General body repairs, exterior

Chapter overview

• Technical data
  1
• 1 \--- Change history ---
  1
• Body - front
  2
• 1 Front end
  2
• 1.1 Front end with complementary parts - assembly overview
  2
• 1.2 Front end with complementary parts - remove and install
  4
• 1.3 Front end with complementary parts - service position
  8
• 2 Wing
  12
• 2.1 Front wing - assembly overview
  12
• 2.2 Front wing - remove and install
  12
• 3 Body - front section
  17
• 3.1 Upper bulkhead panel - assembly overview
  17
• 3.2 Plenum chamber cover - assembly overview
  17
• 3.3 Plenum chamber cover trim - remove and install
  18
• 3.4 Plenum chamber cover - remove and install
  19
• Bonnet, rear lid
  23
• 1 Bonnet
  23
• 1.1 Bonnet - assembly overview
  23
• 1.2 Operating cable - assembly overview
  24
• 1.3 Bonnet - remove and install
  25
• 1.4 Bonnet - adjust
  28
• 1.5 Bonnet latches - remove and install
  34
• 1.6 Bonnet latch handle - remove and install
  39
• 1.7 Bonnet fasteners - remove and install
  42
• 1.8 Hinges - remove and install
  43
• 1.9 Bonnet trim - remove and install
  45
• 1.10 Bonnet support rod - remove and install
  47
• 1.11 Bowden cable - remove and install
  49
• 2 Rear lid
  57
• 2.1 Rear lid - assembly overview
  57
• 2.2 Rear lid - remove and install
  59
• 2.3 Rear lid - adjust
  61
• 2.4 Rear lid lock - remove and install
  68
• 2.5 Rear lid hinges - remove and install
  70
• 2.6 Rear lid stop - remove and install
  73
• 2.7 Rear lid trim - remove and install
  74
• 2.8 Rear lid struts - remove and install
  75
• 2.9 Rear lid gas strut - remove
  77
• 3 Rear lid
  79
• 3.1 Rear lid - assembly overview
  79
• 3.2 Rear lid - remove and install
  79
• 3.3 Rear lid - adjust
  82
• 3.4 Rear lid lock - remove and install
  84
• 3.5 Rear lid hinges - remove and install
  86
• 3.6 Rear lid stop - remove and install
  88
• 3.7 Rear lid trim - remove and install
  90
• 3.8 Rear lid spring - remove and install
  92
• 4 Fuel tank cap unit
  94
• 4.1 Fuel tank flap unit - assembly overview
  94
• 4.2 Fuel tank flap unit - remove and install
  94
• 4.3 Fuel tank flap - remove and install
  97
• Front doors, door components, central locking
  99
• 1 Front doors
  99
• 1.1 Front doors - assembly overview
  99
• 1.2 Front door inner trim - remove and install
  102
• 1.3 Front door outer trim - remove and install
  104
• 1.4 Front doors - remove and install
  105
• 1.5 Front doors - adjust
  109
• 1.6 Front door strikers - adjust
  111
• 1.7 Door arresters - remove and install
  113
• 2 Door installation components
  116
• 2.1 Assembly parts - assembly overview
  116
• 2.2 Front door latch operation mechanism - assembly overview
  118
• 2.3 Front door external handle and lock - assembly overview
  119
• 2.4 Front door window mechanism motor - remove and install
  120
• 2.5 Front door window drive mechanism - remove and install
  122
• 2.6 Internal door trim - remove and install
  125
• 2.7 Front door striker - remove and install
  127
• 2.8 Exterior door handle cover - remove and install
  129
• 2.9 Door lock cylinder - remove and install
  135
• 2.10 External door handle - remove and install
  138
• 2.11 External handle support - remove and install
  140
• 2.12 Door lock - remove and install
  142
• 2.13 Window guide - remove and install
  147
• 2.14 Window compartment external trim - remove and install
  150
• 2.15 Window compartment internal trim - remove and install
  152
• 3 Central locking system
  153
• 3.1 Central locking - general assembly overview
  153
• 3.2 Ignition key battery - remove and install
  155
• 3.3 Ignition key cover - remove and install
  157
• 3.4 Fuel tank cap lock motor V155 - remove and install
  158
• Rear doors, door components
  160
• 1 Rear passenger doors/components (Polo)
  160
• 1.1 Rear door
  160
• 1.2 Door installation components
  177
• 2 Rear passenger doors/components (Polo)
  209
• 2.1 Rear door
  209
• 2.2 Door installation components
  226
• Bumpers
  258
• 1 Front bumper
  258
• 1.1 Front bumper cover - assembly overview
  258
• 1.2 Front bumper cover (Polo/Virtus GTS) - assembly overview
  260
• 1.3 Front protector support - assembly overview
  262
• 1.4 Front bumper protector - remove and install
  262
• 1.5 Support of the parking aid device sensor - install
  266
• 2 Rear bumper (Polo)
  271
• 2.1 Rear bumper protector - assembly overview
  271
• 2.2 Rear bumper cover (Polo/Virtus GTS) - assembly overview
  272
• 2.3 Rear protector support - assembly overview
