General body repairs, exterior

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• Body - front
  2
• 1 Lock carrier
  2
• 1.1 Assembly overview – lock carrier
  2
• 1.2 Removing and installing lock carrier
  6
• 1.3 Moving to and back from service position
  12
• 2 Wings
  16
• 2.1 Assembly overview – wing
  16
• 2.2 Removing and installing wing
  16
• 3 Bulkhead
  21
• 3.1 Assembly overview – bulkhead
  21
• 3.2 Assembly overview – plenum chamber cover
  21
• 3.3 Removing and installing bulkhead
  22
• 3.4 Removing and installing plenum chamber cover
  23
• Bonnet, rear lid
  27
• 1 Bonnet
  27
• 1.1 Assembly overview – bonnet
  27
• 1.2 Assembly overview – Bowden cable
  28
• 1.3 Removing and installing bonnet
  29
• 1.4 Adjusting bonnet
  32
• 1.5 Removing and installing bonnet lock
  39
• 1.6 Removing and installing bonnet lock operating lever
  44
• 1.7 Removing and installing striker pin
  47
• 1.8 Removing and installing hinges
  48
• 1.9 Renewing hinges
  50
• 1.10 Removing and installing insulation
  52
• 1.11 Removing and installing bonnet stay
  53
• 1.12 Removing and installing Bowden cable
  55
• 2 Rear lid
  63
• 2.1 Assembly overview – rear lid
  63
• 2.2 Removing and installing rear lid
  65
• 2.3 Adjusting rear lid
  68
• 2.4 Removing and installing bonnet lock
  75
• 2.5 Removing and installing operating mechanism
  77
• 2.6 Removing and installing hinges
  82
• 2.7 Removing and installing striker pin
  85
• 2.8 Removing and installing rear lid seal
  86
• 2.9 Removing and installing gas strut
  88
• 2.10 Releasing gas from gas strut
  89
• 3 Tank flap unit
  91
• 3.1 Assembly overview – tank flap unit
  91
• 3.2 Removing and installing tank flap unit
  91
• 3.3 Removing and installing fuel tank flap
  94
• Front doors, door components, central locking
  96
• 1 Door
  96
• 1.1 Assembly overview – door
  96
• 1.2 Removing and installing inner door seal
  99
• 1.3 Removing and installing outer door seal
  101
• 1.4 Removing and installing door
  103
• 1.5 Adjusting door
  107
• 1.6 Adjusting striker pin
  109
• 1.7 Removing and installing door arrester
  111
• 2 Door components
  114
• 2.1 Assembly overview – door components
  114
• 2.2 Assembly overview – window regulator
  116
• 2.3 Assembly overview – door handle and door lock
  116
• 2.4 Removing and installing window regulator motor
  117
• 2.5 Removing and installing window regulator
  120
• 2.6 Removing and installing inner door cover
  123
• 2.7 Removing and installing striker pin
  125
• 2.8 Removing and installing cap on door handle
  127
• 2.9 Removing and installing lock cylinder
  133
• 2.10 Removing and installing door handle
  136
• 2.11 Removing and installing mounting bracket
  138
• 2.12 Removing and installing door lock
  140
• 2.13 Removing and installing window channel
  145
• 2.14 Removing and installing window slot outer seal
  148
• 2.15 Removing and installing window slot inner seal
  150
• 3 Central locking
  151
• 3.1 Overview of fitting locations – central locking system
  151
• 3.2 Removing and installing ignition key battery
  153
• 3.3 Removing and installing cap on ignition key
  155
• 3.4 Removing and installing tank filler flap locking motor V155
  156
• Rear doors, door components
  158
• 1 Door
  158
• 1.1 Assembly overview – door
  158
• 1.2 Removing and installing door
  161
• 1.3 Adjusting door
  164
• 1.4 Adjusting striker pin
  166
• 1.5 Removing and installing door arrester
  168
• 1.6 Removing and installing inner door seal
  170
• 1.7 Removing and installing outer door seal
  172
• 2 Door components
  174
• 2.1 Assembly overview – door components
  174
• 2.2 Assembly overview – window regulator
  176
• 2.3 Assembly overview – door handle and door lock
  176
• 2.4 Removing and installing window regulator motor
  177
• 2.5 Removing and installing window regulator
  180
• 2.6 Removing and installing window crank
  183
• 2.7 Removing and installing inner door cover
  186
• 2.8 Removing and installing striker pin
  188
• 2.9 Removing and installing cap on door handle
  190
• 2.10 Removing and installing door handle
  194
• 2.11 Removing and installing mounting bracket
  196
• 2.12 Removing and installing door lock
  199
• 2.13 Removing and installing window channel
  203
• 2.14 Removing and installing window slot outer seal
  206
• 2.15 Removing and installing window slot inner seal
  207
• Sunroof
  209
• 1 Sliding sunroof
  209
• 1.1 Assembly overview – sliding sunroof
  209
• 1.2 Assembly overview - sunroof seals
  211
• 1.3 Assembly overview – sunroof roller blind
  211
• 1.4 Removing and installing glass panel
  212
• 1.5 Adjusting sunroof panel
  215
• 1.6 Removing and installing front trim for sliding sunroof
  217
• 1.7 Removing and installing wind deflector
  218
• 1.8 Removing and installing sunroof roller blind
  221
