Volkswagen Jetta 2011 Workshop Manual Download Page 7

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2.8

Removing and installing exterior mirror (manual operation) . . . . . . . . . . . . . . . . . . . . . . . . 252

2.9

Removing and installing exterior mirror (electrical operation) . . . . . . . . . . . . . . . . . . . . . . 256

Radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

3.1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

3.2

Removing and installing radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

3.3

Removing and installing emblem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Rear spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

4.1

Removing and installing rear spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Mouldings and trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

5.1

Water deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

5.2

Assembly overview - sill panel cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

5.3

Assembly overview - B-pillar trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

5.4

Removing and installing B-pillar trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

5.5

Side member extension “GLI” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

Lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

6.1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

6.2

Installation instructions for lettering and emblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

6.3

Lettering dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

Jetta 2011 ➤ , Jetta Hybrid 2013 ➤

General body repairs, exterior - Edition 08.2012

Contents

Summary of Contents for Jetta 2011

Page 1: ...uthorisedbyVolkswagenAG 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...

Page 2: ...ual 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...

Page 3: ...r covers 17 4 Noise insulation 21 4 1 Tools 21 4 2 Assembly overview noise insulation for combustion engines 22 4 3 Assembly overview noise insulation for diesel engines 23 5 Underbody cladding 24 5 1...

Page 4: ...moving and installing door 78 1 4 Installing after renewing A pillar 81 1 5 Door alignment 82 2 Door components 84 2 1 Tools 84 2 2 Assembly overview front door 85 2 3 Removing and installing door cov...

Page 5: ...55 1 Sunroof with glass panel 155 1 1 Tools 155 1 2 Function 155 1 3 Assembly overview 156 1 4 Removing and installing sliding tilting sunroof glass panel 157 1 5 Height adjustment of glass panel 158...

Page 6: ...t damage 203 1 17 Cleaning off excess adhesive sealing material 203 2 Front door window 205 2 1 Tools 205 2 2 Assembly overview front door window 206 2 3 Removing and installing door window 206 2 4 Re...

Page 7: ...tion 252 2 9 Removing and installing exterior mirror electrical operation 256 3 Radiator grille 261 3 1 Tools 261 3 2 Removing and installing radiator grille 261 3 3 Removing and installing emblem 264...

Page 8: ...r m i t t e d u 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...

Page 9: ...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 50 Body front 1 Lock c...

Page 10: ...rvice position page 3 2 Air duct 3 Bolt Qty 2 Specified torque 2 Nm 4 Bolt Qty 3 on each side Specified torque 8 Nm 5 Retaining bracket Left 6 Air guide Left 7 Bolt Qty 2 on each side Specified torque...

Page 11: ...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 15 Support for lock carri...

Page 12: ...e 8 Only remove one bolt 4 on left and right side of each longi tudinal member Attach special tool guide pins T 10093 to left and right lon gitudinal members where these bolts were located Remove rema...

Page 13: ...ition Carry out following work Push lock carrier together with add on parts 1 on the guide pins T10093 and onto the longitudinal member Fit bolts 3 and 4 in place Align lock carrier together with add...

Page 14: ...4 Removing and installing lock carrier with add on parts 1 4 1 Removing Note The lock carrier is a safety relevant component It must not be repaired for this reason In the event of damage renew lock...

Page 15: ...must only be carried out by suitable workshops with expert mechanics Removing and installing condenser Support bonnet and remove support rod from bonnet Together with a second mechanic unscrew guide...

Page 16: ...lign lock carrier together with add on parts 1 to longitudinal members and between wings Body Repairs Rep gr 00 Body gaps shut lines Body front 1 5 Removing and installing pressure hoses 1 5 1 Pressur...

Page 17: ...ving pressure hose Carry out following work Loosen screw of hose clamp A Pull pressure hose together with hose clamp A off the ribbed union Fitting pressure hose Carry out following work Push pressure...

Page 18: ...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...

Page 19: ...installing page 11 2 Bolt Qty 1 A pillar Qty 2 wheel housing Qty 1 side member Qty 2 wing bracket Qty 3 wing connection piece Specified torque 6 Nm 3 Wing end plate Removing and installing page 15 4...

Page 20: ...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 Carry out following work Remove wheel housing liners page 236 Pull out foam between wing and longitudinal member Item 5 page...

Page 21: ...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 3 2 Installing Note Install wing 1 without subjecting it to tensile stress Carry out following...

Page 22: ...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 Insulation and foam elements for wing and wing end plate Note Only the left side is shown The right side is similar Dif...

Page 23: ...y the left side is shown The right side is similar 1 Wing end plate Placed in front of wing web plate When installing ensure correct seating of posi tioning lug in hole of side member 2 Locking lug Qt...

Page 24: ...b y V o l k s w a g e n A G Undo bolts for fastening front wing to wing bracket 2 page 11 Undo bolts 1 and remove wing bracket 2 2 6 2 Installing Carry out following work Fit wing bracket 2 Screw in...

Page 25: ...o l k s w a g e n A G 3 Plenum chamber cover 3 1 Assembly overview plenum chamber cover 1 Plenum chamber right Removing and installing page 17 2 Plenum chamber cover left Removing and installing page...

Page 26: ...rk Remove wiper arms Electrical system Rep gr 92 Wind screen wiper system Removing and installing windscreen wiper system Pull off entire length of seal 4 from plenum chamber covers 1 and 2 Caution Th...

Page 27: ...a g e n A G Remove left plenum chamber cover 2 from vehicle towards front in direction of travel taking care not to damage horn between windscreen and wing Remove bracket for washer jets lines from r...

Page 28: ...n Push horn of right plenum chamber cover 1 between wind screen and wing Make sure that the retaining clamps at side of right plenum chamber cover 1 are correctly seated in the flat plate of the upper...

Page 29: ...wagenAGdoesnot 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...

Page 30: ...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 noise insulation for combustion engines Note The removal and installation procedures may...

