VW Passat b8 Var Body Repairs Exterior Eng

Service
Workshop Manual
Passat Variant 2015 ➤
Passat Variant 2019 ➤
General body repairs, exterior
Edition 02.2020
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
50 - Body - front
55 - Bonnet, rear lid
57 - Front doors, door components, central locking
58 - Rear doors, door components
60 - Sunroof
63 - Bumpers
64 - Glazing
66 - Exterior equipment
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness
and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as
a matter of course, be observed.
Passat Variant 2015 ➤, Passat Variant 2019 ➤
General body repairs, exterior - Edition 02.2020
Contents
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Assembly overview – lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Removing and installing lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Moving to and back from service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Assembly overview - wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Removing and installing wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Assembly overview - plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Assembly overview - plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 Removing and installing plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 Removing and installing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1 Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.1 Assembly overview - bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2 Assembly overview - Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 Assembly overview - gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4 Removing and installing bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.5 Adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.6 Removing and installing rear lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.7 Removing and installing bonnet release lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.8 Removing and installing striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.9 Removing and installing hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.10 Removing and installing insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.11 Removing and installing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.12 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.13 Removing and installing Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2 Rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1 Assembly overview - rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.2 Assembly overview - gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.3 Removing and installing rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.4 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.5 Removing and installing rear lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.6 Removing and installing operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.7 Removing and installing hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.9 Removing and installing rear lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.10 Removing and installing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.11 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.12 Removing and installing drive unit for rear lid VX69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.13 Removing and installing rear lid control unit J605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3 Tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.1 Assembly overview - tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.2 Removing and installing tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.3 Removing and installing fuel tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4 Charging flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.1 Assembly overview - Charging flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.2 Removing and installing charging flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Contents i
1 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.1 Assembly overview - door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.2 Removing and installing inner door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.3 Removing and installing outer door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.4 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.5 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.6 Adjusting striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.7 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2 Door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.1 Assembly overview - door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.2 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.3 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.4 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.5 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.6 Removing and installing inner door cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.8 Removing and installing cap on door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.9 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.10 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.11 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.12 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.13 Removing and installing window channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.14 Removing and installing window slot inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.15 Removing and installing window slot outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3 Central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.1 Overview of fitting locations - central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.2 Assembly overview - ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.3 Removing and installing bonnet contact switch F266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.4 Removing and installing driver door control unit J386 and front passenger door control unit
J387 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.5 Removing and installing rear left door control unit J388 and rear right door control unit
J389 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.6 Removing and installing tank filler flap locking motor V155 . . . . . . . . . . . . . . . . . . . . . . . . 174
3.7 Removing and installing actuator for high-voltage charging flap lock 1 F496 . . . . . . . . . . 175
3.8 Removing and installing ignition key battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.9 Removing and installing cap on ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.1 Assembly overview - door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.2 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.3 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.4 Adjusting striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.5 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.6 Removing and installing inner door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
1.7 Removing and installing outer door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2 Door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.1 Assembly overview - door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.2 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.3 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.4 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2.5 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.6 Removing and installing inner door cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
2.8 Removing and installing cap on door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.9 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
ii Contents
2.10 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

2.11 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
2.12 Removing and installing window channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
2.13 Removing and installing window slot outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
2.14 Removing and installing window slot inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1 Sliding sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.1 Assembly overview - sliding sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.2 Assembly overview - sunroof roller blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
1.3 Removing and installing sunroof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
1.4 Removing and installing rear sunroof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.5 Adjusting sunroof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
1.6 Removing and installing sliding sunroof frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
1.7 Removing and installing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
1.8 Removing and installing sunroof motor V1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.9 Removing and installing sunroof roller blind motor V260 . . . . . . . . . . . . . . . . . . . . . . . . . . 253
1.10 Removing and installing sunroof roller blind control unit J394 . . . . . . . . . . . . . . . . . . . . . . 255
1.11 Removing and installing sliding sunroof adjustment control unit J245 . . . . . . . . . . . . . . . . 256
1.12 Removing and installing sliding sunroof seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
1.13 Removing and installing sunroof roller blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
1.14 Programming sliding sunroof adjustment control unit J245 . . . . . . . . . . . . . . . . . . . . . . . . 266
1.15 Adapting sunroof roller blind control unit J394 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
1.16 Removing and installing rear part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
1.17 Removing and installing tilt mechanism for sliding sunroof . . . . . . . . . . . . . . . . . . . . . . . . 271
1.18 Removing and installing sunroof roller blind cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
1.19 Operating without current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
2 Water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
2.1 Assembly overview - water drainage hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
2.2 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
2.3 Removing and installing water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
1 Bumper, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
1.1 Assembly overview - bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
1.2 Assembly overview - add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
1.3 Assembly overview - impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
1.4 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
1.5 Removing and installing add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
1.6 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
1.7 Installing brackets for parking aid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
1.8 Installing brackets for park assist steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
2 Bumper, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
2.1 Assembly overview - bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
2.2 Assembly overview - guides for bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
2.3 Assembly overview - add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
2.4 Assembly overview - impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
2.5 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
2.6 Removing and installing add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
2.7 Removing and installing impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
2.8 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
2.9 Installing brackets for parking aid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
2.10 Installing brackets for park assist steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
1 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Contents iii
1.1 Minimum curing periods for bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

1.2 Window repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
1.3 Installation instructions for bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
1.4 Preparing old undamaged windows for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
1.5 Preparing new windows for installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
1.6 Preparing body flange for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
1.7 Cleaning off excess adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
2 Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
2.1 Assembly overview - windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
2.2 Removing and installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
3 Rear windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
3.1 Assembly overview - rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
3.2 Removing and installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
4 Side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
4.1 Assembly overview - rear side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
4.2 Removing and installing rear side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
5 Door windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
5.1 Assembly overview - front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
5.2 Assembly overview - rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
5.3 Removing and installing front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
5.4 Removing and installing rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
5.5 Removing and installing fixed front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
5.6 Removing and installing fixed rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

1 Radiator grille and front trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
1.1 Assembly overview - radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
1.2 Removing and installing radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
1.3 Removing and installing radiator grille seal, R-Line models as of 07.2019 . . . . . . . . . . . . 394
2 Spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
2.1 Assembly overview - spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
2.2 Removing and installing spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
3 Mouldings, trims, extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
3.1 Assembly overview - trim strip and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
3.2 Assembly overview - side member trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
3.3 Assembly overview - water deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
3.4 Assembly overview - heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
3.5 Removing and installing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
3.6 Removing and installing wheel arch covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
3.7 Removing and installing side member trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
3.8 Removing and installing water deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
3.9 Removing and installing B-pillar trim on door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
3.10 Removing and installing trim strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
3.11 Removing and installing entry moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
3.12 Removing and installing underbody heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
4 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
4.1 Assembly overview - noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
5 Underbody cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
5.1 Overview of fitting locations - trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
5.2 Assembly overview - bracing on underbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
5.3 Removing and installing underbody cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
5.4 Removing and installing tunnel cross-piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
6 Roof moulding and roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
6.1 Assembly overview - roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
iv Contents
6.2 Removing and installing roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467

