Volkswagen Jetta 2011 Скачать руководство пользователя страница 25

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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 17

3 - Moulded foam element

❑ Left.

4 - Seal
5 - Moulded foam element

❑ Right.

6 - Windscreen seal

❑ Part of windscreen

7 - Windscreen

3.2

Removing and installing plenum cham‐

ber covers

Note

The removal and installation procedures for the plenum chamber

covers may have to be modified slightly depending on model var‐

iants.

Jetta 2011 ➤ , Jetta Hybrid 2013 ➤

General body repairs, exterior - Edition 08.2012

3. Plenum chamber cover

Содержание Jetta 2011

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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