Page 31: ...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 Assembly overview noise insulation for diesel engines Note The removal and installation procedures may have to be modified slightly...

Page 32: ...genAGdoesnot 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...

Page 33: ...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 2 Assembly overview underbody panel Note The right side is shown The left side is similar 1 Underbody claddin...

Page 34: ...a g e n A G 5 3 Rear right door underbody cladding Note Slight differences may be encountered on the rear right underbody trim depending on the vehicle model 1 Rear right door underbody cladding Diff...

Page 35: ...o p y r i g h t b y V o l k s w a g e n A G 6 Cross panel 6 1 Tools Special tools and workshop equipment required Torque wrench V A G 1331 Cartridge heater V A G 1939 Cartridge gun V A G 1628 6 2 Mat...

Page 36: ...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 6 3 Assembly overview bulkhead Note The bulkhead 1 is bolted and also bonded in place with PUR adhesive sealant 4...

Page 37: ...genAGdoesnot 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...

Page 38: ...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 2 Assembly overview tunnel cross piece Note Arrow points in direction of normal trave...

Page 39: ...snot 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...

Page 40: ...justing page 51 2 Adjustment buffer 3 Seal in centre Left and right 4 Striker pin Removing and installing page 46 Adjusting page 53 5 Insulation Removing and installing page 37 6 Hinge Removing and in...

Page 41: ...l k s w a g e n A G 1 3 Removing and installing bonnet 1 3 1 Removing Carry out following work Remove spray jets 5 Electrical system Rep gr 92 Win dow washer system Removing and installing spray jets...

Page 42: ...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 2 Installing Carry out following work Installation of bonnet 1 is carried out accordingly in reverse or der of removal Note Install the line 6 in a...

Page 43: ...t 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...

Page 44: ...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 4 2 Installing Carry out following work Ins...

Page 45: ...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 Removing and installing insulation 1 5 1 Removing C...

Page 46: ...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 2 Installing Carry out following work When installing insulatio...

Page 47: ...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 Assembly overview seals 1 Bonnet Removing and installing p...

Page 48: ...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 installi...

Page 49: ...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 2 Installing Carry out f...

Page 50: ...h t b y V o l k s w a g e n A G 1 8 Assembly overview bonnet lock and release components 1 Striker pin Removing and installing page 46 Adjusting page 53 2 Release lever Removing and installing page 4...

Page 51: ...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 9 Removing and installing lid lock 1 9 1 Removing Carry out following work Open bonnet Remove radiator grille page...

Page 52: ...from lock carrier Unclip bracket 3 by squeezing catch on bracket together arrows b After releasing the catch on bracket remove cable 2 from bonnet lock 1 Note Removing and installing bonnet contact s...

Page 53: ...Specified torque for bolts 4 12 Nm Attach connector for contact switch for bonnet F266 if there is one Fit cable 2 to cable coupling page 45 Adjust bonnet lock page 52 Install radiator grille page 26...

Page 54: ...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 When installing cable 3 ensure that grommets 4 and 5 are fitted correctly and securely Be...

Page 55: ...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 11 2 Installing Carry...

Page 56: ...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 12 Assembly overview release lever and mounting bracket 1 Mounting bracket 2 Cabl...

Page 57: ...y r i g h t b y V o l k s w a g e n A G 1 13 Removing and installing release lever 1 13 1 Removing Carry out following work Pull release lever 1 to release bonnet Insert a small screwdriver in gap be...

Page 58: ...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 13 2 Installing Carry out following work Lower A pillar tri...

Page 59: ...2 on the left and right are not a means of adjustment They have the function of stabilising and damping the bonnet The bonnet is adjusted correctly if the gaps shut lines are even all around the door...

Page 60: ...sion protection measures on bonnet hinges 5 and hexagon nuts 4 Turn adjusting buffer 2 to adjust arrow After bonnet has been adjusted the striker pin 1 can be re installed and adjusted page 53 Front p...

Page 61: ...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 1 14 2 A...

Page 62: ...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...

Page 63: ...age 64 4 Lid lock Removing and installing page 66 With emergency re lease function page 66 5 Hinge Removing and installing page 61 6 Gas strut Removing and installing page 57 Releasing gas page 60 7 S...

Page 64: ...e n A G Thread electric cables wire 2 together with rubber grommet out of rear lid 1 Loosen bolts 3 on left and right hinges do not unbolt com pletely Further dismantling requires the assistance of a...

Page 65: ...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 Assembly overview gas strut 1 Gas strut Removing and installing page 57 Releasing gas page 60 2 Ball head pin...

Page 66: ...a g e n A G 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...

Page 67: ...r i g h t b y V o l k s w a g e n A G 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 spri...

Page 68: ...ent Saw through cylinder of gas strut within first third of cylinder s overall length using piston rod end of cylinder as reference point Note Wear eye protection when sawing Cover area of saw cut wit...

Page 69: ...w a g e n A G 2 8 Removing and installing rear lid hinge 2 8 1 Removing Carry out following work Removing rear lid 1 page 55 If the left hinge 6 is to be removed Remove electric cable 5 from left hin...

Page 70: ...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 8 2 Installing Carry out following work Installation...

Page 71: ...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 9 Removing and installing striker plate 2 9 1 Removing Carry out following work Remove cover of striker plate in lock carrier cover...

Page 72: ...have elongated holes so it cannot be adjusted The adjustment buffers 2 on the left and right are not a means of adjustment Their purpose is to stabilise and dampen the rear lid 1 The rear lid is adju...

Page 73: ...o that the recess of the rear lid lock with rotary latch is centred relative to the striker plate 2 when it engages Carry out following work Remove cover of striker plate in lock carrier cover Loosen...

Page 74: ...does not open it can be opened in an emergency by reaching through the rear lid trim and actuating the emergency release 4 Operating Manual Carry out following work Remove rear lid trim General body...

Page 75: ...w a g e n A G 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 sealing and firm seating are no longe...

Page 76: ...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 14 2 Installing C...

