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Volkswagen 2004 Golf, Workshop Manual

The Volkswagen 2004 Golf Workshop Manual is a comprehensive guide that offers step-by-step instructions for servicing and repairing your vehicle. This invaluable manual can be downloaded for free from our website, providing you with the necessary knowledge and expertise to maintain your Volkswagen Golf.

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15 - Cable

❑ To release lock from outer door handle

1.15

Removing and installing housing

Note

Removal and installation sequence is only for right housing. Re‐

moval and installation of left housing is similar.

1.15.1

Removing

– Lever out caps in front of bolts -1-.
– Pull door handle -2- in -direction of arrow- and unscrew bolt

-1- using socket wrench -T 10072- until housing -3- can be

pulled out.

– Pull housing -3- out of door handle mounting bracket at right

angles to door.

1.15.2

Installing

– Fit housing -2- into door handle mounting bracket at right an‐

gles.

Door handle -1- must rest only lightly against door panel.
– Now tighten bolt -3- in bearing plate using socket -T 10072- .
The door handle engages in the lock cylinder housing with an

audible click.

Note

During installation, housing must be pressed against door panel.

Door handle rests only lightly against door panel.

– Then perform remaining installation in reverse order of remov‐

al.

• Then always check function while door is still open, as an in‐

correctly fitted and adjusted Bowden cable cannot open the

door.

1.16

Removing and installing door handle

Note

The removal and installation sequence is only for the right door

handle. The removal and installation of the left door handle is

similar.

Golf 2004 ➤

General body repairs, exterior - Edition 04.2008

106

     Rep. Gr.58 - Rear doors, door components

Summary of Contents for 2004 Golf

Page 1: ... n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Workshop Manual Golf 2004 General body repairs exterior Edition 04 2008 Service Service Department Technical Information ...

Page 2: ...nual Repair GroupsList of Workshop Manual Repair Groups Repair Group 50 Body front 55 Bonnet rear lid 57 Front doors door components central locking 58 Rear doors door components 60 Sunroof 63 Bumpers 64 Glazing 66 Exterior equipment Technical information should always be available to the foremen and mechanics because their careful and constant adherence to the instructions is essential to ensure ...

Page 3: ... 5 2 Assembly overview plenum chamber bulkhead 16 55 Bonnet rear lid 17 1 Bonnet 17 1 1 Tools 17 1 2 Assembly overview bonnet 18 1 3 Removing and installing bonnet 19 1 4 Removing gas strut 20 1 5 Releasing gas from gas strut 20 1 6 Removing and installing flap hinge 20 1 7 Removing and installing insulation 22 1 8 Assembly overview bonnet latch and release components 24 1 9 Removing and installin...

Page 4: ...mbly overview side impact protection 74 1 20 Door inner seal 74 1 21 Removing and installing door inner seal 75 1 22 Removing and installing door outer seal 77 2 Central locking 80 2 1 Location overview central locking components 80 2 2 Adapting keys with remote control 81 2 3 Assembly overview battery for folding key with remote control 82 2 4 Removing and installing battery for folding key with ...

Page 5: ...l running 130 1 17 Assembly overview carrier unit 131 1 18 Removing and installing carrier unit 132 1 19 Operating without electrics 134 1 20 Removing and installing guide plate 134 1 21 Removing and installing sliding gate 135 1 22 Cleaning water drain hoses 136 63 Bumpers 139 1 Front bumper 139 1 1 Tools 139 1 2 Repairing bumper cover 139 1 3 Assembly overview bumper cover 140 1 4 Removing and i...

Page 6: ...erview windscreen 178 1 5 Assembly overview plenum chamber cover 179 1 6 Removing windscreen 182 1 7 Installing windscreen 182 1 8 Assembly overview rear window 183 1 9 Removing undamaged rear window 183 1 10 Removing broken rear window 184 1 11 Installing rear window 185 1 12 Assembly overview rear side window 186 1 13 Removing undamaged rear side window 186 1 14 Removing damaged rear side window...

Page 7: ...g exterior mirror 227 3 Radiator grille 229 3 1 Tools 229 3 2 Assembly overview radiator grille 229 3 3 Removing and installing radiator grille 230 3 4 Assembly overview radiator grille for GTI GTI special models and GT 231 3 5 Removing and installing radiator grille for GT GTI special models and GT 233 3 6 Radiator grille for GTI GTI special models GT and R32 number plate carrier 235 3 7 Assembly...

Page 8: ... h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 6 1 Attachment notes for protective backing 266 6 2 Renewing scuff protection film 267 7 Lettering 268 7 1 Tools 268 7 2 Installation instructions for lettering and emblems 268 7 3 Rear lettering dimensions 269 7 4 Rear lettering dimensions for GTI and R32 270 7 5 Rear lettering dimensions USA 272 7 6 Side lettering dimensions In...

Page 9: ... b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 50 Body front 1 Lock carrier 1 1 Tools 1 1 1 Required special tools workshop equip ment test and measuring devices and auxiliary items Guide pins T 10093 Torque wrench 5 50 Nm V A G 1331 Torque wrench 40 200 Nm V A G 1332 Golf 2004 G...

Page 10: ... c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 2 Assembly overview lock carrier service position 1 Lock carrier with add on parts Removing and installing page 4 Service position page 3 2 Bolt Qty 4 8 Nm 3 Bolt Qty 8 60 Nm Golf 2004 General body repairs exter...

Page 11: ...Remove front bumper page 140 GTI page 147 R32 page 151 Unhook Bowden cable at coupling page 26 If vehicle has charge air cooler disconnect pressure hoses page 4 Unscrew horn 4 with bracket on right side of longitudinal member Electrical system Rep Gr 96 Interior lights lamps switches Removing and installing horn Remove bolts 3 from left and right longitudinal members Attach special tool guide pins...

Page 12: ...carrier to longitudinal members and between wings Body Repairs Rep Gr 00 Technical data Body gap di mensions Note Ensure that the charge air cooler pressure hoses are properly engaged again Hoses and lines must not be pinched 1 3 3 Releasing pressure hoses Release push on coupling 1 and pull pressure hose 2 in direction of arrow out of coupling During installation of pressure hoses ensure that pus...

Page 13: ...dd on parts 1 to service position page 3 Disconnect all electrical connectors Drain coolant and disconnect coolant lines Engine cooling system Rep Gr 19 Parts of cooling system Draining and filling coolant Disconnect wiring for condenser Heating and air condition ing system Rep Gr 87 Air conditioning system Removing and installing condenser Together with a second mechanic unscrew guide pins T 1009...

Page 14: ...f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Note Do not hang condenser and hydraulic oil cooler from lines Do not kink condenser and hydraulic lines 1 4 2 Installing Install in reverse order of removal During assembly ensure that all connectors and hose con nections are properly installed Align lock carrier to longitudinal members and between wings B...

Page 15: ... VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 Wing 2 1 Tools Special tools and workshop equipment required Torque wrench 2 10 Nm V A G 1783 Hot air blower V A G 1416 Golf 2004 General body repairs exterior Edition 04 2008 2...

Page 16: ...ide is similar 1 Wing Removing and installing page 8 2 Bolt Qty 1 A pillar Qty 2 side member Qty 2 wheel housing Qty 2 wing strut Qty 3 wing connection piece 6 Nm 3 Intermediate piece zinc AKL 381 035 50 4 Foam piece Loosely inserted be tween wing and top of longitudinal member 5 Wing strut Removing and installing page 10 6 Moulded foamed plastic part Inserted on top of longi tudinal member Bonds ...

Page 17: ... i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 3 1 Removing Remove front bumper page 140 Remove wheel housing liners page 218 Remove guide Item 10 page 143 Loosen hexagon nut 6 and remove bolts 2 Pull out moulded plastic part 3 between wing and longitudinal member Lightly heat outside of wing 1 in area of moulded foam part arrow using hot air blower V A G 1416 T...

Page 18: ... 2 3 2 Installing Install in reverse order of removal Always insert zinc intermediate piece AKL 381 035 50 be tween wing and side member Specified torque for bolts 2 and hexagon nuts 5 6 Nm Ensure that gaps are parallel and specified dimensions are maintained Body Repairs Rep Gr 00 Technical data Body panel gaps shut lines 2 4 Removing and installing wing strut Note The removal and installation se...

Page 19: ...b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove bolts 2 and remove wing strut 1 2 4 2 Installing Install wing strut 1 Specified torque for bolts 2 6 Nm Wing and wing strut are adjusted together to bonnet and bumper Body Repairs Rep Gr 00 Technical data Body gap dimensions Go...

Page 20: ... VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 Noise insulation 3 1 Tools Special tools and workshop equipment required Torque wrench 2 10 Nm V A G 1783 Golf 2004 General body repairs exterior Edition 04 2008 12 Rep Gr 50 Bo...

Page 21: ...t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 2 Assembly overview noise insulation Note The removal and installation procedures may have to be modified slightly depending on engine fitted 1 Noise insulation Arrow points forwards Removing Remove bolts 2 and 3 2 Bolt Qty 8 2 Nm 3 Bolt Qty 3 6 Nm...

Page 22: ...VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 Underbody cladding 4 1 Tools Special tools and workshop equipment required Torque wrench 2 10 Nm V A G 1783 Golf 2004 General body repairs exterior Edition 04 2008 14 Rep Gr 50 B...

Page 23: ...n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 2 Assembly overview underbody cladding Note Only the left side is shown The right side is similar 1 Underbody cladding Arrow points forwards Removing Remove hexagon nuts 2 2 Hexagon nut Qty 8 1 5 Nm 3 Rear underbody cladding Installed only on left hand side Removing Remove hexagon nut 4 and bolts 5 4 Hexagon nut Qty 1 1 ...

Page 24: ... c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 5 Plenum chamber bulkhead 5 1 Tools Special tools and workshop equipment required Torque wrench 2 10 Nm V A G 1783 5 2 Assembly overview plenum chamber bulkhead 1 Plenum chamber bulkhead 2 Hexagon nut 8 Nm 3 Plenum chamber bulkhead seal When fitting bulkhead ensure seal is cor...

Page 25: ...enAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 55 Bonnet rear lid 1 Bonnet 1 1 Tools Special tools and workshop equipment required Torque wrench 5 50 Nm V A G 1331 Removal lever 80 200 Golf 2004 General body repairs exterior Edition 04...

Page 26: ...r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 2 Assembly overview bonnet 1 Bonnet Removing and installing page 19 Adjusting page 26 2 Adjustment buffer Qty 2 Adjusting page 26 3 Stop buffer Qty 2 4 Insulation Removing and installing page 22 5 Guide Qty 2 6 Hinge Removing and installing page 20 Adjusting page 26 7 Gas strut Removing page 20 Releasing gas ...

Page 27: ...emoving and installing bonnet 1 3 1 Removing Remove left and right washer jets 6 Electrical system Rep Gr 92 Window wiper washer system Windscreen washer system Removing and installing windscreen washer system jets Unclip line 2 from hinge 3 and bonnet 5 Pull line 2 out through aperture in bonnet 5 Loosen hexagon nuts 1 on left and right do not remove Further dismantling requires the help of a sec...

Page 28: ...as strut 1 slide spring clip 2 back immediately WARNING Proceed with care if gas strut is reused Spring clip must not be levered completely out of ball socket as it will otherwise be damaged Gas strut will spring out of mounting causing dam age or injury to operator Specified torque for ball head pins 3 and 4 22 Nm Releasing gas from gas strut page 20 1 5 Releasing gas from gas strut Clamp gas str...

Page 29: ...nteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 6 1 Removing Remove bonnet page 19 Remove bolts 2 and remove bonnet hinge 1 1 6 2 Installing Install flap hinge 1 Specified torque for bolts 2 22 Nm Install flap page 19 Golf 2004 General body repairs ex...

Page 30: ...c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 7 Removing and installing insulation 1 7 1 Removing Lever retaining clips 1 Qty 10 out of insulation 2 using removal lever 80 200 Pull insulation 2 out of elongated holes Golf 2004 General body repairs exterior E...

Page 31: ...y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 7 2 Installing Push insulation 2 underneath gas strut and place assembly tongues in elongated holes Engage all retaining clips 1 Qty 10 in insulation 2 When installing insulation 2 ensure that retaining clips 1 are fitted with wider side outw...

Page 32: ... 8 Assembly overview bonnet latch and release components 1 Arrester Removing Remove bolts 2 and remove latch hook Adjusting Adjustment is carried out by moving arrester to left or right in elonga ted holes 2 Bolt Qty 3 10 Nm 3 Expanding nut Qty 2 4 Bearing bracket 5 Bowden cable Clipped into bearing bracket 6 Bolt Qty 2 1 5 Nm 7 Release lever Removing and installing page 28 8 Bowden cable Clipped ...