7 Exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
7.1 Assembly overview - exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
7.2 Removing and installing exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
7.3 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
7.4 Removing and installing mirror adjustment unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
7.5 Removing and installing mirror cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
7.6 Removing and installing mirror frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
8 Wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
8.1 Assembly overview - front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
8.2 Assembly overview - rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
8.3 Removing and installing front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
8.4 Removing and installing rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
9 Lettering and emblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
9.1 Dimensions - lettering and emblems on rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
9.2 Dimensions - lettering and emblems on sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
9.3 Removing and installing badges at front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
9.4 Removing and installing lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
10 Decorative film / protective film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
10.1 Removing and installing protective film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
11 Special add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
11.1 Assembly overview – special add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
12 Towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
12.1 Assembly overview - towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
12.2 Removing and installing towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
12.3 Removing and installing trigger unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Contents v
vi Contents
50 – Body - front
1 Lock carrier
(VRL013962; Edition 02.2020)
⇒ o1.1 verview – lock carrier”, page 1
⇒ a1.2 nd installing lock carrier”, page 3
⇒ t1.3 o and back from service position”, page 5
1.1 Assembly overview – lock carrier
1.1.1 Assembly overview – lock carrier

Optional equipment Volkswagen R GmbH
Note
Different versions; for allocation refer to ⇒ Electronic parts catalogue “ETKA”
1. Lock carrier 1
1 - Lock carrier with add-on

parts
❑ Removing and instal‐
ling ⇒ page 3
❑ Moving to and back
from service position ⇒
page 5
2 - Mounting plate
❑ Left and right
3 - Bolts
❑ Qty. 1 on each side
❑ 8 Nm
4 - Bolts
❑ 8 Nm
5 - Bolt
❑ 2 Nm
6 - Air guide
❑ Left and right
❑ Different versions, al‐
location ⇒ Electronic
parts catalogue “ETKA”
7 - Support for lock carrier
8 - Bolts
❑ 12 Nm
9 - Caps
❑ Qty. 2
10 - Charging socket
❑ Instructions and work specifications for charging socket ⇒ Rep. gr. 93; Charging socket; Assembly
overview - charging socket
11 - Centre guide profile
12 - Expanding nuts
13 - Bolts
❑ Qty. 4
❑ 8 Nm
14 - Bolts
❑ 8 Nm
15 - Bolts
❑ 55 Nm
16 - Bumper carrier
17 - Adaptive cruise control unit J428
❑ On vehicles ► 06/2019, observe instructions and work specifications for adaptive cruise control unit
-J428- ⇒ Electromechanical power steering; Rep. gr. 27; Adaptive cruise control
2 Rep. gr.50 - Body - front

❑ On vehicles 07/2019 ►, observe instructions and work specifications for adaptive cruise control unit
-J428- ⇒ Driver assist systems; Rep. gr. 98; Fitting locations; Overview of fitting locations - senders,
sensors and control units in front area of vehicle
1.2 Removing and installing lock carrier

Special tools and workshop equipment required
♦ Guide pins -T10093-
♦ Torque wrench -V.A.G 1331-
1. Lock carrier 3
Note
♦ The lock carrier is a safety-relevant component. For this reason, the lock carrier must only be repaired at
the points indicated.
♦ In the event of damage, renew lock carrier.
♦ For vehicles with adaptive cruise control unit -J428-, the adaptive cruise control unit -J428- must be
adjusted anew whenever the lock carrier has been removed, installed or replaced.
♦ On vehicles ► 06/2019, observe instructions and work specifications for adaptive cruise control unit
-J428- ⇒ Electromechanical power steering; Rep. gr. 27; Adaptive cruise control.
♦ On vehicles 07/2019 ►, observe instructions and work specifications for adaptive cruise control unit
sensors and control units in front area of vehicle.
♦ For »GTE« hybrid vehicles, the instructions and work specifications for the charging socket are located in
⇒ Rep. gr. 93; Charging socket; Assembly overview - charging socket
Removing
– Always use guide pins -T10093- to move lock carrier to serv‐
ice position ⇒ page 5 .

– Remove guide pins -T10093- from left and right longitudinal

members with the aid of a second mechanic. Put down lock
carrier -1- with attachments. For example on engine and
gearbox jack -VAS 6931-.
– Remove bumper carrier and support arm ⇒ page 1 .
– Detach radiator module from lock carrier -arrow a-, but do
not remove it ⇒ Rep. gr. 19; Radiator, radiator fan; Assembly
overview - radiator cowl and radiator fan.
– Lift condenser -3- off radiator module -2- -arrow b-, swing it
slightly out of lock carrier -arrow c-, but do not remove it.
– Pull out lock carrier -1- upwards between radiator module
and condenser -arrows d-.
Note
♦ Do not hang condenser and hydraulic oil cooler from lines.

♦ Do not kink lines for condenser and hydraulic systems.
Installing
Install in the reverse order of removal observing the following:
Note
♦ Always fit lock carrier on the bolting points at the foremost

position in the elongated hole. Only then can the lock carrier
move in a crash situation.
♦ On vehicles equipped with adaptive cruise control unit -
J428-, the adaptive cruise control unit -J428- must be read‐
justed whenever the lock carrier has been removed, installed
or renewed.
♦ On vehicles ► 06/2019, observe instructions and work spec‐
ifications for adaptive cruise control unit -J428- ⇒ Electrome‐
chanical power steering; Rep. gr. 27; Adaptive cruise con‐
trol.
♦ On vehicles 07/2019 ►, observe instructions and work spec‐
ifications for adaptive cruise control unit -J428- ⇒ Driver
assist systems; Rep. gr. 98; Fitting locations; Overview of
fitting locations - senders, sensors and control units in front
area of vehicle.
♦ For information and work specifications for the charging
socket in »GTE« hybrid vehicles, refer to ⇒ Rep. gr. 93;
Charging socket; Assembly overview – charging socket.
Specified torques
♦ Lock carrier ⇒ o1.1 verview – lock carrier”, page 1 .
1.3 Moving to and back from service posi‐

tion
1. Lock carrier 5
♦ Guide pins -T10093-
♦ Adapter -T10467-

Moving to service position
Note
♦ The lock carrier is a safety-relevant component. The lock carrier must not be repaired for this reason.
♦ In the event of damage, renew lock carrier.
♦ For vehicles with adaptive cruise control unit -J428-, the adaptive cruise control unit -J428- must be
adjusted anew whenever the lock carrier has been removed, installed or replaced.
♦ For information and work specifications for the charging socket in »GTE« hybrid vehicles, refer to ⇒ Rep.
gr. 93; Charging socket; Assembly overview – charging socket.
– Remove front bumper cover ⇒ page 293 .

– Remove headlights ⇒ Electrical system; Rep. gr. 94; Head‐
lights; Removing and installing headlights.
1. Lock carrier 7
– Remove cable on mounting bracket of electrically operated

lid ⇒ page 47 .
– Unhook filler neck for washer fluid reservoir on carrier -2-
⇒ Electrical system; Rep. gr. 92; Window washer system;
Removing and installing washer fluid reservoir.
– Only remove one bolt -3- on left and right side of each longi‐
tudinal member.
– Screw in special tool guide pins -T10093- to left and right
longitudinal members where the bolts were previously loca‐
ted.
– Remove remaining bolts -3- on left and right side of longitu‐
dinal members.
– The lock carrier with add-on parts -1- can be pulled forwards
about 10 cm on the special tool guide pins -T 10093-. When
doing this, be careful with the electrical wires/cables leading
to lock carrier and, if necessary, detach connectors.
– Install special tool adapter -10467- (2 on each side) on left
and right between bumper carrier and longitudinal member.
Moving from service position

– Remove special tool adapter -T10467- on left and right from

between bumper carrier and longitudinal member.
– Push lock carrier together with add-on parts -1- on the guide
pins -T10093- and onto the longitudinal member.
– Place bolts -3- on left and right.
– Unscrew guide pins -T10093- on left and right.
– Align lock carrier together with add-on parts -1- to longitu‐
dinal members and between wings ⇒ Body Repairs; Rep.
gr. 00; Body gaps/shut lines; Body - front.
Note
♦ Always fit lock carrier on the bolting points at the foremost position in the elongated hole. Only then can
the lock carrier move in a crash situation.
♦ On vehicles equipped with adaptive cruise control unit -J428-, the adaptive cruise control unit -J428- must
be readjusted whenever the lock carrier has been removed, installed or renewed.
♦ For »GTE« hybrid vehicles, the instructions and work specifications for the charging socket are located in
⇒ Rep. gr. 93; Charging socket; Assembly overview - charging socket
Further installation is carried out in reverse order of removal.