Page 77: ...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 15 Registration plate carrier Note Number plate carrier is not installed in a...

Page 78: ...Gdoesnot 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...

Page 79: ...l k s w a g e n A G 3 2 Assembly overview tank flap unit 1 Connector For tank filler flap lock ing motor V155 2 Tank filler flap locking motor V155 Removing and installing page 73 3 Tank flap unit Rem...

Page 80: ...removal wedge 3409 A release locking mechanism of bottom right tank flap unit arrow 1 Release remaining locking mechanisms of tank flap unit using removal wedge 3409 in specified sequence arrows 2 4...

Page 81: ...3 with hinge side leading into side panel arrow a Then push tank flap unit fully home in side panel arrow b ensuring that locking lugs engage correctly in side panel Tighten bolt 2 Specified torque f...

Page 82: ...d load compartment Detach connector 2 of tank filler flap locking motor V155 3 Remove fuel tank flap unit page 71 Press rubber grommet 3 out of side panel and pull cable 2 together with plug in connec...

Page 83: ...sedbyVolkswagenAG 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...

Page 84: ...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...

Page 85: ...0 Nm 3 Door hinge Hinge is split Upper part is secured to hinge lower part with bolt 4 4 Bolt Connects upper part of hinge 3 to bottom part of hinge 7 Specified torque 23 Nm 5 Cover Fit onto bolt 4 6...

Page 86: ...1 Bolt Qty 2 Specified torque 9 Nm 12 Bolt Always renew it is permissible to loosen them once in order to align door Specified torque 40 Nm Installed from inside vehicle To remove and install the dash...

Page 87: ...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 Carry out following work Release boot 2 by pressing fastener arrow a and pull off A pillar Swing release lever 3 do...

Page 88: ...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 3 2 Installing Carry out following work Install in reverse order of removal Sp...

Page 89: ...t b y V o l k s w a g e n A G 1 4 Installing after renewing A pillar WARNING If A pillar is renewed bolts on A pillar must absolutely be tight ened as described in the following Carry out following w...

Page 90: ...ote Vehicle must be standing on its wheels to enable front door to be adjusted The front door is correctly adjusted when all shut lines are even when closed When the door does not project in or out to...

Page 91: ...the door have no effect Subsequent pressure from above will cause the door to sack again Adjusting striker pin page 83 1 5 2 Adjusting striker pin Note Only the adjustment for the right front door is...

Page 92: ...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 Door components 2 1 Tools Special tools and workshop equipment r...

Page 93: ...installing page 103 4 Door handle Removing and installing page 98 5 Lock cylinder Removing and installing page 93 Not always installed in front passenger door depending on the extras in vehicle 6 Bas...

Page 94: ...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 Specified torque 9 Nm 17 Door retaining strap Removing and installing page 88 18 Window slot inner seal Removing and installing page 105 1...

Page 95: ...G Carry out following work Removing front door trim General body repairs interior Rep gr 70 Door trim Lift lower end of cover 1 Pull cover 1 downwards and take out of door 4 Note If required for subs...

Page 96: ...a g e n A G 2 4 Removing and installing door retaining strap Note Removal and installation are described only for the right door re taining strap The removal and installation of the left door retaini...

Page 97: ...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 4 2 Installing Carry out following work Install in reverse order of removal Specified torque for...

Page 98: ...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 5 1 Removing Carry out following work Unscrew bolt 2 and remove striker pin 1 2 5 2 Installing Carry out following work Position strike...

Page 99: ...ng page 100 2 Bolt Specified torque 4 Nm For lock cylinder 3 Bearing bracket Removing and installing page 103 4 Lock cylinder Removing and installing page 93 Not always installed in front passenger do...

Page 100: ...r should not be turned and the screwdriver should not be used as a lever Carry out following work Pull door handle off door Push a small screwdriver 3 slightly arrow a into opening on underside of loc...

Page 101: ...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 Removing and installing lock cylinder Note The removal and installation sequence is only for the left lock cyl inder The removal...

Page 102: ...es lock cylinder Pull door handle 2 off door 8 arrow a Pull lock cylinder housing 1 perpendicular arrow b to the door out of the bearing bracket 3 2 8 2 Installing Carry out following work Pull door h...

Page 103: ...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 It is essential that a functional check is...

Page 104: ...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 9 2 Removing Note Forms other than the cover shown here 2 may also be installed C...

Page 105: ...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 handle 2 off door in direction of arrow a Pull cover cap 1 ou...

Page 106: ...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 Insert screwdriver 4 up to locking hook 3 in bearing bracket Press cover cap 1 onto door Push screwdriver arrow so far into ho...

Page 107: ...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 10 1 Removing Carry out following work Remove lock cylinder page 93 or cover cap page 95 Pull door handle...

Page 108: ...ector if there is one to door handle 1 Seat door handle 1 in bearing bracket whereby handle must be at right angles to door arrow a Swing door handle 1 into door arrow b Slide door handle forcibly for...

Page 109: ...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 11 1 Removing Carry out following work Remove cover page 86 Unclip cover 3 Disconnect connector 4 Remove lock cylinder if it is bui...

Page 110: ...A G Swivel cable arrow b so far until cable can be threaded out of eye in door lock 1 arrow c Detach cable from interior door handle Turn cable 6 90 and take it out of holding device Swivel cable arro...

Page 111: ...y r i g h t b y V o l k s w a g e n A G Install in reverse order of removal Specified torque for bolts 2 18 Nm It is essential that a functional test is then carried out because the door lock is not r...

Page 112: ...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 12 1 Removing Carry out following work Remove cover page 86 Remove lock cylinder page 93 or cover cap page 95 Remove door handle page 98 Unscrew bolt...

Page 113: ...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 12 2 Installing Carry out following work Install in reverse order of removal Specified torque for bolt 4 1 Nm 2 13 Removing and ins...

Page 114: ...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 1 Removing Carry out followin...

Page 115: ...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 2 Installing Carry out...