Page 33: ... radiator grille page 237 All models Separating Bowden cable page 26 Separate connector 5 for bonnet contact switch F 266 The connector is secured over the right headlight Remove bolts 4 Qty 3 on lock carrier 3 and remove bon net lock 1 upwards To unclip Bowden cable 2 press tab and Bowden cable to gether arrows The fastening is released and the Bowden cable 2 can be removed from the bonnet lock 1...

Page 34: ...10 Separating Bowden cable Open bonnet Unclip Bowden coupling 1 above headlight on driver side of lock carrier 2 Open Bowden cable coupling 1 upwards and remove Bow den cable 3 in direction of arrow out of Bowden cable coupling Note When installing ensure that the Bowden cable sleeve is inserted correctly and the coupling engages Before closing the bonnet check the function of the release lever an...

Page 35: ...he stop buffers 7 Qty 2 are not used for adjustment They have the function of stabilising and damping the bonnet 1 The front part of the bonnet 1 can be adjusted to wing height by using the adjustment buffers 8 Qty 2 Ensure that gaps are uniform Body Repairs Rep Gr 00 Technical data Body gaps shut lines Carry out corrosion protection measures on hinge 4 hexa gon nuts 5 and bolts 3 following assemb...

Page 36: ...y r i g h t b y V o l k s w a g e n A G 1 12 Removing and installing release lever 1 12 1 Removing Pull release lever 1 and release bonnet Insert a small screwdriver in gap between release lever 1 and clip 2 Lever clip 2 out of release lever 1 and pull off release lever 1 12 2 Installing Slide clip 2 completely into release lever 1 Then press release lever 1 onto mounting in mounting brack et and ...

Page 37: ...g h t b y V o l k s w a g e n A G 2 Rear lid 2 1 Tools Special tools and workshop equipment required Torque wrench 5 50 Nm V A G 1331 2 2 Assembly overview rear lid 1 Lid Removing and installing page 30 Adjusting page 34 2 Rear lid lock Removing and installing page 39 3 Adjustment buffer Left and right Adjusting page 35 4 Gas strut Removing page 31 Releasing gas page 31 5 Hinge Removing and instal...

Page 38: ...r lid 2 3 1 Removing Open rear lid 1 Remove rear lid trim General body repairs interior Rep Gr 70 Trims and insulation Rear lid trim Separate connectors for all electrical components and pull hose off rear window wash and wipe system Guide hose and lines out through opening Loosen bolts 3 for hinges 4 on left and right do not remove Further dismantling is possible only with the help of a second me...

Page 39: ...as strut 1 slide spring clip 2 back immediately WARNING Proceed with care if gas strut is reused Spring clip must not be levered completely out of ball socket as it will otherwise be damaged Gas strut springs out of mounting and causes dam age or injury to operator Specified torque for ball head pins 3 and 4 21 Nm Releasing gas from gas strut page 31 2 5 Releasing gas from gas strut Clamp gas stru...

Page 40: ...r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 6 1 Removing Remove rear lid 1 page 30 Lower rear of moulded headlining General body repairs interior Rep Gr 70 Trims insulation Roof trims Removing and installing moulded headlining Remove hexagon nut 3 and remove rear lid hinge 2 from roof bracing Go...

Page 41: ... n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 6 2 Installing Note After installing rear lid 1 tighten hexagon nut 3 for rear lid hinge 2 again to 24 Nm Install rear lid hinge 2 and tighten hexagon nut 3 to 24 Nm Install rear lid 1 page 30 Retighten hexagon nuts 3 to 24 Nm after completing assem bly procedure Install moulded headlining General body repairs interior ...

Page 42: ... Nm Adjust striker pin page 35 Further installation is performed in the reverse order of removal 2 8 Adjusting lid Note Vehicle must be standing on the ground to perform the basic adjustment of the rear lid The rear lid lock is bolted directly to the rear lid It does not have elongated holes so it cannot be adjusted Adjusting buffers cannot be used to adjust rear lid as they are in some other vehi...

Page 43: ...ours align when the lid closed 2 8 1 Adjusting striker pin Remove lock carrier cover General body repairs interior Rep Gr 70 Luggage and load area compartment trim Re moving and installing lock carrier cover Loosen striker pin 2 Move striker pin 2 to rearmost position arrow and tighten bolts 1 Close rear lid and check adjustment By loosening bolts 1 it is possible to slide striker pin 2 within ove...

Page 44: ...i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Adjust detent slide to dimension a 12 5 mm Close rear lid to detent position with light pressure at centre of lid Open rear lid again Screw in adjustment buffer clamping screw 1 to a depth of dimension a 25 mm Check setting Golf 2004 Genera...

Page 45: ...embly overview rear lid latch and release components 1 Release element with but ton E234 Removing and installing page 37 2 Bolt Qty 5 4 Nm 3 Emergency release Emergency release can be found through an aperture in the rear lid trim 4 Lid lock Removing and installing page 39 5 Lid lock connector 6 Retaining bracket 7 Release element connector 2 10 Removing and installing release ele ment Note If rea...

Page 46: ...move rear lid trim General body repairs interior Rep Gr 70 Trims and insulation Rear lid trim Remove rear window wiper motor Electrical system Rep Gr 92 Window wiper and washer system Rear window wiper system Separate connector 7 from release element 1 Remove bolts 2 Loosen release element contrary to the arrow from the re taining brackets 6 Then remove release element 1 2 10 2 Installing Installa...

Page 47: ...mergency release can be found through an aperture in the rear lid trim 2 11 1 Removing Remove rear lid trim General body repairs interior Rep Gr 70 Trims and insulation Rear lid trim Disconnect connector 4 from lid lock 2 Remove bolts 3 and guide lid lock 2 downwards and out of lid 2 11 2 Installing Guide rear lid lock 2 into rear lid and tighten bolts 3 Specified torque for bolts 3 23 Nm Attach c...

Page 48: ...d the sealant will spread to the inside of the seal and the flanks will be bent out slightly If the seal is then refitted a leak free tight seal is not guaranteed Therefore each seal which is removed completely should be replaced by a so called tap on seal If a seal has been partially removed squeeze sides of seal together before installing 2 13 Removing and installing rear lid seal 2 13 1 Removin...

Page 49: ...r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 Tank flap unit 3 1 Tools Special tools and workshop equipment required Socket T 10010 3 2 Assembly overview tank flap unit 1 Tank flap unit Removing page 42 2 Bolt 1 5 Nm 3 Drain hose 4 Assembly piece 5 Release rod 6 Securing bolt for actuator Qty 2 1 5 Nm 7 Fuel tank filler flap a...

Page 50: ... e n t C o p y r i g h t b y V o l k s w a g e n A G 3 2 1 Removing tank flap unit Note If the fuel tank filler flap does not open open by hand using the release rod 5 The side trim must be removed to do this Open fuel tank flap Remove fuel filler cap Remove bolt 2 Pull rubber part off fuel tank filler neck Pull fuel tank flap unit 1 with drain hose 3 to rear and swing fuel tank flap unit out of s...

Page 51: ...g h t b y V o l k s w a g e n A G 3 2 2 Installing tank flap unit The mounting part 4 has been pushed in Pass drain hose 3 through the opening in tank flap unit and pull hose through as far as possible Guide drain hose into side panel With hinge side leading guide tank flap unit 1 into side panel Then swivel tank flap unit completely into side panel ensure that the locating hooks at top and bottom...

Page 52: ... i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 2 3 Removing actuator Remove luggage compartment side panel trim General body repairs interior Rep Gr 70 Trims insulation Luggage and load compartment trims Disconnect connector on actuator 7 Release actuator 7 using hexagon socket screwdriver T 10010 Pull actuator 7 together with release rod 5 out of seal 8 3 2 4 Install...

Page 53: ... s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 57 Front doors door components central locking 1 Front door 1 1 Tools Special tools and workshop equipment required Socket T 10072 Assembly tool T 10118 Door alignment tool 3320 Universal joint for 3320 3320 1 Bit for 3320 3320 2 Bit for 3320 3320 3 Roller for fitting door insu lation foil 3356...

Page 54: ...y tool set T 10237 1 2 Materials 1K window adhesive DH 009 100 012 3 Glass primer paint primer D 009 200 021 Cleaning solution D 009 401 041 Primer applicator D 009 500 251 Door repair kit D 438 520 A24 1 Materials are stored in box D 004 700 2 Observe minimum curing period page 64 3 Heat according to manufacturers instructions using cartridge heater V A G 1939 4 Folding cardboard carton with 10 s...

Page 55: ...ter panel 1 is additionally bolted to the lower edge of the door inner part The window slot seals insulation and door outer handle are mounted on the door outer panel Caution Bolts of different types are used to secure door outer panel If these are fitted in the wrong positions the door outer skin will be damaged 1 Door outer panel Removing and installing page 94 2 Edge protection Between door out...

Page 56: ... t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 10 Nm 9 Insulation Self adhesive To bond first heat the insulation and then press on firmly 10 Clip Qty 6 11 Window slot seal Must be fitted before assembling door outer panel 1 4 Assembly overview door hinges Caution Bolt of eccentric pin 10 should not be loosened under any circumstances on vehicles up to 01 2004 It cannot be ...

Page 57: ...oving and installing page 50 Adjusting page 52 2 Guide bolt 10 Nm 3 Door hinge with arrester 4 Multi point socket head bolt 50 Nm Bolts must always be re placed by new ones af ter being undone 5 Multi point socket head bolt Installed from inside the vehicle Remove lower A pillar trim General body re pairs interior Rep Gr 70 Trims insulation Pillars and side trims 20 Nm 1 4 turn further 90 Bolts mu...

Page 58: ...one part 12 Multi point socket head bolt 20 Nm 1 4 turn further 90 Bolts must always be renewed after being loosened 13 Multi point socket head bolt 20 Nm 1 4 turn further 90 Bolts must always be replaced by new ones after being undone 14 Multi point socket head bolt 50 Nm Bolts must always be replaced by new ones after being undone 15 Eccentric pin Eccentric pin is used to adjust gap on vehicles ...

Page 59: ...Removing Release bellows 6 by pressing the catch arrow a and pull bellows off A pillar Swing release lever 7 downwards arrow b and disconnect electrical connector 8 from coupling station Remove bolts 4 5 and 11 from hinge using special door alignment tool 3320 and bit 3320 3 Pull door in direction of arrow off guide bolts 2 and 9 1 5 2 Installing Installation is carried out in reverse order of rem...

Page 60: ...shut lines are even all around the door is not too deep or does not stand proud and all contours align when the is door closed Vehicle must be standing on its wheels on flat level ground when adjustments are performed If door outer panel has been removed door inner part window frame must be adjusted to roof frame and B pillar or rear door 1 6 1 Adjusting door gaps Special tools and workshop equipm...

Page 61: ...ote front door gap dimensions Body Repairs Rep Gr 00 Technical data Body gap dimensions Adjustments are carried out using eccentric pin 7 Other measures such as raising the door have no effect Subse quent pressure from above will cause the door to sack again Loosen bolt for eccentric pin 5 Adjust eccentric pin 7 within adjustment range 6 using 15 mm ring spanner T10344 Tighten bolt 5 before checki...

Page 62: ... e n A G 1 6 2 Adjusting door fittings for flushness Use bolts 2 3 4 5 and 6 on hinge to adjust correctly for flush ness Use door alignment tool 3320 with bit 3320 3 Adjusting upper area of door loosen bolts 5 and 6 Specified torque for bolt 5 10 Nm Specified torque for bolt 6 50 Nm To adjust lower area of door loosen bolts 5 and 6 Specified torque for bolt 2 10 Nm Specified torque for bolts 3 and...

Page 63: ...AGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 7 Removing and installing door outer pan el 1 7 1 Removing Lever out clips 3 from the bottom starting on the door 1 and remove cover 2 Golf 2004 General body repairs exterior Edition 04 20...

Page 64: ...i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove lock cylinder page 67 Remove door handle page 68 Remove bolt 1 from mounting bracket 2 which is located behind door outer panel Remove all bolts 2 3 and 4 Carefully remove door outer panel Golf 2004 General body repairs exterior Edit...

Page 65: ... Bolts of different types are used to secure door outer panel If these are fitted in the wrong positions the door outer panel will be damaged Carefully fit door outer panel Insert all bolts 2 3 and 4 Observe correct usage for the different types of bolts Feature for bolt 2 bolt with pointed end and thin washer Feature for bolt 3 bolt without pointed end but with thick washer Feature for bolt 4 bol...

Page 66: ...A G Observe correct specified torque for the different types of bolts Specified torque for bolt 2 10 Nm Specified torque for bolt 3 14 Nm Specified torque for bolt 4 10 Nm Further installation is performed in the reverse order of removal 1 8 Installing new outer panel for door Caution Bolts of different types are used to secure door outer panel If these are fitted in the wrong positions the door o...