When proceeding, observe the following:
Note
♦ Make sure that the charge air cooler pressure hoses are properly refitted.
♦ Do not permit hoses and lines to be pinched.
– Adjust headlights ⇒ Electrical system; Rep. gr. 94; Head‐

lights; Adjusting headlights.
Specified torques
♦ Lock carrier ⇒ o1.1 verview – lock carrier”, page 1 .
1. Lock carrier 9
2 Wings
⇒ o2.1 verview - wing”, page 10
⇒ a2.2 nd installing wing”, page 10
2.1 Assembly overview - wing
Note
The illustrations show the left-hand side. The right side is similar.
1 - Wings
ling ⇒ page 10
2 - Insulation for rib section
❑ Inserted between wing
and A-pillar.
3 - Bolt
❑ Qty. 7
❑ 6.0 Nm
4 - Centre hex stud
❑ Qty. 2, wing bracket
❑ 6.0 Nm
5 - Deformation element
❑ Qty. 2
6 - Bolt
❑ Qty. 2 for each defor‐
mation element
❑ 6.0 Nm
7 - Wing bracket
8 - Bolt
❑ Qty. 2
❑ 6.0 Nm
9 - Deformation element
❑ Qty. 1, shape may vary
❑ Qty. 2
10 - Wing insulation
❑ Inserted between wing
and upper A-pillar
2.2 Removing and installing wing


Removing
Note
Removal and installation are described only for the left wing. Removal and installation of the right wing are
similar.
– Remove front wheel housing liner ⇒ page 484 .
2. Wings 11
– Remove front bumper cover ⇒ page 293 .

– Remove headlights ⇒ Electrical system; Rep. gr. 94; Head‐
lights; Removing and installing headlights.
– If fitted, detach washer fluid reservoir on right side ⇒ Elec‐
trical system; Rep. gr. 92; Windscreen washer system; Re‐
moving and installing washer fluid reservoir.
– Removing left plenum chamber cover ⇒ page 17 .
– Remove water deflector ⇒ page 433 .
– Push trim strip -5- out of catches.
– Unscrew hexagon nut -6-, and detach guide bracket.
– Pull out wing insulation -3 and 4-.
– Unscrew centre hex studs -6-.
– Unscrew bolts -2-.
– Loosen bolt -2- on windscreen, but do not unscrew it com‐
pletely.
– Remove wing -1- carefully.
Note
The zinc intermediate piece -AKL 381 035 50- (if there is one) will be damaged during removal.
Installing
Note
Install wing -1- without subjecting it to tensile stress.


– The wing is aligned free of tension with wing bracket loos‐
ened.
– Always insert zinc intermediate piece -AKL 381 035 50- be‐
tween wing and side member.
– Ensure joints are parallel and shut lines are equal ⇒ Body
Repairs; Rep. gr. 00; Body gaps; Body, front.
Specified torques
♦ Wing ⇒ o2.1 verview - wing”, page 10
2. Wings 13
– Thoroughly wax area -1- of wing in which insulation -2- is

installed.
– Once wax has dried, insulation -2- can be installed.
– Install wheel housing liner ⇒ page 484 .

3 Bulkhead
⇒ o3.1 verview - plenum chamber bulkhead”, page 15
⇒ o3.2 verview - plenum chamber cover”, page 15
⇒ a3.3 nd installing plenum chamber bulkhead”, page 16
⇒ a3.4 nd installing plenum chamber cover”, page 17
3.1 Assembly overview - plenum chamber bulkhead
1 - Bulkhead
ling ⇒ page 16
2 - Hexagon nut
❑ Qty. 2
❑ 8.0 Nm
3 - Seal, plenum chamber
bulkhead
3.2 Assembly overview - plenum chamber cover
3. Bulkhead 15
1 - Plenum chamber cover

❑ Right side
ling ⇒ page 17
❑ Left side
ling ⇒ page 17
3 - Clip
❑ Qty. 3
4 - Foam element
❑ Left and right
5 - Seal
6 - Windscreen seal
❑ Part of windscreen
7 - Seal
8 - Windscreen
3.3 Removing and installing plenum cham‐

ber bulkhead

Removing
– Removing plenum chamber cover ⇒ page 15 .
– Unscrew hexagon nuts -2- and remove plenum chamber
bulkhead -1-.
Installing
Specified torques
Hexagon nut ⇒ Item 2 (page 15)
3.4 Removing and installing plenum chamber cover

Removing
Note
The procedures for removing and installing the plenum chamber covers may have to be modified slightly
depending on model variants.
3. Bulkhead 17
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92; Wind‐

screen wiper system; Removing and installing wiper arms.
– Pull off entire length of seal -5- from plenum chamber covers
-1- and -2-.
– Loosen clips -3- (qty. 3) at bottom.
– First pull plenum chamber covers -2- by hand, starting from
middle, upwards from windscreen seal -6-.
– Pull plenum chamber covers -2- forwards out of wing and
remove.
– Then, pull plenum chamber covers -1- by hand, starting from
middle, upwards from windscreen seal -6-.
– Pull plenum chamber covers -1- forwards out of wing and
remove.
Installing

Note
♦ An insert is fitted in windscreen seal of new windscreens. Remove this insert before installing plenum
chamber cover.
♦ Push the plenum chamber cover into the windscreen seal by hand using only slight force. Never force it in
by hitting or using tools.
♦ Striking or banging the plenum chamber cover into the windscreen seal may crack the windscreen.
– Spray windscreen seal -6- with a soapy solution so that ple‐

num chamber covers -1- and -2- are easier to press in.
– First insert plenum chamber cover -1- into wing.
– Place plenum chamber covers -1- on windscreen seal -6-.
Starting from the outside, press into beading -6- by applying
light pressure.
– Then insert plenum chamber cover -2- into wing.
– Place plenum chamber covers -2- on windscreen seal -6-.
Starting from the outside, press into beading -6- by applying
light pressure.
– Attach clips -3- (qty. 3) at bottom.
3. Bulkhead 19
– Fit seal -5- on plenum chamber covers -1- and -2-.

– Install wiper arms ⇒ Electrical system; Rep. gr. 92; Wind‐
screen wiper system; Removing and installing wiper arms.

55 – Bonnet, rear lid

1 Bonnet
⇒ o1.1 verview - bonnet”, page 21
⇒ o1.2 verview - Bowden cable”, page 23
⇒ a1.4 nd installing bonnet”, page 24
⇒ b1.5 onnet”, page 26
⇒ a1.6 nd installing rear lid lock”, page 32
⇒ a1.7 nd installing bonnet release lever”, page 37
⇒ a1.8 nd installing striker pin”, page 39
⇒ a1.9 nd installing hinges”, page 41
⇒ a1.10 nd installing insulation”, page 43
⇒ a1.11 nd installing gas strut”, page 45
⇒ g1.12 as from gas strut”, page 47
⇒ a1.13 nd installing Bowden cable”, page 47
1.1 Assembly overview - bonnet
1. Bonnet 21
1 - Bonnet
ling ⇒ page 24
❑ Adjusting ⇒ page 26
2 - Dampers
ling ⇒ page 43
3 - Striker
ling ⇒ page 39
4 - Hexagon nut
❑ Qty. 2
❑ Renew bolts each time
they have been loos‐
ened
❑ 12 Nm
5 - Adjusting buffer
❑ Qty. 4
Note
The threads of the adjusting buf‐

fers and the key hole must be
sprayed with preservative wax be‐
fore screwing in and adjusting.
❑ Contact point for adjusting buffer is always protected by protective film.
6 - Seal on side
❑ Left and right
7 - Hinge
❑ Removing and installing ⇒ page 41
8 - Hexagon nut
❑ For securing bonnet
❑ 22 Nm
9 - Bolt
❑ For securing hinge
❑ 22 Nm
22 Rep. gr.55 - Bonnet, rear lid

