05 >
  110
• 3.3 Front bumper attachments 04.05 >
  112
• 3.4 Front bumper attachments - Blue Motion and GT Rocket
  112
• 3.5 Assembly overview - front bumper carrier 04.05 >
  114
• 4 Front bumper, Polo Fun
  115
• 4.1 Assembly overview - bumper cover, Polo Fun
  115
• 4.2 Removal and installation of front bumper cover, Polo Fun
  116
• 4.3 Assembly overview - bumper carrier, Polo Fun
  117
• 5 Front bumper, Cross Polo
  118
• 5.1 Assembly overview - bumper cover, Cross Polo
  118
• 5.2 Removal and installation of bumper cover, Cross Polo
  119
• 5.3 Assembly overview - bumper carrier, Cross Polo
  120
• 6 Front bumper, Polo GTI Cup Edition
  121
• 6.1 Assembly overview - bumper cover, Polo GTI Cup Edition
  121
• 6.2 Removing and installing bumper cover, Polo GTI Cup Edition
  122
• 6.3 Bumper cover attachments, Polo GTI Cup Edition
  123
• 6.4 Assembly overview - bumper carrier, Polo GTI Cup Edition
  124
• 6.5 Assembly overview - dimensions for number plate attachment
  125
• 7 Rear bumper
  126
• 7.1 Tools
  126
• 7.2 Repairing rear bumper cover
  126
• 8 Rear bumper
  127
• 8.1 Assembly overview - rear bumper cover
  127
• 8.2 Assembly overview - rear bumper cover, Blue Motion and GT Rocket
  127
• 8.3 Removal and installation of rear bumper cover
  129
• 8.4 Assembly overview - bumper carrier
  130
• 9 Rear bumper, Polo Fun
  131
• 9.1 Assembly overview - bumper cover, Polo Fun
  131
• 9.2 Removal and installation of bumper cover, Polo Fun
  132
• 9.3 Assembly overview - bumper carrier, Polo Fun
  133
• 10 Rear bumper, Cross Polo
  134
• 10.1 Assembly overview - bumper cover, Cross Polo
  134
• 10.2 Removal and installation of bumper cover, Cross Polo
  135
• 10.3 Assembly overview - bumper carrier, Cross Polo
  136
• 10.4 Adapting bumper to wheel housing liner
  137
• 11 Rear bumper, Polo GTI Cup Edition
  138
• 11.1 Assembly overview - rear bumper cover, Polo GTI Cup Edition
  138
• 11.2 Removing and installing rear bumper cover, Polo GTI Cup Edition
  139
• 11.3 Rear bumper cover attachments, Polo GTI Cup Edition
  140
• 11.4 Assembly overview - bumper carrier, Polo GTI Cup Edition
  141
• 12 Towing bracket
  142
• 12.1 Assembly overview - towing bracket
  142
• Glazing
  143
• 1 Flush bonded windows
  143
• 1.1 Tools
  143
• 1.2 Materials
  144
• 1.3 Repairing windscreen
  145
• 1.4 Assembly overview - windscreen
  145
• 1.5 Removal and installation of plenum chamber cover
  147
• 1.6 Removing windscreen
  149
• 1.7 Installing windscreen
  150
• 1.9 Assembly overview - side window (2-door)
  151
• 1.10 Removal of undamaged side window (2-door)
  151
• 1.11 Removal of damaged side window (2-door)
  152
• 1.12 Installation of side window (2-door)
  152
• 1.13 Assembly overview - side window (4-door)
  153
• 1.14 Removal of undamaged side window (4-door)
  153
• 1.15 Removal of damaged side window (4-door)
  154
• 1.16 Installation of side window (4-door)
  154
• 1.17 Assembly overview - rear window
  155
• 1.18 Removal of undamaged rear window
  155
• 1.19 Removal of broken rear window
  157
• 1.20 Installation of rear window
  157
• 1.21 Preparing old undamaged window for glazing
  157
• 1.22 Preparing new window with precoating for glazing
  158
• 1.23 Preparing new window without precoating for glazing
  158
• 1.24 Preparing body flange for glazing
  163
• 1.25 Installation instructions
  164
• 1.26 Minimum curing period
  164
• 1.27 Touching up paint damage
  165
• 1.28 Cleaning off excess adhesive sealing material
  165
• 2 Screw-fastened windows
  166