Page 67: ... bolt without point with thick washer Specified torque for bolts 3 and 5 10 Nm Fit two guide bolts in lower edge of door inner part The painted door outer panel is first offered up without bonding agent Assembly block from assembly tool set T 10237 is required to offer up the door outer panel A strip of Tesa Power Strips large 6 is applied on the lower side The pin has the minimum dimen sion for t...

Page 68: ... u m e n t C o p y r i g h t b y V o l k s w a g e n A G Place door outer panel with assembly blocks on surrounding components 2 and 5 Check gap dimension using setting gauge 3371 Body Re pairs Rep Gr 00 Technical data Body gap dimensions If gap dimension cannot be adjusted further door inner part must be adjusted page 52 Remove door outer panel again Apply a bead of adhesive material 2 using cart...

Page 69: ...n ded to the contact surfaces Guide door outer panel 1 over guide bolts in lower edge of door inner part Bring door outer panel with assembly blocks 3 into contact with surrounding components Adjust the gap to side member and adjust door outer panel height using wedges 4 from assembly tool set Check gap dimensions using setting gauge 3371 Body Repairs Rep Gr 00 Technical data Body gap dimensions B...

Page 70: ... be avoided When cutting through the adhesive bead always hold the re taining rail and door outer skin together as shown in the illus tration If this is not done the door outer skin will come away from the retaining rail thus rendering it useless Note The following work steps should be carried out with the aid of an assistant Door outer panel with retaining rail is removed page 55 Place door outer...

Page 71: ...entitled Installing new door outer panel page 58 Note Observe also instructions for bonding in new door outer panel when installing a new retaining rail In place of removed retaining rail install a new retaining rail on the door inner panel Apply adhesive to new retaining rail Tighten screws to secure door panel on lower edge and on retaining rail still in place Secure door outer panel on new reta...

Page 72: ...nts and gap dimension must be even If adhesive bead is too thick and adhesive exudes between retaining rail and door outer panel excess adhesive must be removed 1 11 Minimum curing period WARNING Special standards must be adhered to when replacing bonded door outer panels One of these standards is for example that a freshly bonded door outer panel must comply with the safety requirements even in a...

Page 73: ...r i g h t b y V o l k s w a g e n A G First clean painted surface as much as possible using a dry cloth Remove remaining adhesive with adhesive remover D 002 000 10 Cleaning plastic trim allow adhesive sealant to cure approx one hour and then peel off 1 13 Assembly overview door inner part Note The right side is shown The left side is similar 1 Door inner part 2 Window slot seal 3 Loudspeaker 4 Wi...

Page 74: ...le 3 Bolt To secure lock on door inner part 18 Nm Qty 2 4 Bearing plate Removing and installing page 70 5 Bolt For lock cylinder 6 Locking screw Not fitted on all models This bolt is installed to provide additional se curity for the bearing plate 7 Base 8 Lock cylinder housing Only on driver side Installed on the passen ger side is just a housing Removing and installing page 67 9 Cover For lock cy...

Page 75: ... right hous ing The removal and installation of the right lock cylinder is similar 1 15 1 Removing Lever out caps in front of bolts 1 Pull door handle 2 in direction of arrow and unscrew bolt 1 using socket wrench T 10072 until housing 3 can be pulled out 1 15 2 Installing Fit housing 3 in door handle mounting plate at right angles arrow Door handle 2 must rest only lightly against door panel Now ...

Page 76: ...t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 16 Removing and installing door handle Note The removal and installation sequence is only for the right door handle The removal and installation of the left door handle is similar 1 16 1 Removing Removing housing page 67 Lever clip 2 out of door handle 1 Swivel door handle 1 out of door ...

Page 77: ... n t C o p y r i g h t b y V o l k s w a g e n A G 1 16 2 Installing Guide assembly tool T 10118 into door through opening in door inner panel Use a hand torch to illuminate inside of door for improved vis ibility Hook assembly tool T 10118 in spring arrow A Hook spring into door lock by pulling assembly tool T 10118 arrow B The release lever is now secured Note Hooking the spring into the operati...

Page 78: ...r Pull clip 2 in the panel opening and engage clip in door han dle 1 arrow Note Door handle 1 must be pressed against door panel when assembling Clip 2 must engage in door handle 1 with a clearly audible click Install housing page 67 Then always check function while door is still open as an in correctly fitted and adjusted Bowden cable cannot open the door 1 17 Removing and installing mounting pla...

Page 79: ... t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 17 1 Removing Remove lock cylinder housing page 67 Remove door handle page 68 Remove door outer panel page 94 Pull retaining rubber 4 upwards off guide pins Pull mounting plate 1 in direction of arrow with guide pins 2 out of mounting 3 Go...

Page 80: ... c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 17 2 Installing Push mounting plate 1 with guide pins 2 in mounting 3 Secure retaining rubber 4 to guide pins and securing bolts on mounting plate support Further installation is performed in the reverse order of removal 1 18 Removing and installing door lock Note The removal and installation sequence is only for the right door lock The ...

Page 81: ...u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 18 1 Removing Remove door outer panel page 94 Remove mounting plate page 70 Disconnect connector 5 Remove bolts 6 Release cable 1 from relay lever 8 and remove door lock 4 Cover 3 is not supplied with door lock 1 18 2 Installing Installation is carried out in reverse order of removal Specified torque for bolts 18 Nm Then always check functi...

Page 82: ... 19 Assembly overview side impact pro tection Caution The nuts and bolts of the side impact protection are also pain ted in the factory This means that a great deal of force is required to remove them resulting in some circumstances in the threads shearing If possible avoid loosening the nuts and bolts 1 Side impact protection 2 Bolt Qty 4 20 Nm 3 Insulation 4 Nut Qty 2 20 Nm 1 20 Door inner seal ...

Page 83: ...n seals are removed the sealant will spread to the inside of the seal and the flanks will be bent out slightly If the seal is then refitted a leak free tight seal is not guaranteed Therefore each seal which is removed completely should be replaced by a so called tap on seal If a seal has been partially removed squeeze sides of seal together before installing 1 21 Removing and installing door inner...

Page 84: ...w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull door inner seal off body flange 1 21 2 Installing Align door inner seal with vulcanisation point arrow b to height of lower hinge Begin installing door inner seal in upper radius arrow a of door aperture Golf 2004 General body repairs exteri...

Page 85: ... l k s w a g e n A G 1 22 Removing and installing door outer seal Note Removal and installation are described for the right door outer seal only Removal and installation of the left door outer seal are similar Remove protective backing immediately before installation Working temperature approx 20 C Adhesive remover D 002 000 10 must be used exclusively The door outer seal must be bonded in place i...

Page 86: ...esidues with adhesive remains re mover VAS 6349 Immediately before bonding the door outer seal clean bond ing surface thoroughly with adhesive remover D 002 000 10 Surfaces to be bonded must be free of dust and grease and there should be no adhesive residue Align door outer seal with aperture arrow b towards door lock securing bolt Door outer seal vulcanised point arrow c should then be in middle ...

Page 87: ...eal 3 on door 1 all around using roller 3356 The seal is pushed aside arrow a when doing this so that the roller 3356 runs directly over the contact surface of the seal The roller can only apply the necessary force arrow B to the adhesive surface 2 when procedure described above is followed correctly If the seal is too long cut seal to required length and press butt joints on well If the seal 3 co...

Page 88: ...Removing and in stalling glove compart ment 3 Front passenger door con trol unit J387 Integrated in window regulator motor Removing page 199 4 Door lock Door lock is secured to door inner part Electric central locking is integrated in door lock Removing page 73 5 Coupling station Fitting location right B pillar To separate connector loosen boot at pillar page 90 6 Rear right door control unit J389...

Page 89: ...oosen boot at pillar page 90 16 Front left door lock Door lock is secured to door inner part Electric central locking is integrated in door lock Removing page 73 17 Central switch for window regulator Fitting location installed in door trim Removing and installing centralized switches for window regulators Vehicle electrical system Rep Gr 96 Electrical system Interior lights lamps switches Lights ...

Page 90: ...t selection and the following menu items one after the other Body General body repairs 01 Self diagnosis capable systems Convenience systems Functions convenience system central control unit Checking adapting key with remote control J393 2 3 Assembly overview battery for folding key with remote control 1 Key with variable code transponder 2 Transmitter unit upper part 3 LED When remote control is ...

Page 91: ... k s w a g e n A G 2 4 Removing and installing battery for fold ing key with remote control 2 4 1 Removing Insert a screwdriver in slot between transmitter unit 1 and key 2 Twist screwdriver in direction of arrow to separate transmitter unit from key Press transmitter unit 1 apart using profile section of key 2 Unclip battery 1 from retainers 2 with a screwdriver in direction of arrow 2 4 2 Instal...

Page 92: ...e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Note polarity and correct position when installing battery Lay battery 1 with positive terminal downwards in sender unit 2 positive terminal is marked on housing Engage battery in transmitter body by pressing down lightly Fit cover to transmitter body do not damage seal Then clip transmitter u...

Page 93: ...e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 58 Rear doors door components 1 Rear door 1 1 Tools Special tools and workshop equipment required Socket T 10072 Assembly tool T 10118 Door alignment tool 3320 Universal joint for 3320 3320 1 Bit for 3320 3320 2 Bit for 3320 3320 3 Roller for fitting door insu lation foil 3356 Torque w...

Page 94: ... Assembly tool set T 10237 1 2 Materials 1K window adhesive DH 009 100 016 7 Glass primer paint primer D 009 200 025 Cleaning solution D 009 401 045 Primer applicator D 009 500 255 Door repair kit D 438 520 A28 5 Materials are stored in box D 004 700 6 Observe minimum curing period page 103 7 Heat according to manufacturers instructions using cartridge heater V A G 1939 8 Folding cardboard carton ...

Page 95: ... lower edge of the door inner part The window slot seals insulation and door outer handle are mounted on the door outer panel 1 Door outer panel Removing and installing door outer panel page 94 2 Edge protection Between door outer skin and door inner panel 3 Bolt Feature bolt with poin ted end and thin washer Qty 4 on lower edge Qty 2 in area of top sec tion of trim 10 Nm 4 Rear retaining rail Adh...

Page 96: ...always be renewed if loosened Hinges are now one piece The specified torque for the hinge bolts to the door bolts 4 6 and 14 has been revised 1 Door Removing and installing page 89 Adjusting page 91 2 Guide bolt 10 Nm 3 Door hinge with arrester 4 Multi point socket head bolt 50 Nm Bolts must always be re placed by new ones af ter being undone 5 Multi point socket head bolt Installed from inside th...

Page 97: ...28 Nm For eccentric pin 11 Door hinge Door hinge no longer comprises of more than one part 12 Multi point socket head bolt 20 Nm 1 4 turn further 90 Bolts must always be renewed after being loosened 13 Multi point socket head bolt 20 Nm 1 4 turn further 90 Bolts must always be replaced by new ones after being undone 14 Multi point socket head bolt 50 Nm Bolts must always be replaced by new ones af...

Page 98: ...lease bellows 6 by pressing catch arrow a and pull bel lows off B pillar Swing release lever 7 downwards arrow b and disconnect electrical connector 8 from coupling station Remove bolts 4 5 and 11 from hinge using special door alignment tool 3320 and bit 3320 3 Pull door in direction of arrow off guide bolts 3 and 9 1 5 2 Installing Installation is carried out in reverse order of removal Specified...

Page 99: ...correctly if the gaps shut lines are even all around the door is not too deep or does not stand proud and all contours align when the is door closed Vehicle must be standing on its wheels on flat level ground when adjustments are performed If door outer panel has been removed door inner part window frame must be adjusted to roof frame and B pillar or rear door 1 6 1 Adjusting door gaps Special too...

Page 100: ...or gap dimensions Body Repairs Rep Gr 00 Technical data Body gap dimensions Adjustments are carried out using eccentric pin 7 Other measures such as raising the door have no effect Subse quent pressure from above will cause the door to sack again Loosen bolt for eccentric pin 4 Adjust eccentric pin 6 within adjustment range 5 using 15 mm ring spanner T10344 Tighten bolt 4 before checking setting I...

Page 101: ...t b y V o l k s w a g e n A G 1 6 2 Adjusting door fittings for flushness Use bolts 2 3 4 5 and 6 on hinge to adjust correctly for flush ness Use door alignment tool 3320 with bit 3320 3 Adjusting upper area of door loosen bolts 5 and 6 Specified torque for bolt 5 10 Nm Specified torque for bolt 6 50 Nm To adjust lower area of door loosen bolts 5 and 6 Specified torque for bolt 2 10 Nm Specified t...

Page 102: ... w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 7 Removing and installing door outer pan el 1 7 1 Removing Lever out clips 3 from the bottom starting on the door 1 and remove rear cover 2 Lever out clips 5 from the bottom starting on the door 1 and remove rear cover 4 Golf 2004 General body...