10 - Lid lock
11 - Bowden cable
12 - Bolt
❑ Qty. 2
❑ 12 Nm
13 - Wire
❑ To lid lock
14 - Gas strut
1.2 Assembly overview - Bowden cable
1 - Operating lever
ling ⇒ page 37
2 - Bowden cable
❑ From mounting bracket
-10- to clutch -4-
3 - Dampers
4 - Clutch
5 - Bowden cable
❑ From clutch -7- to bon‐
net lock -9-
6 - Lid lock
ling ⇒ page 32
7 - Bolt
❑ Qty. 2
❑ 12 Nm
8 - Mounting plate
9 - Bolt
❑ Qty. 1
❑ 1.5 Nm
10 - Mounting bracket
11 - Expansion nut
❑ Qty. 1
1.3 Assembly overview - gas strut
Volkswagen Technical Site: http://vwts.ru http://vwts.info 1. Bonnet 23

1 - Gas strut
ling ⇒ page 45
2 - Securing clip
3 - Ball pin
❑ Not an individual part,
cannot be renewed in‐
dividually
1.4 Removing and installing bonnet

Removing

– Remove spray jets -5- ⇒ Electrical system; Rep. gr. 92; Win‐
dow washer system; Removing and installing spray jets.
– Pull line -2- out of opening in bonnet -1-.
– Loosen hexagon nuts -3- in left and right hinges -4- (do not
remove).
Further dismantling requires the assistance of a second me‐
chanic.
– Remove gas strut -6-.
– Now, and only now, unscrew and remove hexagon nuts -3-
and lift bonnet -1- out of hinges -4-.
Installing
1. Bonnet 25
Installation of bonnet -1- is carried out accordingly in reverse

order of removal.
Note
Install the line -2- in a curve. If line is installed twisted it will kink.
– Adjusting bonnet -1- ⇒ page 26 .

Specified torques
♦ Hexagon nuts ⇒ o1.1 verview - bonnet”, page 21
1.5 Adjusting bonnet


Note
♦ Vehicle must be standing on its wheels to enable bonnet to be adjusted.

♦ The adjusting buffers -2- on the left and right sides cannot be used to adjust the rear lid. They have the
function of stabilising and damping the bonnet.
♦ The bonnet is correctly adjusted when all shut lines are even when closed. The bonnet must not protrude
too far inwards or outwards. The contours must also be flush with each other.
♦ The bonnet must engage into the lid lock without excessive force.
1. Bonnet 27
– Remove striker pin ⇒ page 39 .

– The gaps/shut lines are adjusted via the hinges ⇒ page 28 .
Note
The threads of the adjusting buffers -2- and the key hole must be sprayed with preservative wax before
screwing in and adjusting.
– Front part of bonnet can be adjusted to height of the wings

using adjustment buffers -2-.
– After bonnet has been adjusted, the striker pin -1- can be
re-installed ⇒ page 39 and adjusted ⇒ page 29 .
Specified torques
♦ Lid lock ⇒ o1.2 verview - Bowden cable”, page 23
Adjusting hinges
Note
Only loosen bolts -5-; do not remove them completely.

– By loosening hexagon nuts -3- on left and right bonnet hing‐

es -1-, the bonnet can be centred laterally -arrow b- and in
longitudinal direction -arrow a- between wings.
– By loosening bolts -2- on left and right lid hinges -1-, the
bonnet can be centred vertically -arrow c- between wings.
– Ensure that gaps are uniform ⇒ Body Repairs; Rep. gr. 00;
Technical data; Body panel gaps/shut lines; Body - front.
– After adjusting, carry out corrosion protection measures on
bonnet hinges -1-, hexagon nuts -3- and bolts -2-.
– If necessary, readjust adjustment buffers.
Specified torques
♦ Hinges ⇒ o1.1 verview - bonnet”, page 21
Adjusting striker pin
1. Bonnet 29
• New hexagon nuts -2- have not been tightened.

• If the hexagon nuts have been loosened, install new hexa‐
gon nuts.
– Adjust lateral position of striker pin -1- on bonnet in elonga‐
ted holes -arrows-.
– Tighten hexagon nuts -2-.

Specified torques
♦ Striker pin ⇒ o1.1 verview - bonnet”, page 21
Adjusting lid lock
♦ Setting gauge -3371-
Note
Use new bolts when adjusting the lid lock.
1. Bonnet 31
– Remove caps -3- from bolts.

– Loosen bolts -2- to adjust bonnet lock -1- laterally -arrow a-
and vertically -arrows b- relative to bonnet ⇒ Body Repairs;
Rep. gr. 00; Body panel gaps/shut lines; Body - front.
Specified torques
1.6 Removing and installing rear lid lock

⇒ a1.6.1 nd installing lid lock, LHD vehicle”, page 32
⇒ a1.6.2 nd installing lid lock, RHD vehicle”, page 35
1.6.1 Removing and installing lid lock, LHD

vehicle

Removing
– Open bonnet.
– Remove Bowden cable on mounting bracket ⇒ page 47 .
– Disconnect connector for bonnet contact switch -5-.
1. Bonnet 33
Note
The connector is secured next to the right headlight.

– Remove bolts -3- from lock carrier and remove lid lock -1-
upwards -arrow a-.
– Unclip retainer -7- from lid lock.
– Pull off retainer -7- from lid lock -1- slightly -arrow b- and
unhook cable -6- -arrow c-.
– Remove microswitch -5- from lid lock.
Installing
– Attach ball of cable -4- -arrow a-, and clip retainer -5- into
bonnet lock -1- -arrow b-.
– Install microswitch -6- in lid lock.
– Insert lid lock -1- into lock carrier -arrow c-.
– Screw in bolts -3-.

– Connect connector for bonnet contact switch -6-.

– Install Bowden cable on mounting bracket ⇒ page 37 .
– Adjust lid lock ⇒ page 26 .
– Install caps.
– Before closing bonnet, check function of release lever and
cable.
Specified torques
1.6.2 Removing and installing lid lock, RHD

vehicle
1. Bonnet 35
– Open bonnet.
– Remove Bowden cable on mounting bracket ⇒ page 47 .
– Disconnect connector for bonnet contact switch.
Note
The connector is secured next to the right headlight.

– Remove bolts -3- from lock carrier and remove lid lock -1-
upwards -arrow a-.
– Unclip retainer -7- from lid lock.
– Pull off retainer -7- from lid lock -1- slightly -arrow b- and
unhook cable -6- -arrow c-.
– Remove microswitch -5- from lid lock.
Installing

– Hook in cable -5- -arrow a- and clip retainer -4- into bonnet
lock -1- -arrow b-.
– Install microswitch -6- in lid lock -arrow c-.
– Insert lid lock -1- into lock carrier -arrow d-.
– Connect connector for bonnet contact switch -6-.
– Install Bowden cable on mounting bracket ⇒ page 37 .
– Adjust lid lock ⇒ page 26 .
cable.
Specified torques
1.7 Removing and installing bonnet re‐

lease lever
Removing
1. Bonnet 37
– Slightly pull operating lever -1-, and unlock bonnet.

– Insert a small screwdriver in gap between release lever -1-
and retaining clip -2-.
– Lever retaining clip -2- out of release lever -1- -arrow b- and
pull release lever off mounting bracket -4- -arrow a-.
For further work on mounting bracket -4- , remove lower A-pillar
trim -3- ⇒ General body repairs, interior; Rep. gr. 70; Trims,
interior; Removing and installing A-pillar trim.
Installing

• Lower A-pillar trim -3- is installed.