• 2.1 Removal and installation of vent wing
  166
• 2.2 Window seal
  167
• 2.3 Adjusting vent wing
  167
• 3 Door windows
  169
• 3.1 Tools
  169
• 3.2 Assembly overview - front door window
  170
• 3.3 Removing front door window
  171
• 3.4 Adjusting front door window
  172
• 3.5 Removal and installation of front and rear assembly carriers
  172
• 3.6 Assembly overview - rear door window
  175
• 3.7 Removing rear door window
  178
• 3.8 Fitting rear door window to window lifter
  179
• 3.9 Removal and installation of assembly carrier
  179
• 3.11 Overcoming resistance with excess force limitation
  185
• 3.12 Removal and installation of window lifter motor in assembly carrier
  185
• Exterior equipment
  188
• 1 Removal and installation of wheel housing liner
  188
• 1.1 Front wheel housing liner
  188
• 1.2 Rear wheel housing liner
  190
• 2 Exterior mirror
  191
• 2.1 Tools
  191
• 2.2 Assembly overview - exterior mirror (with electric actuation) > 02.05
  191
• 2.3 Assembly overview - exterior mirror (with manual actuation) > 02.05
  193
• 2.4 Removing mirror housing > 02.05
  193
• 2.5 Assembly overview - exterior mirror 03.05 >
  194
• 2.6 Removal and installation of mirror glass 03.05 >
  195
• 2.7 Removal and installation of mirror housing 03.05 >
  196
• 2.8 Removal and installation of cover with side turn signal repeaters 03.05 >
  197
• 2.9 Removal and installation of exterior mirror 03.05 >
  197
• 3 Radiator grille
  199
• 3.1 Tools
  199
• 3.2 Assembly overview - radiator grille > 03.50
  199
• 3.3 Removal and installation of radiator grille > 03.05
  200
• 3.4 Assembly overview - radiator grille 04.05 >
  201
• 3.5 Removal and installation of radiator grille 04.05 >
  202
• 3.6 Radiator grille, Polo Blue Motion
  204
• 4 Mouldings and trims
  207
• 4.1 Tools
  207
• 4.2 Renewing side protective strips
  207
• 4.3 Assembly overview - side member extension, Polo GTI
  209
• 4.4 Removing and installing side member extension, Polo GTI
  210
• 4.5 Removing and installing retaining strip for side member extension
  212
• 4.6 Assembly overview - wheel arch trims, Polo GTI Cup Edition and GT Rocket
  214
• 5 Roof edge spoiler
  215
• 5.1 Tools
  215
• 5.2 Materials
  215
• 5.3 Roof spoiler, Polo GTI and GT Rocket
  216
• 5.4 Assembly overview - roof spoiler, Polo GTI Cup Edition
  219
• 5.5 Roof spoiler, Polo Blue Motion
  224
• 5.6 Preparing body kit component for bonding
  227
• 5.7 Installation instructions
  227
• 5.8 Minimum curing period
  228
• 5.9 Touching up paint damage
  228
• 5.10 Cleaning off excess adhesive sealing material
  228
• 6 Special attachments
  229
• 6.1 Safety requirements
  229
• 6.2 Tools
  229
• 6.3 Materials
  229
• 6.4 Special attachments, Polo Fun
  230
• 6.5 Special attachments, Cross Polo
  235
• 6.6 Special attachments, Polo GTI Cup Edition
  248
• 6.7 Special attachments, Polo Blue Motion
  249
• 6.8 Special attachments Polo GT Rocket
  250
• 6.9 Side member extension, Polo Blue Motion, GTI Cup Edition and GT Rocket
  251
• 6.10 Preparing body kit component for bonding
  254
• 6.11 Preparing body kit component for bonding
  254
• 6.12 Installation instructions
  254
• 6.13 Minimum curing period
  255
• 6.14 Touching up paint damage
  255
• 6.15 Cleaning off excess adhesive sealing material
  255
• 7 Roof rail
  256
• 7.1 Roof rail, Polo Fun
  256
• 7.2 Roof rail, Cross Polo
  258
• 8 Lettering
  261
• 8.1 Tools
  261
• 8.2 Attachment notes for lettering
  261
• 8.3 Rear lettering dimensions
  261
• 8.4 Side lettering
  264