Page 103: ... n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove lock cylinder housing page 67 Remove door handle page 68 Remove bolt 1 from mounting bracket 2 which is located behind door outer panel Remove all bolts 2 3 and 4 Carefully remove door outer panel Golf 2004 General b...

Page 104: ...ifferent types are used to secure door outer panel If these are fitted in the wrong positions the door outer skin will be damaged Carefully fit door outer panel Insert all bolts 2 3 and 4 Observe correct usage for the different types of bolts Feature for bolt 2 bolt with pointed end and thin washer Feature for bolt 3 bolt without pointed end but with thick washer Feature for bolt 4 bolt with point...

Page 105: ...V o l k s w a g e n A G Observe correct specified torque for the different types of bolts Specified torque for bolt 2 10 Nm Specified torque for bolt 3 14 Nm Specified torque for bolt 4 10 Nm Further installation is performed in the reverse order of removal 1 8 Installing new outer panel for door Caution Bolts of different types are used to secure door outer panel If these are fitted in the wrong ...

Page 106: ...ithout point with thick washer Specified torque for bolts 3 and 5 10 Nm Fit two guide bolts in lower edge of door inner part The painted door outer panel is first offered up without bonding agent To fit door outer panel assembly block from assembly tool set T 10237 is required A strip of Tesa Power Strips large 6 is applied on the lower side The pin has the minimum dimension for the gap width The ...

Page 107: ...t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Place door outer panel with assembly blocks on surrounding components 2 and 5 Check gap dimension using setting gauge 3371 Body Re pairs Rep Gr 00 Technical data Body gap dimensions If gap dimension cannot be adjusted door inner part must be adjusted page 104 Remove door outer panel again Apply a bead of adhesive mat...

Page 108: ...e bonded to the contact surfaces Guide door outer panel 1 over guide bolts in lower edge of door inner part Place door outer panel with assembly blocks 3 on surround ing components Adjust gap to side member and door outer panel height using wedges 4 from assembly tool set Check gap dimensions using setting gauge 3371 Body Repairs Rep Gr 00 Technical data Body gap dimensions Bond short fixing block...

Page 109: ...ts and scratches must be avoided When cutting through the adhesive bead always hold the re taining rail and door outer skin together as shown in the illus tration If this is not done the door outer skin will come away from the retaining rail thus rendering it useless Note The following work steps should be carried out with the aid of an assistant Door outer panel with retaining rail is removed pag...

Page 110: ...alling new door outer panel page 58 Note Observe also instructions for bonding in new door outer panel when installing a new retaining rail In place of removed retaining rail install a new retaining rail on the door inner panel Apply adhesive to new retaining rail Tighten screws to secure door panel on lower edge and on retaining rail still in place Secure door outer panel on new retaining rail wi...

Page 111: ...wells out between retaining rail and door outer panel excess adhesive must be removed 1 11 Minimum curing period WARNING Special standards must be adhered to when replacing bonded door outer panels One of these standards is for example that a freshly bonded door outer panel must comply with the safety requirements even in an accident following the minimum specified curing time For 1K adhesive DH 0...

Page 112: ... h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Cleaning plastic trim allow adhesive sealant to cure approx one hour and then peel off 1 13 Assembly overview door inner part Note The right side is shown The left side is similar 1 Window slot seal 2 Insulation Qty 4 20 mm x 40 mm com mercially available tex tile adhesive...

Page 113: ...ving and installing page 110 2 Retaining bracket Not installed on Golf 3 Spreader rivet Not installed on Golf 4 Cable To release lock from in ner door handle 5 Cover Not supplied as part of door lock Secured to door lock with three locking lugs 6 Bearing plate Removing page 108 7 Bolt 8 Base Part of door handle 9 Door handle with base Removing and installing page 106 10 Cover For lock cylinder hou...

Page 114: ...2 until housing 3 can be pulled out Pull housing 3 out of door handle mounting bracket at right angles to door 1 15 2 Installing Fit housing 2 into door handle mounting bracket at right an gles Door handle 1 must rest only lightly against door panel Now tighten bolt 3 in bearing plate using socket T 10072 The door handle engages in the lock cylinder housing with an audible click Note During instal...

Page 115: ...r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 16 1 Removing Remove housing page 106 Lever clip 2 out of door handle 1 Swivel door handle 1 out of door arrow 1 16 2 Installing Guide assembly tool T 10118 into door through opening in door inner panel Use a hand torch to illuminate inside of door for improved vis ibility Hook a...

Page 116: ...B The release lever is now secured Swivel door handle 1 into door Pull clip 2 in the panel opening and engage clip in door han dle 1 arrow Note Door handle 2 must be pressed against door panel when assembling Clip 2 must engage in door handle 1 with a clearly audible click Installing housing page 106 Then always check function while door is still open as an in correctly fitted and adjusted Bowden ...

Page 117: ...t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 17 1 Removing Remove housing page 106 Remove door handle page 106 Remove door outer panel page 94 Pull retaining rubber 4 off upwards from guide pins and re taining pins on mounting Pull mounting plate 1 with guide pins 2 out of mounting 3 ...

Page 118: ... e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 17 2 Installing Push mounting plate 1 with guide pins 2 in mounting 3 Secure retaining rubber 4 to guide pins and securing pins on mounting 1 18 Removing and installing door lock Note The removal and installation sequence is only for the right door lock The removal and installation of the l...

Page 119: ...r 4 Remove bolts 6 Release cable 3 from relay lever 5 and remove door lock 1 Cover 2 is not supplied with door lock 1 18 2 Installing Installation is carried out in reverse order of removal Specified torque for bolts 18 Nm Then always check function while door is still open as an in correctly fitted and adjusted Bowden cable cannot open the door 1 19 Assembly overview side impact pro tection Cauti...

Page 120: ... 2 Bolts Qty 2 20 Nm 3 Nut Qty 2 20 Nm 4 Door inner part 1 20 Door inner seals During production a sealant is applied to the door inner seals which are then placed on the door flange and rolled on Note When seals are removed the sealant will spread to the inside of the seal and the flanks will be bent out slightly If the seal is then refitted a tight seal is not guaranteed Therefore each seal whic...

Page 121: ... w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 21 Removing and installing door inner seal Note The removal and installation sequence is only for the right door inner seal The removal and installation of the left door inner seal is similar 1 21 1 Removing Pull door inner seal off body flang...

Page 122: ...n door inner seal with vulcanisation point arrow b to height of lower hinge Begin installing door inner seal in upper radius arrow a of door aperture 1 22 Removing and installing door outer seal Note Removal and installation are described for the right door outer seal only Removal and installation of the left door outer seal are similar Remove protective backing immediately before installation Wor...

Page 123: ...n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 22 1 Removing Pull door outer seal 1 from door 2 Golf 2004 General body repairs exterior Edition 04 2008 1 Rear door 115 ...

Page 124: ...2 2 Installing Remove existing adhesive residues with adhesive remains re mover VAS 6349 Immediately before bonding the door outer seal clean bond ing surface thoroughly with adhesive remover D 002 000 10 Surfaces to be bonded must be free of dust and grease and there should be no adhesive residue The vulcanised point arrow b of outer door seal 1 must be located in centre of side member Pull prote...

Page 125: ...eal 3 on door 1 all around using roller 3356 The seal is pushed aside arrow a when doing this so that the roller 3356 runs directly over the contact surface of the seal The roller can only apply the necessary force arrow B to the adhesive surface 2 when procedure described above is followed correctly If the seal is too long cut seal to required length and press butt joints on well If the seal 3 co...

Page 126: ... t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 60 Sunroof 1 Sliding tilting sunroof with glass pan el Meritor 1 1 Tools 1 1 1 Required special tools workshop equip ment test and measuring devices and auxiliary items Roller 3356 Hooks for front end 3370 Torque wrench 2 10 Nm V A G 1783 Wedge 3409...

Page 127: ...Pre selector switch The sliding tilting sunroof with glass panel is equipped with a force limitation roll back feature while closing If an obstacle is en countered during closing or opening from the elevating or sliding position the glass panel will be moved in the opposite direction In addition there is an emergency closure function If problems occur during closure the sliding tilting sunroof wit...

Page 128: ...ing sunroof page 124 Adjusting glass panel of sliding tilting sunroof page 124 2 Panel seal Adjusting panel seal page 125 Seal joint positioned in middle of rear area Renewing panel seal page 126 3 Sliding headliner Removing and installing sliding headliner page 127 4 Bolt Bolts are microencap sulated and must al ways be renewed after loosening Qty 4 1 8 Nm 5 Spring slide Screwed onto sliding head...

Page 129: ...ion The hexagon key to operate the system in an emergency has been discontinued Use a commercially available hexagon key to operate the system in an emergency 14 Electric drive Removing page 128 Adjusting drive 0 position page 129 15 Spring Qty 2 Pushes up wind deflector Is clipped onto wind deflector and can be renewed individually Removing page 126 16 Wind deflector Removing page 126 Adjusting o...

Page 130: ...o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 4 Removing and installing bellows 1 4 1 Removing Move sliding headliner to rear Run sliding tilting sunroof glass panel to tilted position Carefully unclip bellows 1 from lower part of guide plate 3 using a removal wedge 3409 Pull bellows 1 off securing pins 4 Detach bellows 1 ...

Page 131: ... n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 4 2 Installing Move sliding headliner to rear Run sliding tilting sunroof glass panel to tilted position Fit bellows 1 first at top rear 2 Clip bellows 1 with securing pins 4 in guide plate Hook in bellows 1 at bottom rear 3 and clip in bellows starting from front in lower part of guide plate 1 5 Removing glass panel of sli...

Page 132: ...ng tilting sunroof Panel must be installed in 0 position panel closed 1 6 1 Zero position The mark arrow on the rear of the guide upper section 1 must on both sides lie within the marks dimension a on the guide plate 2 The guide plate 2 must be located in the guide rails cannot be moved by hand If this is not the case adjust parallel running page 130 Insert sliding tilting sunroof glass panel 2 fr...

Page 133: ...r than roof Arrow Forwards Tighten front screws 5 Nm Panel adjustment rear b 0 1 mm higher than roof Arrow Forwards First tighten middle and then rear screws 5 Nm Note To achieve the best possible optical appearance ensure that the adjustment on left and right are as far as is possible uniform symmetric The glass panel should not be higher than the roof at any point at the front or lower than the ...

Page 134: ...wing panel seal Remove glass panel of sliding tilting sunroof page 123 Pull seal 1 off sliding tilting sunroof glass panel 2 Fit new seal 1 to rear edge of panel start in middle and push onto sliding tilting sunroof glass panel 2 from bottom to top Note To ease fitting of seal coat panel edge with a soapy solution If the seal is not correctly installed the surface will be wavy The panel seal must ...

Page 135: ... guide rail and slide wind deflector with height limit stop under front of roof aperture on both sides Using light pressure press wind deflector bearings into guide rails Note Wind deflector bearings must audibly engage in the guide rails 1 10 3 Adjusting wind deflector on vehicles as of 08 2005 The wind deflector can be adjusted on vehicles as of 08 2005 Place special tool front end hook 3370 bet...

Page 136: ...s 1 11 2 Installing Installation is carried out in reverse order of removal Finally carry out a functional check 1 12 Removing and installing sliding tilting sunroof glass panel drive 1 12 1 Removing Remove lights and operating unit Electrical system Rep Gr 96 Lights bulbs switches interior Lights and switches in roof trim Removing and installing front interior light W1 ve hicles with sunroof Chan...

Page 137: ...ing sunroof drive 1 12 2 Installing The screws for the sliding tilting sunroof drive are microen capsulated and must always be renewed 3 5 Nm Installation is carried out in reverse order of removal After installation is complete the key can be placed in ignition and starter switch again Finally carry out a functional check 1 13 Adjusting drive for sliding tilting sunroof glass panel 0 position The...

Page 138: ...g tilting sunroof glass panel automatic preselec tion switch Removing sliding tilting sunroof glass panel automatic prese lection switch Electrical system Rep Gr 96 Lights bulbs switches interior Removing and installing sliding sunroof switch 1 15 Checking parallel running Removing glass panel for sunroof page 123 The mark arrow on the rear of the guide upper section 1 must on both sides lie withi...

Page 139: ... of the guide upper section 1 must on both sides lie within the marks dimension a on the guide plate 2 The guide plate 2 must be located in the guide rails cannot be moved by hand Push guide upper part 1 both sides centrally between the marks Install drive zero position in this position Then check zero position 1 17 Assembly overview carrier unit 1 Carrier unit Removing and installing page 132 2 B...