– Push retaining clip -2- into release lever -1-.
– Press release lever -1- onto mounting bracket -4-.
cable.
1.8 Removing and installing striker pin

1. Bonnet 39
Removing
– Open bonnet -2-.

– Remove hexagon nuts -3-.
– Remove striker pin -1- from bonnet -2-.
Installing
Note
Renew hexagon nuts -3- each time they have been loosened.

Installation of the striker pin -1- is carried out in the reverse

order of removal.
– Screw hexagon nuts -3- onto studs, but do not tighten them.
– Adjust striker pin ⇒ page 26 .
1.9 Removing and installing hinges

1. Bonnet 41
Note
Removal and installation are described for the right hinge only.
Removal and installation of the left hinge are similar.
Removing
– Remove bonnet ⇒ page 24 .

– Pull off hinge -1-.
Installing

Installation of the hinge -1- is carried out in the reverse order of

removal.
– Install bonnet ⇒ page 24 .
Specified torques
♦ Hinges ⇒ o1.1 verview - bonnet”, page 21
1.10 Removing and installing insulation

Removing
1. Bonnet 43
– Lever retaining clips -2- out of bonnet using removal lever

-80-200-.
– Pull insulation -1- out of elongated holes -arrows a-.
– Pull out insulation by guiding gas strut -3- through slot
-arrow b-.
Installing

• When installing insulation -1-, ensure that retaining clips -2-

are fitted with wider side facing outwards -arrow c-.
– Fit insulation -1- so that gas strut -3- is guided through the
slot -arrow b-.
– Push insulation -1- with fitting lugs -arrows a- into elongated
holes.
– Insert all retaining clips -2- into bonnet until they engage.
1.11 Removing and installing gas strut
1. Bonnet 45
Removing
– Open and support bonnet.
NOTICE
Risk of damage to spring clip caused by levering it out too far.
The spring clip may break.
– Never lever spring clip completely out of ball socket.
– Position a small screwdriver -3- beneath spring clip -4-.

– Raise spring clip -4- in such a way that it can be moved over
ball socket -arrow a-.
– Pull off gas strut -1- from ball-head pin -2- -arrow b-.
After removing gas strut -1-, slide spring clip -4- back immedi‐
ately.
– When the gas strut is disposed, gas needs to be released
from gas strut ⇒ page 47 .
Installing
– Press gas strut -1- onto ball-head pins -2-.

Component Specified tor‐

ques
Ball pin 20 Nm
1.12 Releasing gas from gas strut

– Clamp gas strut in vice in area x = 50 mm.
CAUTION
Risk of eye injury caused by flying swarf.
Risk of eye injury or eye irritation.
– Wear protective goggles.
– Cover area of saw cut with a cloth.

– Saw through cylinder of gas strut within first third of cylin‐
der's overall length using piston rod end of cylinder as refer‐
ence point.
– Feed oil and cleaning clothes into existing method of dispos‐
al.
1.13 Removing and installing Bowden cable

Removing
1. Bonnet 47
– Open bonnet.
– Remove release lever ⇒ page 37 .
– Remove Bowden cable -6- from mounting bracket -5-
-arrow a-.
– Pull Bowden cable coupling -2- off carrier -7- -arrow f-.
– Slightly pull off Bowden cable -1- -arrow b-.
– Open cap of Bowden cable coupling -arrow c-.
– Release Bowden cable -1- -arrow d- and remove from Bow‐
den cable coupling -2- -arrow e-.
Note
In order to be able to remove or install the Bowden cable -3-, remove the support arm -7- ⇒ page 1 .

Installing
Note
♦ If the Bowden cable -6- is not removed from mounting bracket, the Bowden cable -1- unhooks again and
again when installing the Bowden cable coupling -2-.
♦ The bonnet cannot be opened in this case.
– Hook in Bowden cable -1- into Bowden cable coupling -2-

-arrow b-.
– Slightly pull Bowden cable off Bowden cable coupling
-arrow c-.
– Close Bowden cable coupling -arrow d-.
– Push Bowden cable -1- into Bowden cable coupling
-arrow e-.
– Attach Bowden cable coupling -2- to lock carrier -4-
-arrow f-.
– Install Bowden cable -6- on mounting bracket -5- -arrow a-.
1. Bonnet 49
– Install release lever ⇒ page 37 .

Bowden cable.

2 Rear lid
⇒ o2.1 verview - rear lid”, page 51
⇒ o2.1.2 f fitting locations - electric rear lid”, page 53
⇒ o2.2 verview - gas strut”, page 54
⇒ a2.3 nd installing rear lid”, page 55
⇒ r2.4 ear lid”, page 57
⇒ a2.5 nd installing rear lid lock”, page 64
⇒ a2.6 nd installing operating mechanism”, page 76
⇒ a2.7 nd installing hinges”, page 81
⇒ a2.9 nd installing rear lid seal”, page 85
⇒ a2.10 nd installing gas strut”, page 87
⇒ g2.11 as from gas strut”, page 89
⇒ a2.12 nd installing drive unit for rear lidVX69”, page 91
⇒ a2.13 nd installing rear lid control unitJ605”, page 96
2.1 Assembly overview - rear lid

⇒ o2.1.1 verview - rear lid”, page 51
⇒ o2.1.2 f fitting locations - electric rear lid”, page 53
2.1.1 Assembly overview - rear lid
2. Rear lid 51
1 - Rear lid
ling ⇒ page 55
2 - Power latching system
ling
3 - Lid lock
ling ⇒ page 64
4 - Adjusting buffer
❑ Left and right
Note
The threads of the adjusting buf‐

fers and the key hole must be
sprayed with preservative wax be‐
fore screwing in and adjusting.
5 - Bolts
❑ Qty. 2
❑ 20 Nm
6 - Operating mechanism
❑ The brand badge can be renewed individually ⇒ page 499
7 - Bolts
❑ Qty. 3
❑ 5 Nm
8 - Ball pin
❑ On rear lid
❑ 20 Nm + 45°

9 - Gas strut
❑ Removing and installing gas strut ⇒ page 87
❑ Releasing gas from gas strut ⇒ page 89 .
10 - Bracket with ball-head pin
❑ On side panel
❑ Tightening torque of bolts 10 Nm + 90°
11 - Hexagon nut
❑ Qty. 1 for each hinge
❑ 20 Nm + 45°
❑ Removing and installing hinge ⇒ page 81
12 - Bolts
❑ Qty. 2 for each hinge
❑ 10 Nm
13 - Seal
14 - Hexagon nut
❑ Qty. 2
❑ 20 Nm
15 - Striker
2.1.2 Overview of fitting locations - electric rear lid
2. Rear lid 53
1 - Drive unit for rear lid -

VX69-
ling drive for rear lid ⇒
page 91
❑ On both sides for vehi‐
cles > 06.19
❑ Only on left side for ve‐
hicles 07.19 >
2 - Ball pin
❑ On rear lid
❑ 20 Nm + 45°
3 - Gas strut with cover
ling gas strut ⇒ page
87
❑ Releasing gas from gas
strut ⇒ page 89 .
❑ On right side for vehi‐
cles 07.19 >
4 - Connector
5 - Rear lid power opening
sender
❑ Fitting location only for
vehicles with towing
bracket
❑ The bracket is bonded
to the bumper cover us‐
ing double-sided adhe‐
sive tape
6 - Rear lid power opening
sender
❑ Fitting location only for
vehicles without towing
bracket
❑ The bracket is bonded to the bumper cover using double-sided adhesive tape
7 - Sensor wire
❑ Is bonded to the bumper cover using double-sided adhesive tape
8 - Wire
9 - Bracket for control unit
❑ Engaged in metal flange, release retaining hooks from behind
10 - Connector
11 - Rear lid power opening control unit -J938-
– Removing: release retaining hooks -arrow a-, pull control unit upwards -arrow b-, and remove it
-arrow c-.
– Installing: slide onto bracket from above, and press it on until retaining hooks can be heard to engage.
2.2 Assembly overview - gas strut