Page 116: ...l k s w a g e n A G 2 14 Removing and installing window slot outer seal 2 14 1 Removing Note The core of the seal is a metal insert If this is bent the seal can no longer be straightened out It will r...

Page 117: ...g e n A G Carry out following work Remove exterior mirror manual operation page 252 elec trical operation page 256 Pull seal 1 uniformly arrows off door flange 2 2 14 2 Installing Carry out following...

Page 118: ...s slightly when this is being done If the seal is then refitted sealing and firm seating are no longer guaranteed Therefore each seal that is completely removed must be re placed with a seal known as...

Page 119: ...w a g e n A G Remove sill panel strip General body repairs interior Rep gr 68 Sill panel strips Pull door inner seal 1 off body flange 2 15 2 Installing Carry out following work Align door inner seal...

Page 120: ...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 16 Removing and installing door outer seal Note Removal and installation are described only for the right door outer seal Removal...

Page 121: ...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 2 16 2 I...

Page 122: ...r i g h t b y V o l k s w a g e n A G 2 17 Assembly overview insulation WARNING Before installing door trim check that the holes in the door panel are sealed with respective stickers page 114 1 Insul...

Page 123: ...ing and installing page 212 3 Door lock on front passen ger side Door lock is secured to inner part of door Electric central locking is integrated into door lock Removing and installing page 100 4 Cou...

Page 124: ...ver side Removing and installing Electrical system Rep gr 96 Lights and switches in front doors Removing and installing switch module of window regulator driver side 16 Coupling station Fitting locati...

Page 125: ...p y r i g h t b y V o l k s w a g e n A G 09 Onboard supply control unit 09 Functions Adapting key with remote control 3 3 Assembly overview battery for folding key with remote control 1 Key with var...

Page 126: ...attery for fold ing key with remote control 3 4 1 Removing Carry out following work Insert screwdriver in slot between transmitter unit 1 and key 2 Turn screwdriver in direction of arrow to separate t...

Page 127: ...ownwards in sender unit 2 positive terminal is marked on housing Press battery into arrow radio container until it latches into place applying only slight pressure while doing so Attach lid and sender...

Page 128: ...unclip cover cap 1 on back of key 2 in direction of arrow Using a suitable screwdriver unclip battery 1 from battery compartment of key 2 in direction of arrow 3 6 2 Installing Note Before installing...

Page 129: ...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 58 Rear doors door components 1 Rear door 1 1 Tools Special tools a...

Page 130: ...hinge Hinge is split Upper part is secured to hinge lower part with bolt 4 4 Bolt Connects upper part of hinge 3 to bottom part of hinge 7 Specified torque 23 Nm 5 Cover Fit onto bolt 4 6 Bolt Always...

Page 131: ...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 10 Door retaining strap Removing and installing page 132 11 Bolt Qty 2 Specified torque 9 Nm 1 3 Removing and i...

Page 132: ...er 3 downwards arrow b and disconnect electrical connector 4 from coupling station Remove caps 8 from bolts 7 Loosen bolts 7 at hinges arrow d Unscrew bolt 5 for door retaining strap 6 Push door retai...

Page 133: ...t b y V o l k s w a g e n A G 1 4 Installing after renewing B pillar WARNING If B pillar is renewed bolts on B pillar must absolutely be tight ened as described in the following Carry out following w...

Page 134: ...d flushness Note Vehicle must be standing on its wheels to enable rear door to be adjusted The rear door is correctly adjusted when all shut lines are even when closed When the door does not project i...

Page 135: ...as raising the door have no effect Subsequent pressure from above will cause the door to sack again Adjusting striker pin page 127 1 5 2 Adjusting striker pin Note Only the adjustment for the right fr...

Page 136: ...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 Door components 2 1 Tools Special tools and workshop equ...

Page 137: ...ing page 148 3 Bearing bracket Removing and installing page 143 4 Door handle Removing and installing page 138 5 Cable From bearing bracket 3 to door lock 9 6 Base 7 Cover Removing and installing page...

Page 138: ...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 19 Window slot inner seal Removing and installing page 145 20 Door window Removing and installing page 221 2 3 Removing and installing cover Note The...

Page 139: ...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 cover 1 from door 4 Note If required for subsequent work pull cable...

Page 140: ...o l k s w a g e n A G 2 4 Removing and installing door retaining strap Note Removal and installation are described only for the right door re taining strap The removal and installation of the left doo...

Page 141: ...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 4 2 Installing Carry out following work Install in reverse order of removal Specified torque for...

Page 142: ...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 5 1 Removing Carry out following work Unscrew bolt 2 and remo...

Page 143: ...que 18 Nm 2 Door lock Removing and installing page 140 3 Cable From door lock 2 to bearing bracket 5 4 Cable From inner door handle to door lock 2 With grommet to pas sage on cover 5 Bearing bracket R...

Page 144: ...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 Assembly tool T10389 2 7 2 Removing Carry out fo...

Page 145: ...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 assembly tool T10389 backwards arrow until locking hook releases Pull door handle 2 off door in direct...

Page 146: ...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 Insert screwdriver 4 up to locking hook 3 in bearing bracket Press cover cap 1 onto door Push screwdriver arrow so far into hole until hook lock...

Page 147: ...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 8 1 Removing Carry out following work Remove cover cap page 135 Pull...

Page 148: ...talling Carry out following work Seat door handle 1 in bearing bracket whereby handle must be at right angles to door arrow a Swing door handle 1 into door arrow b Slide door handle forcibly forwards...

Page 149: ...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 9 1 Removing Carry out following work Remove cover page 130 Unplug connector 1 from door lock Remove bolts 4 Remove door lock 1 from door 2 Note Cab...

Page 150: ...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 Detach cable from interior door handle Turn cable 6 90 and take it out of holding device Swivel cable arrow d so far until cable can be thread...

Page 151: ...y r i g h t b y V o l k s w a g e n A G Install in reverse order of removal Specified torque for bolts 4 18 Nm It is essential that a functional test is then carried out because the door lock is not r...