Page 140: ...NING Remove or install drive for tilting sliding sunroof glass panel only when sunroof is closed 0 position The requirements for removing and installing drive are Engine not running and ignition off key not in ignition and door open 1 18 1 Removing Remove moulded headlining General body repairs interior Rep Gr 70 Trims insulation Roof trims Removing and in stalling moulded headlining Pull off wate...

Page 141: ...carrier unit 1 in roof via two cylin drical pins shank end of drill 12 mm front right arrow and 10 mm rear left arrow Carrier unit must not contact roof frame Install bolts 2 Check routing of wiring and connectors of electrical consum ers in roof and restore if necessary Tighten screws 8 Nm for carrier unit 1 starting at sunroof drive 5 and moving rearward alternating between left and right sides ...

Page 142: ...dliner on right next to opening for rear interior light and reading lamp Removing lights and operating unit Electrical system Rep Gr 96 Lights bulbs switches interior Lights and switches in moulded headlining Guide hexagon key into bolt on drive Press key upwards arrow to release the drive The bolt will be pressed a few millimetres inwards a Sliding tilting sunroof glass panel can only be moved in...

Page 143: ...de 2 1 20 2 Installing Installation is carried out in reverse order of removal 1 21 Removing and installing sliding gate Note Always renew guide and cable as a pair 1 21 1 Removing Remove glass panel of sliding tilting sunroof page 123 Remove carrier unit page 132 Remove sunroof glass panel drive page 128 Remove guide plate page 134 Detach water channels 1 carefully using a screwdriver at both sid...

Page 144: ...y r i g h t b y V o l k s w a g e n A G Slide rear guide lower part 1 in direction of arrow in guide rail 3 until the locating hook guide locking mechanism 2 is released Pull out rear guide lower part 1 and locking hook guide 2 together in direction of arrow from guide rail 3 and remove 1 21 2 Installing Installation is carried out in reverse order of removal 1 22 Cleaning water drain hoses Note F...

Page 145: ...y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 22 1 Front water drain hoses The front water drain hoses run through the A pillars and end at the bulkhead cross member Cleaning is done from the sunroof panel aperture Golf 2004 General body repairs exterior Edition 04 2008...

Page 146: ...n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 22 2 Rear water drain hoses The rear water drain hoses run through the C pillars and end in the rear wheel housings Cleaning is done from the wheel hous ing The wheel housing liner must be removed Golf 2004 General body re...

Page 147: ... m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 63 Bumpers 1 Front bumper 1 1 Tools Special tools and workshop equipment required Torque wrench V A G 1783 Torque wrench V A G 1332 1 2 Repairing bumper cover Note If bumper cover is damaged determine whether plastic can be repaired before renewing bumper Details can be found under General Information Body Repai...

Page 148: ...n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 3 Assembly overview bumper cover 1 Cover Material PP EPDM Removing and installing page 140 2 Bolt 1 5 Nm 3 Bolt Qty 4 per side 2 Nm 4 Bolt Qty 6 1 5 Nm 5 Bolt Qty 2 5 Nm 6 Bolt Qty 2 5 Nm 1 4 Removing and installing front bumper cover Note The removal and installation procedures may have t...

Page 149: ...G 1 4 1 Removing Remove radiator grille page 230 Remove bolts 5 and 6 Remove bolts 4 from below Remove bolts 3 and 2 point upwards on left and right in area of wheel housing liner Further dismantling is possible only with the help of a second mechanic Press locking devices 5 downwards arrow on left and right sides and pull cover 1 parallel out of guide profiles with aid of a second mechanic Discon...

Page 150: ...on version 1 Cover Material PP EPDM Removing and installing page 140 2 Side marker light Left and right Not for all countries Removing Electrical system Rep Gr 94 Removing side marker lights 3 Left bumper moulded strip Material PP EPDM Engaged in cover Bumper strip can be lev ered out of fastenings carefully from outside using a plastic wedge and removed 4 Left air intake grille Pull forwards out ...

Page 151: ...rrier Qty 4 12 Number plate carrier For various countries Installing Item 2 page 235 13 Right bumper strip Material PP EPDM Engaged in cover Bumper strip can be levered out of fastenings carefully from outside using a plastic wedge and removed 1 6 Front bumper substructure 1 Left air duct Engages in lock carrier 2 Left guide Bolted to lock carrier 3 Bolt Qty 2 per retainer 2 Nm 4 Transverse member...

Page 152: ...aranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 7 Assembly overview bumper carrier 1 Bumper carrier 2 Bolt Qty 4 per side 60 Nm 3 Bolt Qty 6 8 Nm 4 Foam piece Self adhesive Available in various shapes Golf 2004 General body repairs exterior Edition...

Page 153: ... b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 8 Assembly overview number plate carrier 1 Bumper cover 2 Number plate carrier Not for all countries Installing Align number plate car rier 3 mark position of holes and drill out Insert clips 3 Centre line 4 Clip Qty 4 Golf 2004 Ge...

Page 154: ... 2 Front bumper for GTI GTI special models GT R32 2 1 Tools Special tools and workshop equipment required Torque wrench V A G 1783 Torque wrench V A G 1332 2 2 Repairing bumper cover Note If bumper cover is damaged determine whether plastic can be repaired before renewing bumper Details can be found under General Information Body Repairs General Body Repairs Work procedures Plastic repair proce du...

Page 155: ... c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 Cover Material PP EPDM Removing and installing page 147 2 Bolt 1 5 Nm 3 Bolt Qty 4 per side 2 Nm 4 Bolt Qty 8 1 5 Nm 5 Bolt Qty 2 5 Nm 2 4 Removing and installing front bumper cover for GT GTI Note The removal and installation procedures may have to be modified slightly depending on v...

Page 156: ...adiator grille page 233 Remove bolts 5 Remove bolts 4 from below Remove bolts 3 and 2 point upwards on left and right in area of wheel housing liner Further dismantling is possible only with the help of a second mechanic With help of a second mechanic pull cover 1 parallel out of guides Disconnect all electrical connections from electrical compo nents and separate hoses 2 4 2 Installing Installati...

Page 157: ... has transverse pieces 1 Cover Material PP EPDM Removing and installing page 147 2 Left bumper moulded strip Material PP EPDM Engaged in cover Bumper strip can be lev ered out of fastenings carefully from outside using a plastic wedge and removed 3 Side marker light Left and right Not for all countries Removing Electrical system Rep Gr 94 Removing side marker lights 4 Left air intake grille Differ...

Page 158: ...e grille Different appearance for Golf GT and Golf GTI Can only be removed when the radiator grille is removed Centre air intake grille can be levered out of latches carefully from outside using a plastic wedge and removed 10 Right air intake grille Different appearance for Golf GT and Golf GTI Removing Remove screw 4 First remove forwards arrow a out of latches then pull out of cover towards cent...

Page 159: ... C o p y r i g h t b y V o l k s w a g e n A G 2 6 Assembly overview bumper cover for R32 Note Minor differences may be encountered in the assembly overview depending on version 1 Cover Material PP EPDM Removing and installing page 151 2 Bolt Qty 2 1 Nm 3 Bolt Qty 4 per side 2 Nm 4 Bolt Qty 8 2 Nm 5 Bolt Qty 2 3 5 Nm 2 7 Removing and installing front bumper cover for R32 Note The removal and insta...

Page 160: ...e 237 Remove bolts 5 Remove bolts 4 from below Remove bolts 3 and 2 point upwards on left and right in area of wheel housing liner Remove side marker lights if fitted Electrical system Rep Gr 94 Side marker lights Further dismantling is possible only with the help of a second mechanic With help of a second mechanic pull cover 1 parallel out of guides Separate electrical connections of all electric...

Page 161: ...oving and installing page 151 2 Left side marker light For various countries Removing Electrical system Rep Gr 94 Removing side marker lights 3 Left air intake grille Removing page 237 4 Bolt Qty 6 per side 1 Nm 5 Cover for headlight washer system 6 Left bumper strip Material PP EPDM Engages in cover Bumper strip can be lev ered out of fastenings carefully from outside using a plastic wedge and re...

Page 162: ... g h t b y V o l k s w a g e n A G 2 9 Assembly overview front bumper cover for GTI special models Note Minor differences may be encountered in the assembly overview depending on version 1 Cover Material PP EPDM PU RIM Removing and installing page 154 2 Bolt Points upwards 1 5 Nm 3 Bolt Qty 4 per side 2 Nm 4 Bolt Qty 8 1 5 Nm 5 Bolt Qty 2 5 Nm 2 10 Removing and installing front bumper cover for GT...

Page 163: ...Remove bolts 4 from below Remove bolts 3 and 2 point upwards on left and right in area of wheel housing liner Further dismantling requires the help of a second mechanic With help of a second mechanic pull cover 1 parallel out of guides Separate connectors of all installed electrical components and hoses Electrical system Rep Gr 92 Windscreen wash wipe system Headlight washer system 2 10 2 Installi...

Page 164: ...ully from outside using a plastic wedge and removed 3 Left air intake grille Removing Unscrew bolt 4 First remove forwards arrow a out of catches then pull out of cover to wards centre of vehicle arrow b 4 Bolt 1 5 Nm 5 Spoiler Material PU RIM Engaged in cover Can be removed only when bumper has been removed and lower part of spoiler has been un bolted 6 Centre air intake grille Can only be remove...

Page 165: ... h t b y V o l k s w a g e n A G 2 12 Front bumper substructure 1 Left air duct Engages in lock carrier 2 Left guide Bolted to lock carrier 3 Bolt Qty 2 per retainer 2 Nm 4 Transverse member for pe destrian protection Not for all countries 5 Bolt Qty 6 8 Nm 6 Right air duct Engages in lock carrier 7 Bolt Qty 2 per retainer 2 Nm 8 Right guide Bolted to bumper carrier 9 Spreader nut Qty 3 10 Guide L...

Page 166: ...aranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 13 Assembly overview bumper carrier 1 Bumper carrier 2 Bolt Qty 4 per side 60 Nm 3 Bolt Qty 6 8 Nm 4 Foam piece Self adhesive Available in various shapes Golf 2004 General body repairs exterior Editio...

Page 167: ...n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 Rear bumper 3 1 Tools Special tools and workshop equipment required Torque wrench V A G 1783 Torque wrench V A G 1331 3 2 Repairing bumper cover Note If bumper cover is damaged determine whether plastic can be repaired before renewing bumper Details can be found under General Information Body Repairs Ge...

Page 168: ... e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 3 Assembly overview bumper cover 1 Cover Material PP EPDM Removing and installing page 160 2 Bolt Qty 2 5 Nm 3 Bolt Qty 4 5 Nm 4 Spreader rivet Qty 2 5 Bolt Qty 3 per side 2 Nm 6 Bolt Qty 4 5 Nm 3 4 Removing and installing bumper cover Note The removal and installation procedures may have t...

Page 169: ...xterior Removing and installing tail lights Remove bolts 5 on left and right in area of wheel housing liner Using a screwdriver lever out spreader rivet 4 on left and right in area of wheel housing liner From below remove bolts 2 and 3 Remove bolts 6 from above Further dismantling is possible only with the help of a second mechanic With help of a second mechanic pull cover 1 parallel out of guides...

Page 170: ...ied out in reverse order of removal Ensure that gaps are parallel and specified dimensions are maintained Body Repairs Rep Gr 00 Technical data Body gap dimensions 3 5 Rear bumper attachments Note Minor differences will be encountered on removal and installing depending on version 1 Cover Material PP EPDM Removing and installing page 160 2 Number plate lights Qty 2 Removing Electrical system Rep G...

Page 171: ...l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 6 Rear bumper substructure 1 Securing strip 2 Hexagon nut Qty 4 2 Nm 3 Guide Left and right 4 Hexagon nut Qty 3 per side 2 Nm 5 Retaining bracket Not installed on all mod els 6 Bolt Qty 2 5 Nm 7 Foil Left and right Self adhesive Golf 20...

Page 172: ...ly overview bumper carrier 1 Cross member 2 Bolt Qty 6 20 Nm 3 Foam piece Only installed in some countries Self adhesive Available in various shapes 3 8 Assembly overview towing bracket DANGER The bolts 3 function as plugs and seal the passenger com partment against exhaust fumes and must without exception be installed Note Minor differences will be encountered on removal and instal ling depending...

Page 173: ...n t C o p y r i g h t b y V o l k s w a g e n A G 1 Towing bracket Towing bracket with re movable ball head is shown in illustration 2 Ball hitch The removable ball head is located in the left side compartment of the luggage compartment 3 Bolt Plugs Qty 4 20 Nm 4 Bolt Qty 4 50 Nm turn 90 further Bolts must always be re placed by new ones af ter being undone 5 Cover Material PP EPDM Removing and in...

