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General body repairs, exterior

For Polo

Original Volkswagen repair manual


21,84 €7% VAT incl.

  • Deutsch
  • English

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Language: English

Digital PDF file

6.015 KB

273 Sites

Detailed technical data

Immediately readable

This repair manual contains: Lock carrier, Wing, Noise insulation, Bonnet, Rear lid, Sliding/tilting sunroof, Front bumper, Rear bumper, Polo GTI Cup Edition, Flush bonded windows, Removal and installation of wheel housing liner, Exterior mirror, Roof edge spoiler and Special attachments. Show more
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Repair manual Polo General body repairs, exterior PDF download has the following content:

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
Manufacturer's designation General body repairs, exterior
Manufacturer Volkswagen
Suitable for Polo (2002 - 2005) / Polo (2005 - 2007)
Suitable car types 9N1, 9N3
Category Reparaturanleitung

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