  273
• 2.4 Rear bumper protector - remove and install
  274
• 2.5 Rear protector support - remove and install
  277
• 2.6 Support of the parking aid device sensor - install
  278
• 3 Rear bumper (Virtus)
  284
• 3.1 Rear bumper protector - assembly overview
  284
• 3.2 Rear protector support - assembly overview
  284
• 3.3 Rear bumper protector - remove and install
  285
• 3.4 Rear protector support - remove and install
  288
• 3.5 Support of the parking aid device sensor - install
  290
• Glazing
  296
• 1 Repair instructions
  296
• 1.1 Minimum adhesive drying time
  296
• 1.2 Assembly instructions and material for bonded windows
  296
• 1.3 Stickers for engraving the VIS number on the windows (only for Brazil) - supply
  298
• 1.4 Undamaged windows - prepare for install
  298
• 1.5 New glass - prepare for install
  299
• 1.6 Body flange - prepare to install the window
  301
• 1.7 Cleaning in case of resulting adhesive residues
  302
• 2 Windscreen
  303
• 2.1 Windscreen - assembly overview
  303
• 2.2 Windscreen - remove and install
  304
• 3 Rear window
  310
• 3.1 Rear window - assembly overview
  310
• 3.2 Rear window - remove and install
  310
• 4 Rear window
  315
• 4.1 Rear window - assembly overview
  315
• 4.2 Rear window - remove and install
  315
• 5 Side windows
  320
• 5.1 Rear side window - assembly overview
  320
• 5.2 Rear side window - remove and install
  320
• 6 Side windows
  324
• 6.1 Rear side window - assembly overview
  324
• 6.2 Rear side window - remove and install
  324
• 7 Door window glass
  328
• 7.1 Front door window glass - assembly overview
  328
• 7.2 Rear door window glass - assembly overview
  329
• 7.3 Front door window glass - remove and install
  329
• 7.4 Rear door window glass - remove and install
  333
• 8 Door window glass
  338
• 8.1 Front door window glass - assembly overview
  338
• 8.2 Rear door window glass - assembly overview
  339
• 8.3 Rear door fixed window - assembly overview
  339
• 8.4 Front door window glass - remove and install
  340
• 8.5 Rear door window glass - remove and install
  344
• 8.6 Rear door fixed window - remove and install
  348
• Exterior equipment
  352
• 1 Front grid
  352
• 1.1 Radiator grille - assembly overview
  352
• 1.2 Front bonnet - remove and install
  352
• 2 Trims and linings
  355
• 2.1 A-pillar exterior trim - remove and install
  355
• 2.2 B-pillar exterior trim - remove and install
  357
• 2.3 C-pillar exterior trim - remove and install
  362
• 2.4 External lining of lower longitudinal member (Polo Beats) - replace
  364
• 2.5 Side member trim - assembly overview
  366
• 2.6 Side member trim - remove and install
  367
• 3 Underbody trim
  374
• 3.1 Floor lower lining - assembly overview
  374
• 3.2 Underbody trim - remove and install
  374
• 4 External rear-view mirror
  377
• 4.1 External rear-view mirror - assembly overview
  377
• 4.2 Exterior rear-view mirror - remove and install
  379
• 4.3 Mirror glass - remove and install
  384
• 4.4 Mirror adjustment unit - remove and install
  386
• 4.5 Mirror glass - remove and install
  388
• 4.6 Mirror trim - remove and install
  389
• 5 Wheel housing liner
  391
• 5.1 Front wheel housing liner - assembly overview
  391
• 5.2 Rear wheel housing liner - assembly overview
  392
• 5.3 Rear wheel housing liner - assembly overview
  392
• 5.4 Front wheel housing liner - remove and install
  393
• 5.5 Rear wheel housing liner - remove and install
  395
• 5.6 Rear wheel housing liner - remove and install
  397
• 6 Badges and letterings
  399
• 6.1 Letterings on the rear lid (Polo) - measurements
  399
• 6.2 Letterings on the rear lid (Virtus) - measurements
  403
• 6.3 Side letterings - measurements
  409
• 6.4 GTS model designation – remove and install
  412
• 6.5 Front badge - remove and install
  413
• 6.6 Badge on the rear lid (Polo)- replace
  414
• 6.7 Badge on the rear lid (Virtus)- replace
  416
• 7 “LATIN NCAP” badge (Rear window) - remove and install
  418
• 8 “LATIN NCAP” badge (Rear window) - remove and install
  420
• 9 Rear spoiler
  422
• 9.1 Rear spoiler
  422
• 9.2 Rear spoiler (Virtus GTS) – assembly overview
  429
• 9.3 Rear spoiler (Virtus GTS) - remove and install
  429
• 10 Heat shields
  433
• 10.1 Heat shields - assembly overview
  433
• 10.2 Heat shield for the centre tunnel - remove and install
  433
• 10.3 Heat shield for the fuel tank region - remove and install
  434
• 10.4 Heat shield for the rear silencer - remove and install
  435