Page 174: ...n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 Rear bumper for R32 and GTI special models 4 1 Tools Special tools and workshop equipment required Torque wrench V A G 1783 Torque wrench V A G 1332 4 2 Repairing bumper cover Note If bumper cover is damaged determine whether plastic can be repaired before renewing bumper Details can be found under General Information Bo...

Page 175: ... g h t b y V o l k s w a g e n A G 4 3 Assembly overview bumper cover for R32 Note Minor differences may be encountered in the assembly overview depending on version 1 Cover With various forms for number plate Material PP EPDM Removing and installing page 167 2 Bolt Qty 2 5 Nm 3 Bolt Qty 3 5 Nm 4 Bolt Qty 4 per side 2 Nm 5 Bolt Qty 4 5 Nm 4 4 Removing and installing bumper cover for R32 Note The r...

Page 176: ...switches exterior Removing and installing tail lights Remove bolts 4 on left and right in area of wheel housing liner From below remove bolts 2 and 3 Remove bolts 5 from above Further dismantling is possible only with the help of a second mechanic With help of a second mechanic pull cover 1 parallel out of guides Disconnect connectors for existing electrical components number plate light Electrica...

Page 177: ...moval and installing depending on version 1 Cover With various forms for number plate Material PP EPDM Removing and installing page 167 2 Number plate lights Qty 2 Removing Electrical system Rep Gr 94 Lights bulbs switches exterior Number plate illumination 3 Right fitting bracket 4 Spoiler With various forms for number plate Material PC ABS Engaged in cover Can be removed only when bumper has bee...

Page 178: ... r i g h t b y V o l k s w a g e n A G 4 6 Assembly overview rear bumper cover for GTI special models Note Minor differences may be encountered in the assembly overview depending on version 1 Cover Material PP EPDM PU RIM Removing and installing page 170 2 Bolt Qty 2 2 Nm 3 Bolt Qty 2 5 Nm 4 Bolt Qty 4 per side 2 Nm 5 Bolt Qty 2 per side 5 Nm 4 7 Removing and installing rear bumper cover for GTI s...

Page 179: ...nd installing tail lights Remove bolts 4 on left and right in area of wheel housing liner From below remove bolts 2 and 3 Unscrew bolts 5 from above on left and right beneath tail lights Further dismantling requires the help of a second mechanic With help of a second mechanic pull cover 1 parallel out of guides Separate connectors for existing electrical components of number plate light Electrical...

Page 180: ...gaps are parallel and specified dimensions are maintained Body Repairs Rep Gr 00 Technical data Body panel gaps shut lines 4 8 Rear bumper attachments for GTI special models Note Minor differences will be encountered on removal and installing depending on version 1 Cover Material PP EPDM PU RIM Removing and instal ling 2 Number plate lights Qty 2 Removing Electrical system Rep Gr 94 Lights bulbs s...

Page 181: ... r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 9 Rear bumper substructure 1 Securing strip 2 Hexagon nut Qty 4 2 Nm 3 Guide Left and right 4 Hexagon nut Qty 3 per side 2 Nm 5 Retaining bracket Not installed on all mod els 6 Bolt Qty 2 5 Nm 7 Foil Left and right Self adhesive Golf 2004 General body...

Page 182: ... t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 10 Assembly overview bumper carrier Note Minor differences will be encountered on removal and installing depending on version 1 Cross member 2 Bolt Qty 6 20 Nm 3 Foam piece Only installed in some countries Self adhesive Available in various shapes...

Page 183: ...s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 64 Glazing 1 Flush bonded windows 1 1 Tools Special tools and workshop equipment required Removal kit for flush bonded windows V A G 1474 A Suction lifter V A G 1344 Cutting tool V A G 1351 Windscreen removal kit V A G 1755 Hand cartridge gun V A G 1628 Cartridge heater V A G 1939 Electric cutte...

Page 184: ...olkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Scraping blade V A G 1561 8 Cutting blade V A G 1561 10 Cutting blade V A G 1561 19 Double cartridge gun VAS 5237 Golf 2004 General body repairs exterior Edition 04 2008 176 Rep Gr ...

Page 185: ... solution D 009 401 049 Primer applicator D 009 500 259 Adhesive remover D 002 000 109 Cutting cord 357 853 999 9 Observe instructions for use on the information sheet provided by the manu facturer 10 Observe minimum curing period page 191 11 Heat according to manufacturers instructions using cartridge heater V A G 1939 12 Double cartridge gun VAS 5237 must be used to apply these materials 13 Smal...

Page 186: ...een Removing page 182 Installing page 182 2 Windscreen adjuster 443 845 631 A 3 Plenum chamber cover Must be removed from windscreen seal by hand only Removing page 180 Installing page 181 4 Windscreen seal Integral part of wind screen 5 Spacing lip Integral part of wind screen 6 PUR adhesive sealant Cross section of bead width 6 5 mm height 10 mm including resid ual material on window glass and w...

Page 187: ...s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 5 Assembly overview plenum chamber cover 1 Plenum chamber cover Must be removed from windscreen seal by hand only Removing page 180 Installing page 181 2 Plenum chamber bulkhead 3 Windscreen 4 Plenum chamber seal 5 Windscreen seal Integral part of wind scr...

Page 188: ... h t b y V o l k s w a g e n A G 1 5 1 Removing plenum chamber cover Unbolt wiper arms Electrical system Rep Gr 92 Wind screen wiper system Removing and installing windscreen wiper system Removing and installing wiper arms WARNING The plenum chamber cover must not be levered off with a tool wedge The windscreen will be damaged and can later crack Pull plenum chamber seal 4 off over entire length o...

Page 189: ... A G 1 5 2 Installing plenum chamber cover WARNING Striking the plenum chamber cover can cause cracks in the windscreen Spray windscreen seal 5 with a soapy solution so that ple num chamber cover 1 is easier to press on Place the plenum chamber cover 1 on the windscreen seal 5 and engage with the windscreen seal 5 starting in the middle and applying light pressure Install plenum chamber seal 4 and...

Page 190: ...material into in side of vehicle using awl V A G 1474 2 2 Secure inside end of cutting cord against falling out using pull handle V A G 1351 1 3 Loosen sealing lip in upper area of windscreen with a plastic wedge and spray in cleaning solution D 009 401 04 as sub stitute for lubricant Place cutting cord 2 using small tube 1 in upper area of window If gap is too small guide cutting cord on outside ...

Page 191: ...moving page 183 Installing page 185 2 Seal For rear window wiper 3 Rear lid 4 PUR adhesive sealant Cross section of bead width 6 5 mm height 10 mm including resid ual material on window glass and window flange Minimum curing period page 191 5 Trim Remove trim General body repairs interior Rep Gr 70 Trim in sulation Rear lid trim in sulation 6 Window aerial contact Right and left 1 9 Removing undam...

Page 192: ...dhesive sealing material to in side using awl V A G 1474 2 1 Secure end of cutting cord 3 against falling out using pull handle 1 Lay cutting cord 3 around window and guide second end of cord inwards into interior Secure end of cord to reel device V A G 1654 2 Position reel device V A G 1654 2 in position I Reposition reel device V A G 1654 2 as necessary and cut window free Use wedge V A G 1474 5...

Page 193: ... V o l k s w a g e n A G Apply textile reinforced adhesive tape all around flange 1 Cut through adhesive sealing material with pieces of glass in window aperture using electric cutter V A G 1561 A 3 and cutting blade V A G 1561 10 2 WARNING Always wear protective goggles and leather gloves 1 11 Installing rear window Preparing old undamaged window for glazing page 188 Preparing new window for glaz...

Page 194: ...187 2 PUR adhesive sealant Cross section of bead width 6 5 mm height 10 mm including resid ual material on window glass and window flange Minimum curing period page 191 3 Window flange 4 Seal with spacing lip Integral part of side win dow 1 13 Removing undamaged rear side window Loosen interior trim in upper area General body repairs interior Rep Gr 70 Trims insulation Load and luggage compartment...

Page 195: ...ricant Place cutting cord 2 around side window Using small tube 3 feed cutting cord 2 between lip and win dow flange feed also second cord end into interior Secure other end of cord to reel device V A G 1654 A and cut window free repositioning reel device as necessary Use wedge V A G 1474 5 to press cutting cord against win dow glass while cutting in order to obtain clearance at window flange 1 14...

Page 196: ... not treat with a cleaning solution Keep adhesion surface free of dirt and grease Exception if bonding is not performed immediately after cutting back the remaining residual material must be activated with ac tivator D 181 801 A1 1 17 Preparing new window without precoat ing for glazing Only the applied ceramic layer and injection moulded sealing lip with spacer rib are found on all new windows Ex...

Page 197: ...a 1 of window Ensure that glass adhesive is applied to primed area at a distance of approx 2 mm from sealing lip 2 Drying time approx 10 minutes 1 18 Preparing new window with precoating for glazing A replacement part rear window is precoated A PUR application area for the adhesive bead is sprayed onto this window Rub over the precoating with a dry lint free cloth WARNING Do not prime precoating a...

Page 198: ... compound Keep dirt and grease off of bonding surfaces WARNING Activator must not have contact with paint or the paintwork will be damaged Exception if bonding is not performed immediately after cutting back the remaining residual material must be activated with ac tivator D 181 801 A1 If the window flange has been repaired or partially renewed after painting the area concerned must be cleaned and...

Page 199: ...eal for rear window wiper motor drive shaft into rear window The activator must not come into contact with the window heater bus bar Marks have been made to the left and right on the rear window to aid in applying adhesive material The sides of the rear window must not project above the con tour of the rear lid under any circumstances Use adhesive tape to secure rear window in position while curin...

Page 200: ...int structure must be restored accord ing to specifications in the Paint workshop manual 1 23 Cleaning off excess adhesive sealing material It is recommended to use cleaning solution D 002 000 10 as a cleaner Observe the appropriate safety precautions when performing this work WARNING Glass which has just been installed should not be pressed out wards whilst cleaning from inside of vehicle First c...

Page 201: ...olkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 Front door windows 2 1 Tools Special tools and workshop equipment required Torque wrench 2 10 Nm V A G 1783 Golf 2004 General body repairs exterior Edition 04 2008 2 Front door wi...

Page 202: ... exterior From exterior the bolt has a right hand thread This means from exterior the bolt is removed by turning it to left from interior the bolt is removed by turning it to right 1 Door window Removing and installing page 195 2 Window guide Removing and installing page 201 3 Mounting 4 Bolt Accessible from exterior right hand thread re move by turning anti clockwise remove door outer panel page ...

Page 203: ...g door window Note The removal and installation sequence is only for the right door window The removal and installation of the left door window is similar The bolt 4 is accessible from interior and exterior From ex terior the bolt has a right hand thread This means from exterior the bolt is removed by turning it to left from interior the bolt is removed by turning it to right 2 3 1 Removing Remove...

Page 204: ...g to right Loosen bolts 3 do not remove from inside by turning to right and press clamping jaws apart Note If the work step cannot be carried out because there is a fault with the electric window motor remove motor to slide window down Lift rear of door window 1 and swivel out of door forwards in direction of arrow 2 3 2 Installing Insert door window 1 in door in direction of arrow Ensure that doo...

Page 205: ...f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 4 Adjusting door window Remove front door trim General body repairs interior Rep Gr 70 Trim insulation Door trims Lever out caps 4 Lower door window 1 until clamping bolts 3 for mounting 2 are accessible WARNING Remove bolt 3 from interior by turning to right Loosen bolts 3 do not remove from inside...

Page 206: ...sure press door window 1 in clamping jaws in direction of arrow and align door window tension free at rear window guide When doing so ensure that door window 1 is positioned par allel to window guide Tighten clamping jaws by turning bolts 3 to left from interior Specified torque for bolt 8 Nm Then check for correct operation Further installation is performed in the reverse order of removal 2 5 Ass...

Page 207: ...g and installing window regula tor motor Note The removal and installation sequence is only for the right door window regulator The removal and installation of the left door window regulator is similar The window regulator motor can also be removed with mount ing plate when door outer panel is removed 2 6 1 Removing Remove front door trim General body repairs interior Rep Gr 70 Trim insulation Doo...

Page 208: ... w a g e n A G Remove window regulator motor and control unit 1 from mounting plate 2 6 2 Installing Place window regulator motor 1 on and attach connectors arrows Move door window lightly up and down so that the splines be tween motor and cable drum engage easier Tighten window regulator motor bolts 2 specified torque 3 5 Nm Run window twice to upper stop and then down to lower stop This normalis...

Page 209: ...s w a g e n A G 2 7 Assembly overview window guide Note The right side is shown The left side is similar For a better representation the illustration is drawn without door outer panel 1 Window guide 2 Trim 3 Bolt Qty 2 2 Nm 4 Window frame on door inner part 2 8 Removing and installing window guide Note The removal and installation sequence is only for the right window guide The removal and install...