1 - Gas strut
ling gas strut ⇒ page
87
❑ Releasing gas from gas
strut ⇒ page 89 .
2 - Ball pin
❑ On rear lid
❑ 20 Nm + 45°
3 - Stop
❑ For stop buffers on left
and right in side panel
4 - Bracket with ball-head pin
❑ On side panel
5 - Bolt
❑ 10 Nm + 90°
6 - Grommet
❑ In roof cross member,
if no wire is routed
through opening
7 - Grommet
❑ In rear lid, if no wire is
routed through opening
2.3 Removing and installing rear lid

Removing
2. Rear lid 55
– Remove upper rear lid trim ⇒ General body repairs, interior;

Rep. gr. 70; Luggage compartment trims; Removing and
installing rear lid trim.
– Remove lower rear lid trim ⇒ General body repairs, interior;
Rep. gr. 70; Luggage compartment trims; Removing and
installing lower rear lid trim.
– Remove high-level brake light ⇒ Electrical system; Rep.
gr. 94; High-level brake light; Removing and installing high-
level brake light
– Disconnect connectors -2, 3, 4 and 5- of installed electrical
components.
– Thread wires together with rubber grommet out of rear lid.
– Loosen bolts -8- of left and right hinges but do not remove
completely yet.
chanic.
– Remove gas struts -7- ⇒ page 87 .
– Now, and only now, remove bolts -8- completely and then
remove rear lid -1-.
Installing

– Install rear lid -1- with the aid of a 2nd mechanic.

– Install gas struts -7- ⇒ page 87 .
– Guide wires -2, 3, 4 and 5- into rear lid, and attach rubber
grommet.
– Connect connectors of all installed electrical components.
The remaining installation steps are carried out in the reverse
sequence of removal.
– Before closing rear lid, check function of lid release compo‐
nents.
– Adjusting rear lid ⇒ page 57 .
2.4 Adjusting rear lid

Volkswagen Technical Site: http://vwts.ru http://vwts.info
2. Rear lid 57
Note
♦ Vehicle must be standing on its wheels to enable rear lid to be adjusted.

♦ The rear lid lock -2- is bolted directly to the rear lid -1-. The rear lid lock cannot be adjusted.
♦ The adjusting buffers -3- on the left and right sides cannot be used to adjust the rear lid. They have the
function of stabilising and damping the rear lid.
♦ The rear lid is correctly adjusted when all shut lines are even when closed. it is not protruding too far
inwards or outwards, and when the contours are flush with each other.
♦ The rear lid must engage in the striker plate without excessive force being applied.

Use the setting gauge -3371-⇒ Body Repairs; Rep. gr. 00;
Bodywork gaps/shut lines; Rear body to check or set the gap
dimensions.
– The rear lid lock -2- cannot be adjusted.
– Loosen striker pin -4-, and adjust it after adjustment of hinge
and adjustment buffer ⇒ page 62 .
– If bolts -6- are loosened on left and right, it is possible to ad‐
just rear lid -1- in the oversized holes of hinge -5- -arrows a-
and -arrows b-.
– After completing adjustments, perform corrosion protection
measures on hinge and bolts -6-.
– Readjust adjusting buffer -3-.
Specified torques
♦ Bolts ⇒ o2.1 verview - rear lid”, page 51
2. Rear lid 59
Adjusting adjusting buffer
Note
♦ If necessary, renew adjusting buffer ⇒ page 61 .

♦ The threads of the adjusting buffers and the key hole must be sprayed with preservative wax before
screwing in and adjusting.
– Loosen clamping bolt -4- until it is visible in rubber buffer.

– Pull detent slide -3- out of adjusting buffer -1-.
– Adjust detent slide to dimension -a- = 12.5 mm.
– Close rear lid in preliminary detent position with slight pres‐
sure in the middle.
– Open rear lid again.

– Screw in clamping screw -1- of adjustment buffer -2- to a

depth of -a- = 20 mm.
– Check the adjustment.
Renew adjustment buffer.
2. Rear lid 61
Removing
– To remove adjustment buffer, turn entire adjustment buffer
-1- through 90° -arrow a-.
– Remove buffer stop from rear lid -2-.
Installing
Note
The threads of the adjusting buffers and the key hole must be sprayed with preservative wax before screwing
in.
– Carefully check that stop -3- is correctly seated in side panel

-4- -arrow d-.
– To install, insert entire bump stop -1- at right-angle into rear
lid -2- -arrow c-.
– Turn bump stop -1- through 90° -arrow b-.
– Adjust adjustment buffer -1- ⇒ page 60 .
Adjusting striker pin

Note
♦ If hexagon nuts are loosened -2-, it is possible to adjust striker pin -1- in the oversized holes of hinge
-arrow a- and -arrow b-.
♦ Adjust striker pin -1- so that the recess of the rear lid lock with rotary latch is centred relative to the striker
pin -1- when it engages.
2. Rear lid 63
– Remove trim for rear lid lock ⇒ General body repairs, interi‐
or; Rep. gr. 70; Luggage compartment trims; Removing and
installing trim for rear lid lock.
– Loosen hexagon nuts -2-.
– Move striker pin -1- into upper position and tighten hexagon
nuts -2-.
– Close rear lid and make sure adjustment has been carried
out correctly.
Specified torques
♦ Hexagon nut ⇒ o2.1 verview - rear lid”, page 51
2.5 Removing and installing rear lid lock

⇒ a2.5.1 nd installing rear lid lock”, page 64
⇒ a2.5.2 nd installing lid lock with power latching system”, page
66
⇒ n2.5.3 ew lid lock with power latching system”, page 70
⇒ a2.5.4 nd installing power latching system”, page 72
⇒ n2.5.5 ew power latching system”, page 75
2.5.1 Removing and installing rear lid lock

Removing

Note
♦ If the rear lid does not open, it can be opened in an emergency by reaching through the rear lid trim and
actuating the emergency release by hand ⇒ Operating Manual.
♦ The Bowden cable -2- is only fitted on vehicles with power latching system.
– Remove rear lid trim ⇒ General body repairs, interior; Rep.

gr. 70; Luggage compartment trims; Removing and installing
lower rear lid trim.
– Pull off anti-theft protection device -5- -arrow b-.
– Disconnect connector on lid lock.
– Press together retaining hooks -6- -arrows d- and remove lid
lock -1- from rear lid -arrow c-.
2. Rear lid 65
Installing
Note
The Bowden cable -5- is only fitted on vehicles with power latching system.
– Insert lid lock -1- in rear lid -arrow a- and tighten hexagon
nuts -3-.
– Attach connector to lid lock.
– Slide on anti-theft protection device -4- -arrow b-.
• Before closing rear lid, check function of lid release compo‐
nents.
Specified torques
2.5.2 Removing and installing lid lock with

power latching system

Removing
Note
If the rear lid does not open, it can be opened in an emergency by reaching through the rear lid trim and
2. Rear lid 67

– Pull off anti-theft protection device -5- -arrow b-.
– Disconnect connector on lid lock.
– Press together retaining hooks -6- -arrows d- and remove lid
lock -1- from rear lid -arrow c-.
– Lock latch -7- of lid lock -4-.