Page 152: ...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 10 1 Removing Carry out following work Remove cover page 130 Remove cover cap page 135 Remove door handle page 138 Unscrew bolt...

Page 153: ...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 10 2 Installing Carry out following work Install in reverse order of removal Specified torque for bolt 4 1 Nm 2 11 Removing and ins...

Page 154: ...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 11 1 Removing Carry...

Page 155: ...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 11 2 Installing Carry out...

Page 156: ...Removing and installing window slot outer seal 2 12 1 Removing Note The core of the seal is a metal insert If this is bent the seal can no longer be straightened out It will remain wavy Therefore the...

Page 157: ...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 12 2 Installing Carry out following work Align seal 1 with B pillar and...

Page 158: ...nt upwards slightly when this is being done If the seal is then refitted sealing and firm seating are no longer guaranteed Therefore each seal that is completely removed must be re placed with a seal...

Page 159: ...a g e n A G Remove sill panel strip General body repairs interior Rep gr 68 Sill panel strips Pull door inner seal 1 off body flange 2 2 13 2 Installing Carry out following work Align door inner seal...

Page 160: ...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 14 Removing and installing door outer seal Note Removal and installation are described only for the right door outer seal...

Page 161: ...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 14 2 Installing Carry out following...

Page 162: ...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 15 Assembly overview insulation 1 Insulation Self adhesive Installing Cut to size if necessary Warm using hot air blower V A G 1...

Page 163: ...mfort position 2 pre vents to a large extent wind noise while driving which can occur when roof is fully open Glass panel can be tilted and closed using pull and push function on rotary switch The sun...

Page 164: ...ft and right To cover guide plate 3 Bolt Qty 3 on each side Specified torque 7 Nm 4 Bolt Qty 2 on each side Specified torque 1 Nm For attaching slide to sliding headlining 5 Slide Qty 2 on each side F...

Page 165: ...moving Carry out following work Push sliding headliner to rear Raise sliding tilting sunroof Unclip bellows along lower strip Loosen the two front catches and push bellows backwards out of guide arrow...

Page 166: ...ustment of glass panel page 158 1 5 Height adjustment of glass panel Carry out following work Bellows not yet removed Push sliding headliner to rear Raise sliding tilting sunroof Unclip bellows along...

Page 167: ...roof line Tighten rear bolt for glass panel Tighten middle bolt for glass panel Specified torque of bolts 7 Nm Raise sliding tilting sunroof Press bellows into mounts of guide plate Clip bellows into...

Page 168: ...nel have been removed in 0 position Carry out following work Remove glass panel page 157 Removing sunroof drive page 162 Move guide plates on both sides by hand until guide pin 1 is aligned with marki...

Page 169: ...t respective pivot point 3 to pre serve preload Remove pivot points 3 with springs and wind deflector 1 1 9 2 Installing Carry out following work Place wind deflector 1 together with springs and pivot...

Page 170: ...over stop 1 and take out Push sliding headliner forwards and raise slightly above the roof cut out Unscrew rear screws arrow on left and right Pull out spring slide to rear and remove sliding headlin...

Page 171: ...torque for bolts arrows 4 Nm Install front interior light W1 Electrical system Rep gr 96 Front interior light W1 with sliding roof Perform programming run for sliding tilting roof page 163 1 12 Setti...

Page 172: ...ed forwards until it finally closes During the entire programming run the operating switch for the sliding tilting roof must remain in the pulled position The programming run is thus completed 1 14 Re...

Page 173: ...i g h t b y V o l k s w a g e n A G 1 15 Removing and installing carrier unit 1 15 1 Removing Carry out following work Lower moulded headliner do not remove from vehicle General body repairs interior...

Page 174: ...oof aperture with the help of a second mechanic During installation use two cylindrical pins inverted drill bits to align carrier unit 1 front right 12 mm 4 and rear left 10 mm 2 in roof Carrier unit...

Page 175: ...t b y V o l k s w a g e n A G Fit water drainage hoses onto nozzles arrows of carrier unit 1 Install moulded headliner General body repairs interior Rep gr 70 Roof trim 1 16 Cleaning water drain hose...

Page 176: ...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 16 2 Rear water drain hoses The rear w...

Page 177: ...b y V o l k s w a g e n A G 63 Bumpers 1 Front bumper cover 1 1 Tools Special tools and workshop equipment required Torque wrench V A G 1783 Torque wrench V A G 1332 1 2 Repairing front bumper cover N...

Page 178: ...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 tool for PDC bracket VAS 6614 Cartridge gun VAS 5155 1 3 2 Materials 2 component plastic adhe sive D 180 K2 A1 1 1 2 2 Bonding agent for p...

Page 179: ...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 The 4 markings for a bracket 1 can be found on the i...

Page 180: ...k s w a g e n A G Fix the hole puncher in position with bolt head 1 washer 2 and thrust bearing 3 from the inside of the bumper cover 5 Screw on punch 4 not quite as far as bumper cover Press punch 4...

Page 181: ...V o l k s w a g e n A G Note Approx 1 cm of adhesive from tip should not be applied Lightly sand inside of bumper cover 6 and clean thoroughly Apply primer to bumper cover and bracket and allow to ai...

Page 182: ...inimum curing period Do not carry out any further work on bumper cover or brackets until the minimum curing period of 30 minutes has expired In this time the bumper cover must remain where it is and s...

Page 183: ...V o l k s w a g e n A G 1 5 Removing and installing front bumper cover Note The removal and installation procedures for front bumper cover may have to be revised slightly depending on model variations...

Page 184: ...front bumper cover 1 parallel arrows d off vehicle Remove connectors of all installed electrical components Notes and work instructions for the parking aid can be found in Electrical system Rep gr 94...

Page 185: ...rille page 261 1 6 Front bumper cover add on parts Note Minor differences may be encountered on add on parts depending on vehicle model 1 Front bumper cover Material PP EPDM Removing and installing pa...