Page 210: ... i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 8 1 Removing Remove exterior mirror page 227 Pull window guide 1 out of mounting Remove bolts 3 Qty 2 and pull trim plate 2 off in direction of B pillar direction of arrow Pull window guide 1 off all around window frame 4 and re move upwards out of window slot 2 8 2 Installing Installation is carried out in reverse order ...

Page 211: ... 2 9 Assembly overview window regulator Note The right side is shown The left side is similar 1 Window regulator Removing and installing page 203 2 Bolt Qty 4 8 Nm 3 Bolt Qty 5 on 4 door models Qty 4 on 2 door models 8 Nm 4 Drive 5 Mounting plate 2 10 Removing and installing window regula tor Note The removal and installation sequence is only for the right window regulator Removal and installation...

Page 212: ...r i g h t b y V o l k s w a g e n A G 2 10 1 Removing Remove door outer panel page 94 Remove side impact protection page 74 Remove door window page 195 Remove bolts 2 from mounting plate 5 Remove window regulator bolts 3 Remove window regulator 1 with drive 4 and window reg ulator motor mounting plate 5 off door inner part Disconnect window regulator motor connector page 199 2 10 2 Installing Inst...

Page 213: ...AGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 Rear door windows 3 1 Tools Special tools and workshop equipment required Release tool T10236 Torque wrench 2 10 Nm V A G 1783 Golf 2004 General body repairs exterior Edition 04 2008 3 Rea...

Page 214: ... part of fixed door window Removing and installing page 209 3 Fixed door window Integral part of window guide Removing and installing page 209 4 Window regulator guide 5 Spreader pin Always renew when working on door window 6 Spreader plug Always renew when working on door window 7 Cover 8 Window regulator Removing and installing page 215 9 Window regulator motor Removing and installing page 212 3...

Page 215: ...eader pin 3 and spreader plug 4 are accessible in aperture of window regulator Note If the work step cannot be carried out because there is a fault with the electric window motor remove motor to slide window down Screw a 5 mm bolt approx 70 mm long into the spreader pin 3 and pull out from spreader plug 4 Screw an 8 mm bolt approx 80 mm long into spreader plug 4 Note Do not exert too great a press...

Page 216: ...Note When installing door window always renew spreader plug and spreader pin Before inserting spreader plug and spreader pin check washer for damage With door window 1 removed insert spreader plug 3 in mid dle centralised Press spreader pin 2 flush into spreader plug 3 Guide door window 1 into door and place door window on window regulator guide mounting 4 With light pressure from above arrow enga...

Page 217: ...onent part of fixed door window Removing and installing page 209 2 Fixed door window Part of widow guide Removing and installing page 209 3 Window frame on door inner part 3 5 Removing and installing fixed door win dow with window guide Note The removal and installation sequence is only for the right fixed door window with window guide The removal and in stallation of the left fixed door window wi...

Page 218: ...s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull window guide 1 out of centre rib 3 and guide window guide inwards Remove bolts 2 and slide centre rib 3 downwards arrow a Pull centre rib 3 off fixed door window seal arrow b Release window guide 1 with fixed door window 2 inside and outside off window frame 4 Using release tool T 10236 relea...

Page 219: ... r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull complete window guide 1 with fixed door window 2 off window frame 3 in direction of arrow 3 5 2 Installing Installation is carried out in reverse order of removal Specified torque for bolts on middle frame 5 5 Nm Note When installing fixed door window with window guide ensure i...

Page 220: ...V o l k s w a g e n A G 3 6 Assembly overview window regulator motor Note The right side is shown The left side is similar 1 Connector 2 Bolt Qty 3 3 5 Nm 3 Window regulator motor Removing and installing page 212 3 7 Removing and installing window regula tor motor Note The removal and installation sequence is only for the right door window regulator The removal and installation of the left door wi...

Page 221: ...c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 7 1 Removing Removing door trim General body repairs interior Rep Gr 70 Trims insulation Door trims Secure door window against sliding down with adhesive tape Remove the three bolts 2 Disconnect connector 1 Remove window regulator motor and control unit 3 from m...

Page 222: ...C o p y r i g h t b y V o l k s w a g e n A G 3 7 2 Installing Place window regulator motor 3 on and attach connector 1 Move door window lightly up and down so that the splines be tween motor and cable drum engage easier Tighten window regulator motor bolts 2 Specified torque for bolts 2 3 5 Nm Run window twice to upper stop and then down to lower stop This normalises and readies the window it als...

Page 223: ... i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 8 Assembly overview window regulator Note The right side is shown The left side is similar 1 Window regulator Removing and installing page 215 2 Bolt Qty 4 8 Nm 3 Mounting plate 4 Drive 5 Bolt Qty 2 8 Nm 3 9 Removing and installing window regula tor Note The removal and installation sequence is only for the right window r...

Page 224: ... y r i g h t b y V o l k s w a g e n A G 3 9 1 Removing Remove door outer panel page 94 Remove impact protection page 111 Remove door window page 206 Remove bolts 2 from mounting plate 3 Remove window regulator bolts 5 Remove window regulator 1 with drive 4 and window reg ulator motor mounting plate 3 off door inner part Disconnect window regulator motor connector page 213 3 9 2 Installing Install...

Page 225: ...nAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 66 Exterior equipment 1 Wheel housing liner 1 1 Tools Special tools and workshop equipment required Torque wrench V A G 1783 Golf 2004 General body repairs exterior Edition 04 2008 1 Wheel ...

Page 226: ... procedure for the right side is similar The removal and installation procedures may have to be modified slightly depending on variations in equip ment The wheel housing liner consists of a front and a rear part Vehicles with vermin repellent system page 276 1 Wheel housing liner rear part Material PP EPDM 2 Bolt Qty 7 2 Nm 3 Wheel housing liner front part Material PP EPDM 4 Bolt Qty 11 2 Nm 5 Spr...

Page 227: ...f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 3 1 Removing Wheel housing liner rear part Remove wheel Running gear Rep Gr 44 Specified tor ques for wheel bolts Remove bolts 2 Qty 7 Pull off rear part of wheel housing liner 1 Wheel housing liner front part Remove bolts 4 Qty 11 Pull off front part of wheel housing liner 3 1 3 2 Installing Instal...

Page 228: ...i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 4 Assembly overview rear wheel housing liner Note Only the left side is shown The procedure for the right side is similar 1 Wheel housing liner Material PP EPDM 2 Bolt Qty 9 2 Nm 3 Spreader nut Qty 4 1 5 Removing and installing rear wheel housing liner Note The removal and installation sequence is only for the left wheel housing l...

Page 229: ...a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 5 1 Removing Remove wheel Running gear Rep Gr 44 Specified tor ques for wheel bolts Remove bolts 2 Qty 9 Pull off wheel housing liner 1 1 5 2 Installing Installation is carried out in reverse order of removal Golf 2004 General bod...

Page 230: ...AGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 Exterior mirror 2 1 Tools Special tools and workshop equipment required Removal lever 80 200 Torque wrench V A G 1783 Golf 2004 General body repairs exterior Edition 04 2008 222 Rep Gr 66 ...

Page 231: ...ht side is similar 1 Mirror mounting Removing and installing page 227 2 Bolt Qty 3 8 Nm 3 Assembly piece Removing and installing page 226 4 Bolt Qty 2 1 Nm 5 Bolt Qty 2 1 Nm 6 Side turn signal Removing and installing page 226 7 Trim Removing and installing page 226 8 Mirror glass Removing and installing page 223 9 Mirror housing Material ABS Removing and installing page 224 2 3 Removing and instal...

Page 232: ...pe Press bottom of mirror glass 2 into mirror housing 1 Using removal lever 80 200 press mirror glass 2 off bracket 5 and housing 1 arrow 6 Swivel mirror glass 2 to side arrow 4 and detach connectors 3 for electric dip and mirror heating on rear of mirror glass 2 2 3 2 Installing Push contacts for mirror heating onto mirror glass Press mirror glass centrally onto bracket in housing Mirror glass en...

Page 233: ...i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 4 1 Removing Remove mirror glass page 224 Insert removal wedge 3409 between mirror housing 1 and side turn signal 2 Move removal wedge 3409 in direction of arrow a along to outer side of mirror This releases latches for mirror housing 4 from locking hooks 3 Pull mirror housing 1 forwards off mirror mounting at front in direction o...

Page 234: ... is only for the left trim plate The removal and installation of the right trim plate is similar 2 5 1 Removing Remove mirror glass page 224 Remove mirror housing page 224 Using a screwdriver lever locking hooks 2 out of mirror base carrier Pull trim plate 1 off in direction of arrow 2 5 2 Installing Installation is carried out in reverse order of removal Finally carry out a functional check 2 6 R...

Page 235: ...om turn signal 3 Remove bolts 2 and take turn signal 3 off assembly piece 1 2 6 2 Installing Installation is carried out in reverse order of removal Finally carry out a functional check 2 7 Removing and installing exterior mirror Note The removal and installation sequence is only for the left exterior mirror The removal and installation of the right exterior mirror is similar 2 7 1 Removing Remove...

Page 236: ...ac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 7 2 Installing Installation is carried out in reverse order of removal Specified torque for exterior mirror bolts 8 Nm Test function before installing door trim Golf 2004 General body repairs exterior Edition ...

Page 237: ...adiator grille 3 1 Tools Special tools and workshop equipment required Torque wrench V A G 1783 3 2 Assembly overview radiator grille 1 Radiator grille Material ASA 2 Retaining hook Qty 6 3 VW emblem Clipped into radiator grille Only remove when the radiator grille is re moved Removing release lock ing hooks on rear of VW emblem with radiator grille removed Installing guide VW em blem with locking...

Page 238: ...w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 3 Removing and installing radiator grille 3 3 1 Removing Remove bolts 4 Release clips arrows on lock carrier using a small screw driver Tilt radiator grille 1 backwards slightly and pull locking hooks 2 upwards out of bumper cover Golf 2004 Gen...

Page 239: ... Installing With radiator grille 1 tilted forward slightly place locking hooks 2 in the bumper cover Clip radiator 1 to lock carrier and engage clips arrows in lock carrier Install bolts 4 3 4 Assembly overview radiator grille for GTI GTI special models and GT Note Minor differences will be encountered on removal and instal ling depending on version The radiator grilles for the Golf GT and the Gol...

Page 240: ...Spreader rivet Qty 4 5 Number plate carrier For various countries Secured to radiator grille with spreader clips For radiator grille with no securing holes page 235 6 VW emblem Clipped into radiator grille Only remove when the radiator grille is re moved Removing release lock ing hooks on rear of VW emblem with radiator grille removed Installing guide VW em blem with locking hooks into recesses in...

Page 241: ... i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 5 Removing and installing radiator grille for GT GTI special models and GT Note The radiator grilles for the Golf GT and the Golf GTI differ only in their appearance 3 5 1 Removing Remove bolts 3 and 6 Loosen locking hooks 2 and 4 Lift radiator grille 1 up arrow a out of guide hooks 5 Tilt upper edge of radiator gri...

Page 242: ... t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 5 2 Installing Insert lower edge of radiator grille horizontally into bumper cover arrow c Fold radiator grille upwards arrow b Guide radiator grille into guide hooks 5 from above arrow c Locking hooks 2 and 4 engage audibly Tighten bolts 3 and 6 specified torque...

Page 243: ... i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 6 Radiator grille for GTI GTI special models GT and R32 number plate carrier 1 Radiator grille With no securing holes 2 Number plate carrier For various countries Observe country specif ic legislative dimensions Installing Align number plate car rier 3 mark position of holes and drill out Secure numb...

Page 244: ...SA Removing 2 Left air intake grille Removing page 237 3 Bolt Qty 6 per side 1 Nm 4 Bolt Qty 4 2 Nm 5 Number plate carrier For various countries Secured to radiator grille with spreader clips For radiator grille with no securing holes page 235 6 Spreader rivet Qty 4 7 Left air intake grille Removing page 237 8 VW emblem Clipped into radiator grille Only remove when the radiator grille is re moved ...

Page 245: ...e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 8 Removing and installing radiator grille for R32 3 8 1 Removing Remove bolts 4 and pull air grilles 3 and 6 in direction of arrow a and out of retaining clips in bumper cover Remove bolts 5 8 and 7 Release locking hooks arrow b and pull radiator grille 1 out of side lockin...

Page 246: ... t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 8 2 Installing Place radiator grille 1 in bumper cover The side locking devices and locking hooks 7 must engage audibly Tighten bolts specified torque for bolts 2 and 5 2 Nm and bolt 8 1 Nm Press air grilles 3 and 6 into bumper cover Tighten bolts specified torque for ...

Page 247: ... c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 9 R32 radiator grille company emblem 1 VW emblem Removing Release locking lugs arrow c Installing Position company em blem arrow a and turn in direction of arrow b 2 R32 lettering Removing Release locking lugs arrow d Installing Press into mounting in radiator grill until the locking ...

