General body repairs, exterior

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with start/stop system
  1
• 2 Repair instructions
  2
• 2.1 Bonding surfaces for self-adhesive components
  2
• 2.2 Secured threaded connections
  2
• Body - front
  3
• 1 Lock carrier
  3
• 1.1 Assembly overview – lock carrier
  3
• 1.2 Removing and installing lock carrier
  4
• 1.3 Moving to and back from service position
  8
• 2 Wings
  13
• 2.1 Assembly overview – wing
  13
• 2.2 Removing and installing wing
  14
• 2.3 Removing and installing wing bracket
  19
• 3 Plenum chamber bulkhead
  23
• 3.1 Assembly overview – bulkhead
  23
• 3.2 Assembly overview – plenum chamber cover
  23
• 3.3 Removing and installing bulkhead
  24
• 3.4 Removing and installing plenum chamber cover
  25
• Bonnet, rear lid
  30
• 1 Bonnet
  30
• 1.1 Assembly overview – bonnet
  30
• 1.2 Assembly overview – Bowden cable
  32
• 1.3 Removing and installing bonnet
  34
• 1.4 Adjusting bonnet
  36
• 1.5 Removing and installing rear lid lock
  40
• 1.6 Removing and installing bonnet lock operating lever
  44
• 1.7 Removing and installing striker pin
  47
• 1.8 Removing and installing hinges
  49
• 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
  67
• 2.4 Removing and installing rear lid lock
  73
• 2.5 Removing and installing operating mechanism
  75
• 2.6 Removing and installing hinges
  79
• 2.7 Removing and installing striker pin
  81
• 2.8 Removing and installing rear lid seal
  83
• 2.9 Removing and installing gas strut
  85
• 2.10 Releasing gas from gas strut
  87
• 3 Tank flap unit
  89
• 3.1 Assembly overview - tank flap unit
  89
• 3.2 Removing and installing tank flap unit
  89
• 3.3 Removing and installing fuel tank flap
  93
• 4 Charging flap unit
  96
• 4.1 Assembly overview – charging flap unit
  96
• 4.2 Removing and installing charging flap unit
  96
• Front doors, door components, central locking
  98
• 1 Door
  98
• 1.1 Assembly overview – door
  98
• 1.2 Removing and installing inner door seal
  101
• 1.3 Removing and installing outer door seal
  103
• 1.4 Removing and installing door
  104
• 1.5 Adjusting door
  108
• 1.6 Adjusting striker pin
  112
• 1.7 Removing and installing door arrester
  114
• 2 Door components
  116
• 2.1 Assembly overview – door components
  116
• 2.2 Assembly overview – subframe
  117
• 2.3 Assembly overview – door handle and door lock
  118
• 2.4 Removing and installing window regulator motor
  120
• 2.5 Removing and installing striker pin
  122
• 2.6 Removing and installing lock cylinder
  124
• 2.7 Removing and installing door handle
  126
• 2.8 Removing and installing door handle trim
  128
• 2.9 Removing and installing mounting bracket
  132
• 2.10 Removing and installing door lock
  135
• 2.11 Removing and installing door subframe
  138
• 2.12 Removing and installing window channel
  141
• 2.13 Removing and installing window slot outer seal
  143
• 2.14 Removing and installing window slot inner seal
  145
• 3 Central locking
  147
• 3.1 Overview of fitting locations – central locking system
  147
• 3.3 Removing and installing tank filler flap locking motor V155
  150
• 3.4 Removing and installing actuator for high-voltage charging flap lock 1 F496
  151
• 3.5 Removing and installing ignition key battery
  152
• Rear doors, door components
  153
• 1 Door
  153
• 1.1 Assembly overview – door
  153
• 1.2 Removing and installing door
  156
• 1.3 Adjusting door
  160
• 1.4 Adjusting striker pin
  163
• 1.5 Removing and installing door arrester
  164
• 1.6 Removing and installing inner door seal
  166
• 2 Door components
  169
• 2.1 Assembly overview – door components
  169
• 2.2 Assembly overview – subframe
  170
• 2.3 Assembly overview – door handle and door lock
  171
• 2.4 Removing and installing window regulator motor
  172
• 2.5 Removing and installing striker pin
  175
• 2.6 Removing and installing door handle
  176
• 2.7 Removing and installing door handle trim
  178
• 2.8 Removing and installing mounting bracket
  180
• 2.9 Removing and installing door lock
  184
• 2.10 Removing and installing door subframe
  187
• 2.11 Removing and installing window channel
  189
• 2.12 Removing and installing window slot outer seal
  192
• 2.13 Removing and installing window slot inner seal
  193
• Sunroof
  195
• 1 Sliding sunroof
  195
• 1.1 Assembly overview – sliding sunroof
  195
• 1.2 Assembly overview - sliding sunroof seals
  197
• 1.3 Assembly overview – sunroof roller blind
  197
• 1.4 Removing and installing sliding sunroof frame
  199
• 1.5 Removing and installing wind deflector
  209
• 1.6 Removing and installing glass panel
  212
• 1.7 Adjusting sunroof panel
  214
• 1.8 Removing and installing slotted guide
  216
• 1.9 Removing and installing front trim for sliding sunroof
  219
• 1.10 Removing and installing sliding sunroof adjustment control unit J245
  221