Page 186: ...t b y V o l k s w a g e n A G 9 Cover For towing eye 1 7 Installing front number plate carrier Note Number plate carrier is not installed in all models or in all markets Number plate carriers of diff...

Page 187: ...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 Holes do not exist Centre the number plate carrier 3 on front bumper cover 2 in relation to VW emblem 1 Set drill depth stop to 12 mm and drill...

Page 188: ...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 9 Assembly overview front bumper carrier 1 Front bumper carrier 2 Bolt Qty 2 on...

Page 189: ...h t b y V o l k s w a g e n A G 2 Rear bumper cover 2 1 Tools Special tools and workshop equipment required Torque wrench V A G 1783 Torque wrench V A G 1331 2 2 Repairing rear bumper cover Note If re...

Page 190: ...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 tool for PDC bracket VAS 6614 Cartridge gun VAS 5155 2 3 2 Materials 2 component plastic adhe sive D 180 K2 A1 3 1 4 2 Bonding agent for p...

Page 191: ...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 The 4 markings for a bracket 1 can be found on the i...

Page 192: ...k s w a g e n A G Fix the hole puncher in position with bolt head 1 washer 2 and thrust bearing 3 from the inside of the bumper cover 5 Screw on punch 4 not quite as far as bumper cover Press punch 4...

Page 193: ...y V o l k s w a g e n A G Note Approx 1 cm of adhesive from tip should not be applied Lightly sand inside of bumper cover 6 and clean thoroughly Apply primer to bumper cover and bracket and allow to a...

Page 194: ...curing period Do not carry out any further work on bumper cover or brackets until the minimum curing period of 30 minutes has expired In this time the bumper cover must remain where it is and should n...

Page 195: ...s w a g e n A G 2 5 Removing and installing rear bumper cover Note The removal and installation procedures for rear bumper cover may have to be revised slightly depending on model variations 2 5 1 Rem...

Page 196: ...right on bumper cover Further dismantling requires the assistance of a second mechan ic Pull rear bumper cover 1 out of fasteners of guides on left and right of side panel arrows b Release fasteners...

Page 197: ...are parallel and shut lines are equal Body Re pairs Rep gr 00 Body gaps Body rear Fit bolts 3 4 and 5 in place and tighten them to the re spective specified torque page 186 If available screw in secur...

Page 198: ...o l k s w a g e n A G 2 7 Assembly overview rear bumper carrier 1 Rear bumper carrier 2 Bolt Qty 3 on each side Specified torque 20 Nm 3 Foam element Self adhesive Not installed in all model versions...

Page 199: ...t b y V o l k s w a g e n A G 1 Towing bracket With detachable ball head Remove rear bumper cover page 187 2 Bolt Sealing plugs Qty 1 on left 1 or 2 bolts on right de pending on model var iant Specifi...

Page 200: ...G 64 Glazing 1 Flush bonded windows 1 1 Tools Note The removal of a bonded window is described using the Removal kit for flush bonded windows V A G 1474 A The respective tools from Removal kit for flu...

Page 201: ...ing blade V A G 1561 8 Assembly tool set T10237 Cutting blade V A G 1561 19 Double cartridge gun VAS 5237 1 2 Materials 2K glass adhesive DA 004 600 A2 1 2 3 1K glass adhesive DH 009 100 A2 1 2 4 5 Ac...

Page 202: ...ording to manufacturer s instructions using cartridge heater V A G 1939 5 Small cartridge 180 ml for sealing and or when a 400 ml dou ble cartridge alone is not sufficient 1 3 Repairing windscreen Not...

Page 203: ...rm 6 Windscreen adjuster 443 845 631 A 7 Windscreen seal Is part of windscreen 8 Plenum chamber cover Must be removed from windscreen seal by hand only Removing and installing page 17 9 Adhesive bead...

Page 204: ...e n A G If featured remove water channel page 274 Removing plenum chamber cover page 17 Slide protective backing V A G 1474 8 1 between front windscreen and dash panel Pull cutting cord 2 through adh...

Page 205: ...cure other end of cord to reel device V A G 1654 A Apply the reel device V A G 1654 A to position I Turn reel device V A G 1654 A accordingly and cut wind screen free Use plastic wedge to press cuttin...

Page 206: ...indow flange Minimum curing period page 203 3 Body flange 4 Spacer 5 Rear lid 6 Windscreen adjuster 7 Adhesive bead butt end The butt end of the ad hesive bead should be located here 1 8 Removing unda...

Page 207: ...ch end of cutting cord to reel device V A G 1654 A Carefully insert protective backing V A G 1474 8 1 between rear window and moulded headliner Place reel device V A G 1654 A in indicated position Ope...

Page 208: ...lass remains in window cut out using electric cutter V A G 1561 A and u shaped blade V A G 1561 WARNING Always wear safety goggles and leather gloves 1 10 Installing rear window Carry out following wo...

Page 209: ...ewly ap plied adhesive sealing compound WARNING Do not prime bonding surface and do not treat with a cleaning solution Keep bonding surface free of dirt and grease Exception if bonding is not performe...

Page 210: ...adhesion base for newly applied adhesive sealing compound Keep bonding surfaces free of dirt and grease WARNING Activator must not have contact with paint or the paintwork will be damaged Exception i...

Page 211: ...and press in onto spacing lip Replace stickers e g for airbag if there were any 1 15 Minimum curing period WARNING Special standards must be adhered to when replacing bonded windows One of these stand...

Page 212: ...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 WARNING When cleaning freshly installed glass from the inside in the ve hicle do not press gl...

Page 213: ...agenAGdoesnot 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...

Page 214: ...ont door window Note The right side is shown The left side is similar 1 Retaining clip 2 Door window Removing and installing page 206 3 Front door 4 Window regulator Removing and installing page 214 5...

Page 215: ...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 Carry out following work Removing front door trim General body repairs interior Rep gr 70 Door trim Remove cover 2 page 86 Lev...