Page 248: ...esnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 Mouldings and trims 4 1 Tools Special tools and workshop equipment required Torque wrench V A G 1783 Hot air blower V A G 1416 Golf 2004 General body repairs exterior Edition 04 2008 240 Rep G...

Page 249: ...eorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 2 Assembly overview water deflector Note The right side is shown The left side is similar 1 Water deflector 2 Retaining strip 3 Pop rivet Qty 5 4 Clip 5 Bracket Golf 2004 General body repairs exterior Editi...

Page 250: ...p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 3 Removing and installing water deflector 4 3 1 Removing Lever water deflector 1 out of retaining strip 2 starting at top Pull clip 4 out of retainer 5 in lower area of wing Golf 2004 General body repairs exterior Ed...

Page 251: ...lkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 3 2 Installing Attach clip 4 in retainer 5 Press water deflector 1 into retaining strip 2 from bottom to top Golf 2004 General body repairs exterior Edition 04 2008 4 Mouldings and...

Page 252: ...n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 4 Assembly overview protective side strips Note Only the left side is shown The procedure for the right side is similar 1 Front door protective side strip Material PP EPDM Self adhesive Left and right protective side strips have different hole patterns 2 Side panel protective side strip Material PP EPDM Self adhesive Lef...

Page 253: ...ght side is similar Remove protective backing immediately before installation Working temperature approx 21 C Curing time after attaching side protective strips is about 4 hours at a room temperature of about 21 C Adhesive remover D 002 000 10 must be used exclusively The side protective strips must be bonded in place immediately after cleaning Before removing heat protective side strips 1 and 2 w...

Page 254: ... before fitting Bonding surfaces must be free of dust and grease Position protective side strips 1 and 2 on vehicle and press on using force 4 6 Removing and installing stone chip pro tection trim 4 6 1 Removing Guide a small screwdriver through the opening on the bottom edge of the side trim and release the locking device 2 by pressing the screwdriver upwards arrow a Slide stone chip protection t...

Page 255: ... h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 6 2 Installing Note The stone chip protection trim securing screws are corrosion resistant No further secondary treatment is required If a screw is overtightened it is essential to replace it with a black oversize screw There are no pre drilled holes for the securing screws Measure holes according to the table below Mark holes ...

Page 256: ... o l k s w a g e n A G Note Dimension a is measured including wheel housing liner 2 The other dimensions b through i are always measured from the centres of the holes Dimension k can only be measured on 4 door vehicles For two door vehicles determine dimension k in height to the front holes The table follows Dimension a 855 mm Dimension b 822 mm Dimension c 617 mm Dimension d 411 mm Dimension e 20...

Page 257: ...rew in self tapping screws 2 with cordless drill driver VAS 5036 using the highest speed until the screw takes hold Remove cordless drill driver from head of screw immediately Tighten screws using lowest torque setting so that screws are not overtightened Position openings on back of stone chip protection trim 1 evenly arrow a over all securing screws 2 until stone chip protection trim contacts si...

Page 258: ...i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 7 Assembly overview side member extension for GTI GTI special models and R32 1 Side member extension Removing page 251 Installing page 252 2 Bolt Side member extension to bracket Qty 4 2 Nm 3 Bolt Retaining strip to side skirts Qty 9 1 2 Nm Installing page 254 4 Retaining strip Removing page 253 Installing page 254 5 Sill ...

Page 259: ...c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 8 Removing and installing side member extension for GTI GTI special models and R32 4 8 1 Removing Remove bolts 2 Before removing heat side member extension 1 in bonding surface area 4 with hot air blower V A G 1416 Loosen adhesive tape 4 by carefully inserting a plastic wedge 5 between side member 3 and side member exten sion 1 As soon as...

Page 260: ... right side is similar Remove protective backing immediately before installation Working temperature approx 21 C Curing period after side member extensions are attached is about 4 hours at a room temperature of about 21 C Adhesive remover D 002000 10 and cleaning solution D 009 401 04 must be used exclusively Bonding surfaces must be free of dust and grease The side member extensions must be bonde...

Page 261: ... extension 1 from above arrows even ly into retaining strip 3 and press side member extension into retaining strip until the two parts engage Now pull protective films 2 on side member extension 1 off upwards and backwards Only now remove film 4 and press side member extension 1 on forcefully in bonding area Tighten bolts 5 beginning with front bolt on wing 4 9 Retaining strip for side member exte...

Page 262: ... i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 9 2 Installing Note The securing screws for the retaining strip are corrosion re sistant No further secondary treatment is required If a screw is overtightened it is essential to replace it with a black oversize screw There are no pre drilled holes for the securing screws Measure holes according to the table below Mark holes for ...

Page 263: ...l k s w a g e n A G Note Dimension a is measured including wheel housing liner 2 The other dimensions b through i are always measured from the centres of the holes Dimension k can only be measured in rear area on 4 door vehicles For two door vehicles determine dimension k in height to the front holes The table follows Dimension a 855 mm Dimension b 822 mm Dimension c 617 mm Dimension d 411 mm Dime...

Page 264: ... drilled page 254 Screw in self tapping screws 3 with cordless drill driver VAS 5036 using the highest speed until the screw takes hold Remove cordless drill driver from head of screw immediately Tighten screws using lowest torque setting so that screws are not overtightened Position openings on back of retaining strip 1 evenly arrows a over all securing bolts 2 until retaining strip con tacts sid...

Page 265: ...i g h t b y V o l k s w a g e n A G 5 Roof edge spoiler 5 1 Tools Special tools and workshop equipment required Removal kit for flush bon ded windows V A G 1474 A Suction lifter V A G 1344 Cutting tool V A G 1351 Windscreen removal kit V A G 1755 Hand cartridge gun V A G 1628 Cartridge heater V A G 1939 5 2 Materials 1K window adhesive DH 009 100 03 Activator D 181 801 A1 Primer D 009 200 02 Clean...

Page 266: ...a 400 ml car tridge alone is not sufficient 5 3 Assembly overview roof spoiler for GTI GTI special models and R32 1 Rear lid 2 Primer area For adhesive bead on retaining strip Position of primer area must be transferred from indentation for ad hesive bead in retaining strip 3 Primer area For adhesive bead on roof spoiler Position of primer area must be transferred from roof spoiler 4 Retaining str...

Page 267: ... d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Installation instructions page 264 5 4 Removing and installing roof spoiler for GTI GTI special models and R32 5 4 1 Removing WARNING Clean all surrounding parts before beginning work and mask them with tape Do not use cutting wire to remove the roof spoiler Thread cutting thread 6 in between rear lid 1 and roof spoil er 4 Using both h...

Page 268: ...s w a g e n A G Repeat adhesive tape and adhesive bead separation on the other side Note The middle hook is present only on vehicles from 02 05 Push several wedges 3409 between rear lid 1 and roof spoiler arrows a until all hooks 2 are released A clear click can be heard The hooks on the sides are dimension c 260 mm and dimension d 400 mm from the centre Reach between roof spoiler and rear lid pre...

Page 269: ...roof spoiler if necessary Retaining strip 6 installed page 263 Brake light in roof spoiler is installed Electrical system Rep Gr 94 Lights bulbs switches exterior Auxiliary brake lights High level brake light bulb M 25 removed and instal led Golf GTI Areas on roof spoiler 3 and rear lid 2 have been primed Apply adhesive bead onto primed area 3 on roof spoiler Place roof spoiler 5 onto retaining st...

Page 270: ...s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G If roof spoilers are re used secure corners of roof spoiler to rear lid with commercially available adhesive tape 5 5 Retaining strip 5 5 1 Removing retaining strip Roof spoiler is removed page 259 Separate adhesive bead 2 using cutting thread and handles Go...

Page 271: ...strip Bonding areas 2 on retaining strip and rear lid have been primed Apply adhesive bead to retaining strip recess Align retaining strip 4 with original cut out for brake light 3 Secure retaining strip with commercially available adhesive tape 5 6 Preparing body kit component for bond ing Note Remaining material serves as adhesion base for newly applied adhesive sealing compound Keep dirt and gr...

Page 272: ...cation for adhesive bead twice thoroughly using cloth applied with solution and allow to dry Now apply primer using applicator D 009 500 25 equally in one stroke Drying time approx 10 minutes Adhesive material should be applied to the primed areas of the body kit parts WARNING Body kit parts should be installed within 10 minutes or bonding properties of adhesive will be impaired Gap dimensions sho...

Page 273: ... r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 5 10 Cleaning off excess adhesive sealing material Use of adhesive remover D 002 000 10 as a cleaning solution is recommended Observe the appropriate safety precautions when performing this work First clean painted surface as much as possible using a dry cloth Remove residue using...

Page 274: ...m e n t C o p y r i g h t b y V o l k s w a g e n A G 6 Protective backing 6 1 Attachment notes for protective backing Note Before removal heat the scuff protection film with a hot air blower V A G 1416 Use only adhesive remover D 002 000 10 to remove residual adhesive Ensure that the adhesive surfaces are free of dust and grease Bond scuff protection film immediately after cleaning Pull protectiv...

Page 275: ...g scuff protection films is described only for the left side The right side is similar Removing Removing inner seal for front door in area of side member page 75 or inner seal for rear door page 114 Heat scuff protection film at the font 1 or at the rear 3 using a hot air blower V A G 1416 and pull scuff protection film from sill Installing Clean installation area with adhesive remover D 002 00 10...

Page 276: ...a g e n A G 7 Lettering 7 1 Tools Special tools and workshop equipment required Hot air blower V A G 1416 7 2 Installation instructions for lettering and emblems Note Before removal heat the lettering or the emblem with a hot air blower V A G 1416 Use only adhesive remover D 002 000 10 to remove residual adhesive Ensure that the adhesive surfaces are free of dust and grease Bond lettering or emble...

Page 277: ... i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 3 Rear lettering dimensions 1 Dimension a 50 mm From outer edge of rear lid to lettering 2 Dimension b 90 mm From lower edge of rear lid to lower edge of let tering 3 Lettering Model designation 4 Lettering Engine designation Golf 20...

Page 278: ... l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 4 Rear lettering dimensions for GTI and R32 1 Dimension a 50 mm From outer edge of rear lid to lettering 2 Dimension b 90 mm From lower edge of rear lid to lower edge of let tering 3 Lettering Golf 2004 General body repairs e...

Page 279: ... n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 4 1 Rear lettering dimensions for GTI special models 1 Dimension a 50 mm From outer edge of rear lid to lettering 2 Dimension b 90 mm From lower edge of rear lid to lower edge of let tering 3 Lettering Golf 2004 General b...

Page 280: ...r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 5 Rear lettering dimensions USA 1 Dimension a 50 mm From outer edge of rear lid to lettering 2 Dimension b 90 mm From lower edge of rear lid to lower edge of let tering 3 Dimension c 15 mm From emblem to letter ing 4 Lettering Rabbit 5 Lettering Golf 2...

Page 281: ... t C o p y r i g h t b y V o l k s w a g e n A G 7 6 Side lettering dimensions Individual 7 6 1 Dimensions of emblem left wing 1 Dimension a 551 mm Transfer the dimension a from the underside of the wing to the wing 2 Dimension b 14 mm Transfer dimension b from end point of dimen sion a to end point of emblem 3 Dimension c 70 mm Use dimension c to check distance from up per edge of emblem to the e...

Page 282: ...o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 6 2 Dimensions of emblem right wing 1 Dimension a 550 mm Transfer the dimension a from the underside of the wing to the wing 2 Dimension b 30 mm Transfer dimension b from end point of dimension a to corner point of emblem 3 Dimension c 86 mm Use dimension c to check distance from up per edge of emblem to the edge of wing 4 Dimension d 9...

Page 283: ... p y r i g h t b y V o l k s w a g e n A G 7 6 3 Dimensions of R line emblem Note The dimensions of the R line emblem are described only for the left side The right side is similar The dimensions b and c indicate the inclination of the logo The logo must be bonded parallel to the lower edge of the wing 1 Dimension a 91 mm From lower edge of wing to corner point of em blem 2 Dimension b 510 mm From...

Page 284: ...repellent system Note The items 2 to 5 are also installed on the passenger side The system prevents access for vermin 1 Protective part for vermin repellent system Various versions de pending on engine type 2 Bolt Qty 2 2 Nm 5 x 20 3 Upper protective part for vermin repellent system Material PP polypropy lene in brush form 4 Front protective part for ver min repellent system Material PP polypropy ...

Page 285: ...i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew bolts 1 Remove parts from vehicle Remove bolts 2 from protective part 1 Note The protective parts may have a different appearance depending on engine fitted 8 1 2 Installing Insert front protective part for vermin repellent system when doing this pay attention to guide arrow Screw in bolts 1 2 N...

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