• 1.11 Removing and installing sliding sunroof seals
  223
• 1.12 Removing and installing sunroof roller blind
  228
• 1.13 Removing and installing sunroof motor V1
  234
• 1.14 Manual operation
  237
• Bumpers
  239
• 1 Bumper, front
  239
• 1.1 Assembly overview – bumper cover
  239
• 1.2 Assembly overview – add-on parts
  240
• 1.3 Assembly overview – bumper carrier
  245
• 1.4 Removing and installing bumper cover
  246
• 1.5 Repairing bumper cover
  249
• 1.6 Removing and installing add-on parts, R-Line
  249
• 1.7 Removing and installing attachments, R model
  256
• 1.8 Removing and installing add-on parts, GTI Clubsport
  260
• 1.9 Installing sender retainer for park assist steering
  264
• 2 Bumper, rear
  269
• 2.1 Assembly overview – bumper cover
  269
• 2.2 Assembly overview – bumper carrier
  273
• 2.3 Removing and installing bumper cover
  274
• 2.4 Removing and installing add-on parts, R-Line
  277
• 2.5 Removing and installing attachments, R model
  279
• 2.6 Removing and installing add-on parts, GTI Clubsport
  280
• 2.7 Removing and installing bumper carrier
  282
• 2.8 Removing and installing forced ventilation in passenger compartment
  284
• 2.9 Checking forced ventilation in passenger compartment
  285
• 2.10 Repairing bumper cover
  286
• 2.11 Installing sender retainer for parking aid
  286
• 2.12 Installing sender retainer for park assist steering
  291
• Glazing
  295
• 1 Repair instructions
  295
• 1.1 Minimum drying times for bonded windows
  295
• 1.2 Window repair
  295
• 1.3 Installation instructions for bonded windows
  296
• 1.4 Preparing old undamaged windows for installing
  297
• 1.5 Preparing new windows for installing
  299
• 1.6 Preparing body flange for installing
  300
• 1.7 Cleaning off excess adhesive
  302
• 2 Windscreen
  303
• 2.1 Assembly overview – windscreen
  303
• 2.2 Removing and installing windscreen
  304
• 3 Rear windscreen
  313
• 3.1 Assembly overview – rear window
  313
• 3.2 Removing and installing rear window
  314
• 4 Side windows
  320
• 4.1 Assembly overview - front side window
  320
• 4.2 Removing and installing front side window
  320
• 5 Door windows
  324
• 5.1 Assembly overview - front door window
  324
• 5.2 Assembly overview - rear door window
  325
• 5.3 Removing and installing front door window
  326
• 5.4 Removing and installing rear door window
  330
• 5.5 Removing and installing fixed rear door window
  334
• Exterior equipment
  337
• 1 Radiator grille and front trim
  337
• 1.1 Assembly overview – radiator grille
  337
• 1.2 Removing and installing radiator grille
  337
• 2 Spoiler
  341
• 2.1 Assembly overview – spoiler
  341
• 2.2 Removing and installing spoiler
  341
• 3 Mouldings, trims, extensions
  345
• 3.1 Assembly overview – water deflector
  345
• 3.3 Removing and installing water deflector
  346
• 3.4 Removing and installing side member trim
  348
• 3.5 Removing and installing B-pillar trim on door
  357
• 3.6 Removing and installing wheel arch trim
  360
• 4 Noise insulation
  363
• 4.1 Assembly overview - noise insulation
  363
• 5 Underbody cladding
  368
• 5.1 Overview of fitting locations - underbody cladding
  368
• 5.2 Assembly overview - bracing on underbody
  372
• 5.3 Removing and installing underbody cladding
  373
• 5.4 Removing and installing tunnel cross-piece
  379
• 6 Trim film and protective film
  383
• 6.1 Renewing protective films
  383
• 7 Exterior mirror
  385
• 7.1 Assembly overview – exterior mirror
  385
• 7.2 Removing and installing exterior mirror
  386
• 7.3 Removing and installing mirror glass
  389
• 7.4 Removing and installing mirror adjustment unit
  390
• 7.5 Removing and installing mirror cover
  392
• 7.6 Removing and installing mirror frame
  393
• 8 Wheel housing liner
  395
• 8.1 Assembly overview – front wheel housing liner
  395
• 8.2 Assembly overview – rear wheel housing liner
  396
• 8.3 Removing and installing front wheel housing liner
  398
• 8.4 Removing and installing rear wheel housing liner
  400
• 9 Lettering and emblems
  403
• 9.1 Dimensions - lettering and emblems on rear
  403
• 9.2 Dimensions - lettering and emblems on sides
  406
• 9.3 Removing and installing badges at front
  408
• 9.4 Renewing lettering and badges at rear
  411
• 9.5 Renewing lettering and badges on sides
  413
• 10 Towing bracket
  414
• 10.1 Assembly overview – towing bracket
  414
• 10.2 Removing and installing towing bracket
  414
• 10.3 Removing and installing trigger unit
  416
• 11 Heat shields
  418
• 11.1 Overview of fitting locations - heat shields
  418
• 11.2 Removing and installing underbody heat shield
  419
• 11.3 Removing and installing heat shield for centre exhaust system
  421
• 11.4 Removing and installing heat shield for propshaft
  422
• 11.5 Removing and installing heat shield for tank system
  422
• 11.6 Removing and installing heat shield for rear silencer
  422