– Using a screwdriver -5-, push lever -6- to stop in
-direction of arrow c-, and hold it in this position.
– Detach Bowden cable -1- from retainer by turning it
-arrow b-.
– Guide Bowden cable -1- out of lever -2- -arrow c-.
Installing

– Using a screwdriver -5-, push lever -6- to stop in

-direction of arrow c-, and hold it in this position.
– Guide Bowden cable -1- into lever -2- -arrow a-.
– Attach Bowden cable -3- to retainer by turning it -arrow b-.
– Release lever -6-, and operate release mechanism -7-
-arrow d-.
Note
The Bowden cable -5- is only fitted on vehicles with power latching system.
2. Rear lid 69
nuts -3-.
nents.
Specified torques
2.5.3 Installing new lid lock with power latching system

– Push clip -3- to stop in -direction of arrow c-, and hold it in

this position.
– Guide Bowden cable -1- into lever -7- -arrow a-.
– Attach Bowden cable -2- to retainer by turning it -arrow b-.
– Release clip -3- and remove from lid lock -4- -arrow d-.
– Operate release mechanism -6- -arrows e-.
2. Rear lid 71
nuts -3-.
nents.
Specified torques
2.5.4 Removing and installing power latching

system
Removing

Note
If the rear lid does not open, it can be opened in an emergency by reaching through the rear lid trim and

– Disconnect connector -5- on power latching system -1-.
– Slightly turn mounting -arrow a- so that Bowden cable is free
of stress.
– Lift Bowden cable retainer -4- out of power latching system
-1-.
– Lift Bowden cable ball head -3- out of mounting -arrow b-.
– Turn retaining clip -2- 90° -arrow c-.
– Pull power latching system -1- off retaining clip -2-.
2. Rear lid 73
Note
♦ The retaining clips -2- remain installed.

♦ If a new power latching system -1- is installed ⇒ page 75 , the retaining clips -2- must be removed.
Installing
– Fit power latching system -1- onto retaining clips -2-.

– Turn retaining clips -2- 90° -arrow c-.
– Fit Bowden cable ball head -4- onto mounting -arrow b-.
– Slightly turn mounting so that Bowden cable -4- is free of
stress.
– Insert Bowden cable retainer -3- in power latching system
-1- -arrow a-.
– Connect connector -5- to power latching system -1-.
nents.

2.5.5 Installing new power latching system
Note
The existing retaining clips -2- must be removed.
– Push retaining clips -2- installed on new power latching sys‐

tem into holes in rear lid -arrows c-.
– Fit Bowden cable ball head -3- onto mounting -arrow a-.
– Slightly turn mounting so that Bowden cable -4- is free of
stress.
– Insert Bowden cable retainer -4- in power latching system
-1- -arrow b-.
– Connect connector -5- to power latching system -1-.
nents.
2. Rear lid 75
2.6 Removing and installing operating

mechanism
⇒ a2.6.1 nd installing handle, without reversing camera”, page
76
⇒ a2.6.2 nd installing handle, with reversing camera”, page 78
2.6.1 Removing and installing handle, with‐

out reversing camera
Note
The brand badge can be renewed individually ⇒ page 499 .

Removing
– Detach connector -4- from handle connection -1-.
– Slightly turn handle -1- -arrow a-, and remove it from rear lid
-2- -arrow b-.
In case of electrical malfunction, rear lid can be opened us‐
ing lock emergency release. Emergency release is accessible
through an aperture in rear lid trim.
Installing
2. Rear lid 77
– Insert handle -1- into rear lid -2- -arrow a-, and turn it slightly
-arrow b-.
– Attach connector -4- to handle.
– Tighten bolts -3-.
• Before closing rear lid -2-, check function of lid release com‐
ponents.
Specified torques
2.6.2 Removing and installing handle, with

reversing camera

Note
The brand badge can be renewed individually ⇒ page 499 .
2. Rear lid 79
Removing
– Separate electrical connectors -1 and 7-.
– Slightly turn handle -2- -arrows a-, and remove it from rear
lid -arrow b-.
– Pull water drain hose -6- off handle -arrow c-.
In case of electrical malfunction, rear lid can be opened us‐
ing lock emergency release. Emergency release is accessible
through an aperture in rear lid trim.
On vehicles ► 06/2019, observe instructions and work specifica‐
tions for reversing camera -4- and gearbox -3- ⇒ Communica‐
tion; Rep. gr. 91; Reversing camera.
On vehicles 07/2019 ►, observe instructions and work specifi‐
cations for reversing camera -4- and gearbox -3- ⇒ Driver as‐
sist systems; Rep. gr. 98; Fitting locations; Overview of fitting
locations - senders, sensors and control units in rear area of
vehicle.
Installing

– Insert handle -2- into rear lid -5- -arrow a-, and turn it slightly
-arrows b-.
– Attach water drain hose -6- to handle -arrow c-.
– Secure connectors -1 and 7-.
nents.
Specified torques
2.7 Removing and installing hinges

2. Rear lid 81
Removing
– Remove end strip ⇒ General body repairs, interior; Rep.

gr. 70; Roof trim; Removing and installing moulded headlin‐
er.
Unscrew hexagon nut -4- without damaging moulded headliner.
– Loosen hexagon nut -4- and bolts -2-. Do not unscrew com‐
pletely.

Note
♦ Mask off the edge of the roof and the upper edge of the rear lid to prevent the paintwork from being
damaged.
♦ For the following procedure a 2nd mechanic is required to support the rear lid in the area indicated by the
-arrow-.
♦ The gas struts -5- remain installed.
– Unscrew hexagon nut -4- and bolts -2-.

– Pull out hinge -1-.
Installing
Hinge -1- installation is carried out in reverse order of removal.
2. Rear lid 83
Note
♦ If there is a separate washer -3-, make sure it is seated correctly.

♦ Hexagon nut -4- and washer -3- may also form one component.
♦ Recreate all seals which have been broken.
Specified torques
♦ Hexagon nut and bolts ⇒ o2.1 verview - rear lid”, page 51 .


Removing
– Remove trim for rear lid lock ⇒ General body repairs, interi‐
or; Rep. gr. 70; Luggage compartment trims; Removing and
installing trim for rear lid lock.
– Unscrew hexagon nuts -2- and remove striker pin -1- from
lock carrier.
Installing
– Mount striker pin -1- with hexagon nuts -2- onto lock carrier.
– Adjust striker pin -1- ⇒ page 57 .
Specified torques
♦ Hexagon nut ⇒ o2.1 verview - rear lid”, page 51
2.9 Removing and installing rear lid seal

In the factory a sealant is applied to the rear lid seal, the seal is
fitted to the body flange and then rolled on.
2. Rear lid 85
Note
♦ When the seal is removed, the sealant on the inside of the

seal will be spread and the flanks will be bent out slightly.
If the seal is then refitted, sealing and firm seating are no
longer guaranteed.
♦ Therefore, each seal that is completely removed must be
replaced with a seal known as a “tap-on seal”.
♦ If a seal has been partially removed, squeeze sides of seal
together before installing.
Removing
– Pull seal -1- off body flange -2-.
Installing
– Align seal -1- with vulcanised point for securing the gas strut
-arrows-.
– Press seal -1- evenly onto body flange by hand.

2.10 Removing and installing gas strut

Removing
Note
The rear lid must be supported when a gas strut is removed. One gas strut alone cannot support an open
rear lid.
– Open rear lid and brace it open.
NOTICE
– Position a small screwdriver -3- beneath spring clips -2-.

– Raise spring clips -2- -arrows a- until spring clips can be
moved over ball sockets.
2. Rear lid 87
– Pull gas strut -1- off ball-head pins -4- -arrows b-.
After removing gas strut, slide spring clips -2- back immediately.
– When the gas strut is disposed, gas needs to be released
from gas strut ⇒ page 89 .
Installing
• The spring clips -2- are pushed onto the ball sockets of the
gas strut -1-.
– Push ball sockets of gas strut -1- onto ball-head pins -4- until
ball sockets engage audibly with the ball-head pins -4-.
Specified torques
♦ Ball-head pin ⇒ o2.1 verview - rear lid”, page 51

2.11 Releasing gas from gas strut

⇒ g2.11.1 as from gas strut”, page 89
⇒ g2.11.2 as from gas strut with cover”, page 90
2.11.1 Releasing gas from gas strut
Note
Only components that have been depressurised may be disposed of through the normal channels.
CAUTION
– Cover area around holes with cloth.