• 1.9 Removing and installing sliding sunroof frame
  228
• 1.10 Removing and installing J245sliding sunroof adjustment control unit
  237
• 1.11 Removing and installing sunroof motor V1
  239
• 1.12 Manual operation
  242
• 1.13 Removing and installing slotted guide
  243
• 1.14 Removing and installing sliding sunroof seals
  247
• 1.15 Programming sliding sunroof adjustment control unit J245
  254
• Bumpers
  255
• 1 Bumper, front
  255
• 1.1 Assembly overview – bumper cover
  255
• 1.2 Assembly overview – bumper carrier
  258
• 1.3 Removing and installing bumper cover
  259
• 1.4 Repairing bumper cover
  263
• 1.5 Installing holder for parking aid sender
  263
• 1.6 Installing retainer for parking aid sender
  269
• 2 Bumper, rear
  274
• 2.1 Assembly overview – bumper cover
  274
• 2.2 Assembly overview – bumper carrier
  276
• 2.3 Removing and installing bumper cover
  277
• 2.4 Removing and installing bumper carrier
  280
• 2.5 Repairing bumper cover
  282
• 2.6 Installing holder for parking aid sender
  282
• 2.7 Installing retainer for parking aid sender
  287
• 2.8 Removing and installing forced ventilation for passenger compartment
  291
• 2.9 Checking forced ventilation for passenger compartment
  293
• Glazing
  294
• 1 Repair notes
  294
• 1.1 Minimum drying times for bonded windows
  294
• 1.2 Window repair
  295
• 1.3 Installation instructions for bonded windows
  295
• 1.4 Preparing old undamaged windows for installing
  297
• 1.5 Preparing new windows for installing
  298
• 1.6 Preparing body flange for installing
  300
• 1.7 Cleaning off excess adhesive
  301
• 2 Windscreen
  302
• 2.1 Assembly overview – windscreen
  302
• 2.2 Removing and installing windscreen
  303
• 3 Rear windscreen
  311
• 3.1 Assembly overview – rear window
  311
• 3.2 Removing and installing rear window
  312
• 4 Side windows
  316
• 4.1 Assembly overview - rear side windows
  316
• 4.2 Removing and installing rear side window
  317
• 5 Door windows
  321
• 5.1 Assembly overview - front door window
  321
• 5.2 Assembly overview - rear door window
  321
• 5.3 Removing and installing front door window
  322
• 5.4 Removing and installing rear door window
  326
• Exterior equipment
  330
• 1 Radiator grille and front trim
  330
• 1.1 Assembly overview – radiator grille
  330
• 1.2 Removing and installing radiator grille
  330
• 2 Spoiler
  333
• 2.1 Assembly overview - spoiler, GTI, R-Line
  333
• 2.2 Removing and installing spoiler, GTI, R-Line
  333
• 3 Mouldings, trims, extensions
  341
• 3.1 Assembly overview - side member trim, GTI, R-Line
  341
• 3.2 Removing and installing A-pillar trim
  341
• 3.3 Removing and installing B-pillar trim on door
  343
• 3.4 Removing and installing C-pillar trim on door
  346
• 3.5 Removing and installing step moulding
  348
• 3.6 Removing and installing side member trim, GTI, R-Line
  350
• 4 Noise insulation
  355
• 4.1 Assembly overview - noise insulation
  355
• 5 Underbody cladding
  358
• 5.1 Overview of fitting locations - underbody cladding
  358
• 5.2 Removing and installing underbody cladding
  358
• 5.3 Removing and installing centre underbody panels
  360
• 5.4 Removing and installing rear underbody cladding
  363
• 6 Exterior mirror
  365
• 6.1 Assembly overview – exterior mirror
  365
• 6.2 Removing and installing exterior mirror
  366
• 6.3 Removing and installing mirror glass
  371
• 6.4 Removing and installing mirror adjustment unit
  373
• 6.5 Removing and installing mirror cover
  375
• 6.6 Removing and installing mirror frame
  376
• 6.7 Removing and installing turn signal
  377
• 7 Wheel housing liner
  379
• 7.1 Assembly overview – front wheel housing liner
  379
• 7.2 Assembly overview – rear wheel housing liner
  380
• 7.3 Removing and installing front wheel housing liner
  380
• 7.4 Removing and installing rear wheel housing liner
  382
• 8 Trim film and protective film
  384
• 8.1 Renewing decorative film and protective film
  384
• 8.2 Decorative film dimensions
  385
• 8.3 Renewing decorative film
  385
• 9 Lettering and badges
  388
• 9.1 Dimensions - lettering and badges on rear
  388
• 9.2 Dimensions – lettering and badges on sides
  395
• 9.3 Renewing lettering and badges on sides, GTI, R-Line
  398
• 9.4 Removing and installing lettering and emblems for radiator grille
  400
• 9.5 Renewing lettering and badges at rear
  404
• 10 Special add-on parts
  405
• 10.1 Assembly overview - special add-on parts, GTI, R-Line
  405
• 11 Towing bracket
  406
• 11.1 Assembly overview – towing bracket
  406
• 11.2 Removing and installing towing bracket
  407
• 12 Heat shields
  410
• 12.1 Overview of fitting locations – heat shields
  410
• 12.2 Removing and installing underbody heat shield
  410
• 12.3 Removing and installing heat shield for centre exhaust system
  411
• 12.4 Removing and installing heat shield for rear silencer
  412