Page 216: ...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 Caution Loosening clamping bolt 3 by turning it clockwise Loosen clamping bolt 3 b...

Page 217: ...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 3 2 Installing Carry out following work Insert door window 1 into window chan...

Page 218: ...w channel as far as it would go arrow Using both hands push door window downwards arrow B Note Ensure that door window is always pushed into B pillar window channel arrow A for this Check visually tha...

Page 219: ...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 Note The door window will seat correctl...

Page 220: ...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 Removing and installing window regula tor motor Note The removal and installation sequence is only for the right window regul...

Page 221: ...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 Caution Switch off ignition and all electrical consumers Remove ignition key Disconnect connector 2 Remove the three screws 3...

Page 222: ...Screw in the three screws 3 Specified torque for bolts 3 4 Nm Connect connector 2 WARNING Before installing door trim check that the holes in the door panel are sealed with respective stickers page 1...

Page 223: ...h t b y V o l k s w a g e n A G 2 5 1 Removing Carry out following work Remove door window page 206 Removing window regulator motor page 212 Release locking hook of cable drum arrows b and push into d...

Page 224: ...5 2 Installing Carry out following work Insert window regulator 2 together with cable drum through opening in door arrows a b and c Insert upper threaded bolts with nuts 3 through the door skin and m...

Page 225: ...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 Removing and installing window chan nel Note Removal and installation is described only for the right window channel The removal and installat...

Page 226: ...he door flange from the inside Pull window channel 1 arrows a off flange 2 uniformly all around it Pull window channel 1 out of mountings arrows b 2 6 2 Installing Carry out following work Openings 4...

Page 227: ...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 To prevent wind noise ensure window channel 1 seats evenly when installing Push in retaining clip 3 arrow c Note Retaining...

Page 228: ...wagenAGdoesnot 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...

Page 229: ...ixed door window Removing and installing page 232 3 Bolt Qty 2 Specified torque 5 5 Nm 4 Window regulator Removing and installing page 227 5 Nut Qty 2 Specified torque 8 Nm 6 Window regulator motor Re...

Page 230: ...V o l k s w a g e n A G 3 3 1 Removing Carry out following work Remove rear door trim General body repairs interior Rep gr 70 Door trim Lower door window 6 as far as stop Note If this part of the wor...

Page 231: ...ader pin 4 and spreader plug 3 are accessible in cut out of window regulator 2 Screw a 5 mm bolt approx 70 mm long in the spreader pin 4 and pull bolt out of spreader plug 3 Screw an 8 mm bolt approx...

Page 232: ...When installing door window always renew spreader plug 3 and spreader pin 4 Before inserting spreader plug 3 and spreader pin 4 check window 1 for damage Carry out following work Insert and centre spr...

Page 233: ...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 4 Removing and installing window regula tor motor Note The removal and installation sequence is only for the right window regu...

Page 234: ...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 Caution Switch off ignition and all electrical consumers Remove ignition key Disconnect connector 3 Remove the three screws...

Page 235: ...een window regulator motor and cable drum engage more easily Screw in the three screws 2 Specified torque for bolts 2 4 Nm Connect connector 3 A new window regulator motor must be coded using the vehi...

Page 236: ...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 1 Removing Carry out following work Remove cover page 130 Remove door window page 221 Removing window regulator mo...

Page 237: ...i g h t b y V o l k s w a g e n A G 3 5 2 Installing Carry out following work Insert window regulator 1 together with cable drum through opening in door and move to mounting position arrows a and b In...

Page 238: ...y V o l k s w a g e n A G 3 6 Removing and installing window chan nel Note Removal and installation is described only for the right window channel The removal and installation of the left window chann...

Page 239: ...a g e n A G 3 6 2 Installing Carry out following work Openings 4 beneath window channel are masked off with textile adhesive tape Adhesive tape dimensions height approx 10 mm width ap prox 40 mm Spray...

Page 240: ...installing The window channel is installed at the B pillar after installation of the door window Push in retaining clip 3 arrow c Note Retaining clip inclination must point to inner side of vehicle ve...

Page 241: ...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 7 1 Removing Carry out following work Remove window...

Page 242: ...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 2 Installing Carry out following work Push fixed door window 1 into door...

Page 243: ...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...

Page 244: ...may be encountered in respect of wheel housing liner depending on vehicle model Only the left side is shown The right side is similar 1 Wheel housing liner Material PP EPDM Removing and installing pag...

Page 245: ...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 3 1 Removing Carry ou...

Page 246: ...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 3 2 Installing Carry out following work Note Check spreader nuts 3 for damage...

Page 247: ...view rear wheel housing liner Note Minor differences may be encountered in respect of wheel housing liner depending on vehicle model Only the left side is shown The right side is similar 1 Wheel housi...

Page 248: ...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 Removing and installing rear wheel housing liner...

Page 249: ...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 2 Installing Carry out following work Note Check spreader nuts 3 for damage and renew if necessary WARNING Check gas tight spread...

Page 250: ...genAG 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...

Page 251: ...Gdoesnot 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...

Page 252: ...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 2 Assembly overview exterior mirror manual operation Note The right side is shown The left side is similar 1 Mirror housing Material ABS Removing...

Page 253: ...shown The left side is similar 1 Mirror housing Material ABS Removing and installing page 248 2 Mirror mounting Removing and installing page 256 3 Adjuster unit with motor for exterior mirror Removin...

Page 254: ...b y V o l k s w a g e n A G 2 4 1 Removing Carry out following work WARNING When doing this repair work always wear safety goggles and leather gloves Protect edge of housing 2 against paint damage wi...

Page 255: ...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 2 Installing Carry out following work Press connector contacts onto mirror glass Push mirror glass centrally onto adjustment unit in housing Mir...

Page 256: ...age locking hook 4 on trim 1 arrow a Swivel trim 1 off retaining lugs 2 arrow b Remove trim 1 from mirror mounting 3 2 5 2 Installing Carry out following work Swivel trim 1 behind retaining lugs 2 on...

Page 257: ...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 6 1 Removing Carry out foll...

Page 258: ...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 Carry out following work Press mirror housing 1 onto mirror mounting 3 until locking hooks 2 engage audibly Installing trim page 247 Ins...

Page 259: ...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 1 Removing Carry out following work Remove mirror gl...

Page 260: ...w a g e n A G 2 7 2 Installing Carry out following work Connect connector 3 to adjustment unit with motor 1 Place adjustment unit with motor 1 on mirror mounting and fix in place by tightening screws...

Page 261: ...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 8 1 Removing Carry out following work...

Page 262: ...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 Swivel lower part of exterior mirror 1 away from the door...

Page 263: ...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 8 2 Installing Carry out following work Check that the foam part 4 is correct...

Page 264: ...o p y r i g h t b y V o l k s w a g e n A G Screw in and tighten bolt 2 for exterior mirror 1 Specified torque for bolt 2 8 Nm Attach connector if there is one for electric mirror heater Install fron...

Page 265: ...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 9 1 Removing Carry out follo...

Page 266: ...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 Swivel lower part of exterior mirror 1 away...

Page 267: ...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 9 2 Installing Carry out following work Check that the foam part 4 is corr...

Page 268: ...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 Screw in and tighten bolt 3 for exterior...

Page 269: ...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 Radiator grille 3 1 Tools Special tools and worksho...

Page 270: ...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 3 2 1...

Page 271: ...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 2 Installing Carry out following work Push radiator grille 1 into fr...

Page 272: ...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 emblem 3 3 1 Removing Carr...

Page 273: ...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 Disengage upper locking hook 3 using a screwdriver...

Page 274: ...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 2 Installing Carry out following work Push...

Page 275: ...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 Push trim cover wit...

Page 276: ...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 Rear spoiler 4 1 Removing and installing re...

Page 277: ...ctivator 1 Glass primer paint primer 1 Cleaning solution 1 Primer applicator 1 Adhesive remover 1 Cutting cord 1 Observe instructions for use on the information sheet provided by the manufacturer 2 Ob...

Page 278: ...ith hot air blower V A G 1416 Carefully detach adhesive tape between rear lid and rear spoiler e g with a plastic wedge Pull cutting cord in under rear spoiler 1 at side Secure a pull handle V A G 135...

Page 279: ...er application of primer with a lint free cloth and cleaning spirit After this time cleaning is no longer possible because the glass paint primer starts to adhere to the paint Prime marked bonding sur...

Page 280: ...e tape using adhesive strip remover VAS 6349 Ensure that surfaces to be bonded are free of dust and grease Glue rear spoiler on immediately after cleaning Remove protective foil just before mounting t...

Page 281: ...il of double sided adhesive tape 3 on left and right on rear spoiler 2 With the help of a second mechanic place rear spoiler 2 on rear lid and align rear spoiler Press left and right outer sides down...

Page 282: ...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 5 Mouldings and trims 5 1 Wat...

Page 283: ...y r i g h t b y V o l k s w a g e n A G 5 1 2 Assembly overview Note The right side is shown The left side is similar 1 Water deflector 2 Retaining strip Caution Only remove and install with windscre...

Page 284: ...n front wing 2 using hot air gun V A G 1416 and carefully pull off 5 1 4 Installing Fitting notes If a water channel is removed and installed only use adhesive remover D 002 000 10 to remove any adhes...

Page 285: ...deviates from the specifica tion the gap arrows must be adapted using for example a plastic wedge 2 and hammer 3 Check gap a again over complete length of retaining strip 1 after making changes using...

Page 286: ...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 Apply pressure to water channel 1 on inside arrow...

Page 287: ...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 2 Assembly overview sill panel cover Note Only the left side is shown The right side is similar 1 Side member cover...

Page 288: ...uaranteeorac 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 5...

Page 289: ...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 4 Removing and installing B pillar trim 5 4 1 Removing Note The trim cannot be removed without being dama...

Page 290: ...C o p y r i g h t b y V o l k s w a g e n A G 5 4 2 Installing Carry out following work Note Check grommets 4 for damage and renew if necessary Place trim 1 against B pillar Press trim securing pins 2...

Page 291: ...y r i g h t b y V o l k s w a g e n A G 5 5 1 Removing Carry out following work Release locking tabs of clips 3 and remove clips from side member extension 1 as far as stop arrow a Heat up adhesive ta...

Page 292: ...i g h t b y V o l k s w a g e n A G 5 5 2 Dimensions for securing screws Note Screws for side member extension are corrosion resistant No secondary treatment is required If the screw is overtightened...

Page 293: ...or securing screws Dimension a 950 mm Dimension b 869 mm Dimension c 435 mm Dimension d 435 mm Dimension e 869 mm Dimension f 60 mm 5 5 3 Installing Fitting notes If side member extension is being ins...

Page 294: ...rews 2 present Follow installation instructions page 285 Screw self tapping securing screws 2 into pilot drilled holes Specified torque for securing screws 2 1 2 Nm Mate side member extension 1 with o...

Page 295: ...Lettering 6 1 Tools Special tools and workshop equipment required Hot air blower V A G 1416 Adhesive strip remover VAS 6349 6 2 Installation instructions for lettering and emblems Note Lettering canno...

Page 296: ...o p y r i g h t b y V o l k s w a g e n A G 6 3 Lettering dimensions 6 3 1 Lettering for model name and engine designation Note When fitting the lettering observe the fitting notes page 287 Dimension...

Page 297: ...mm from lower edge of engine designation to upper edge of additional designation Ma b 43 mm from edge of rear lid to outer edge of lettering 6 3 3 GLI lettering 1 Left tail light in rear lid 2 GLI let...

Page 298: ...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 Rear lid lettering 1 Right tail light i...

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Summary of Contents for Jetta 2011

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Volkswagen Jetta 2011, Workshop Manual

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Summary of Contents for Jetta 2011

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