– Saw cylinder of gas strut -1- at notch -2- or drill open
-arrow b-.
2. Rear lid 89
– Saw cylinder of gas strut -1- at a distance of 20 mm

-dimension a- from edge of housing or drill open -arrow c-.
al.
2.11.2 Releasing gas from gas strut with cover
Note
Only components that have been depressurised may be disposed of through the normal channels.
CAUTION
– Saw housing -2- of gas strut -1- at cutting line shown -3- and
remove.
– Cover area around hole with cloth.

– Saw off cylinder of gas strut -5- at a distance of 50 mm

-dimension a- from ball socket, or drill it open -arrow b-.
al.
– Saw through compression spring -4- at 3 positions -6- and
rotate inwards -arrow c-.
The gas strut is now depressurised and can be disposed of.
2.12 Removing and installing drive unit for

rear lid -VX69-
⇒ a2.12.1 nd installing drive unit for rear lidVX69”, page 91
⇒ a2.12.2 nd installing pinch protection”, page 94
2.12.1 Removing and installing drive unit for

rear lid -VX69-
Removing
Note
♦ On vehicles > 06.19, the rear lid drive unit -VX69- is installed
on both sides.
♦ On vehicles 07.19 >, the rear lid drive unit -VX69- is installed
on the left side only.
2. Rear lid 91
– Remove D-pillar trim ⇒ General body repairs, interior; Rep.

gr. 70; Trims, interior; Removing and installing D-pillar trim.
– Disconnect connectors -9- for wires of drive unit -1-.
– Pull out wires with rubber grommet -6-.
Note
The rear lid must be supported if a drive unit is removed.

– Support rear lid.
NOTICE
– Position a small screwdriver -3- beneath spring clips -2-.

– Raise spring clips -2- until spring clips can be moved over
ball sockets.
– Pull drive unit -1- off ball head pins -4-.
After removing drive unit, slide spring clips -2- back immediate‐
ly.
Installing
2. Rear lid 93
– Push drive unit with ball sockets onto ball studs -2 and 8-
until they engage audibly.
– Rout wires with rubber grommet -6-, and push in rubber
grommet firmly.
– Fit connectors -9- for wires of drive unit -1-.
If the rear lid drive unit -VX69- is renewed, start the respective
function ⇒ Vehicle diagnostic tester.
2.12.2 Removing and installing pinch protec‐

tion
Removing


gr. 70; Luggage compartment trims.
– Disconnect connectors -5- for line -4- of sensor strip -1-.
– Detach adhesive tape -2-.
– Detach sensor strip -1- from rear lid.
– Pull rubber grommet -6- with sensor strip -1- and wire -4- out
of rear lid.
Installing
Note
♦ Adhesive remover -D 002 000 10- must be used exclusively.

♦ Ensure that the adhesive surfaces are free of dust and
grease.
♦ Remove backing only immediately before installation. Work‐
ing temperature approx. 21 °C.
2. Rear lid 95
– Attach sensor strip -1- to rear lid.

– Route wire -4- in rear lid, and push in rubber grommet -3-
firmly -arrow a-.
– Connect connector -5-.
– Pull protective film off adhesive tape -3- and press on force‐
fully.
2.13 Removing and installing rear lid control unit -J605-

Removing
– Remove luggage compartment side trim on left ⇒ General
body repairs, interior; Rep. gr. 70; Luggage compartment
trims; Removing and installing luggage compartment side
trim.
– Separate electrical connectors -2-.
– Lift retaining hook -3- -arrows a- and push out control unit -1-
-arrow b-.
Installing
– Push control unit -1- into mounting until the retaining hook
-3- engages.
If the rear lid control unit -J605- is renewed, start the respective
function ⇒ Vehicle diagnostic tester.
2. Rear lid 97
3 Tank flap unit

⇒ o3.1 verview - tank flap unit”, page 98
⇒ a3.2 nd installing tank flap unit”, page 98
⇒ a3.3 nd installing fuel tank flap”, page 101
3.1 Assembly overview - tank flap unit
1 - Tank flap unit

ling ⇒ page 98
2 - Tank flap
– Removing and instal‐
ling ⇒ page 98
3 - Water drain hose

❑ Routed between wheel
housing and wheel
housing liner
4 - Bolt
❑ Qty. 2
❑ 1.5 Nm
5 - Tank filler flap locking mo‐
tor -V155-
ling ⇒ page 174
6 - Electrical connector
3.2 Removing and installing tank flap unit


♦ Radio release tool -T10057-
Removing
– Screw off tank cover.

– Using radio release tool -T10057-, punch through tank flap
unit at markings -2- -arrows a-.
– Insert radio release tool -T10057- through these openings
-2- until the notch is reached.
Retaining hooks -3- -arrow b- are released.
3. Tank flap unit 99

Note
Make sure that the tank flap unit -1- does not strike the side panel -arrow c-.
– Roll rubber sleeve off fuel filler neck -2-.

– Swing tank flap unit -1- out of side panel -4- -arrow a-.
– Pull out tank flap unit -1- towards rear -arrow b-.
– Guide water drain hose -3- together with tank flap unit out of
side panel.
Installing
Note
Make sure that the tank flap unit -1- does not strike the side
panel -arrow c-.

– Insert water drain hose -3- through opening in tank flap unit
-1- and then pull it through as far as it will go.
– Push water drain hose -3- into side panel -4-.
– Insert tank flap unit -1- into side panel -arrow d-.
– Swing tank flap unit -1- into side panel -arrow e- until retain‐
ing hooks engage.
– Fit sleeve -2- over filler neck.
• Check function of release components.
Specified torques
♦ Bolt ⇒ page 98
3.3 Removing and installing fuel tank flap

Removing

– Push tank flap -1- out of catches of tank flap unit -2-
-arrow a-.
– Remove tank flap -arrows b-.
Installing

– Position tank flap -1- on tank flap unit -2- -arrows a-.
– Push tank flap into catches of tank flap unit -arrow b-.

4 Charging flap unit

⇒ o4.1 verview - Charging flap unit”, page 104
⇒ a4.2 nd installing charging flap unit”, page 104
⇒ a4.2.1 nd installing immediate charge buttonE766”, page 106
4.1 Assembly overview - Charging flap unit
1 - Radiator grille
ling ⇒ page 392
2 - Seal
❑ Clipped into radiator
grille.
3 - Actuator for high-voltage
charging flap lock 1 -F496-
ling ⇒ page 175
4 - Bolts
❑ Qty. 3
❑ 2 Nm
5 - Immediate charging button
-E766-
ling ⇒ page 106
6 - Bolts
❑ Qty. 2
❑ 2 Nm
7 - Bolts
❑ Qty. 4
❑ 2 Nm
8 - Charging flap unit
ling ⇒ page 104
9 - Cover
10 - Tailgate
11 - Badge
12 - Badge
❑ Model designation
4.2 Removing and installing charging flap unit

Removing charging flap unit

– Remove radiator grille ⇒ page 392 .
– Separate electrical connector on actuator -5- and immediate
charge button -6-.
– Rotate charging flap unit -1- by approx. 90°, and detach it
inwards from radiator grille.
Installing tailgate unit
Guide charging flap unit -1- with charging socket flap from in‐
side through radiator grille.
– Rotate charging flap unit -1-, and bring it in installation posi‐
tion.
– Tighten bolts -2-, specified torque ⇒ page 390
Remove actuator for high-voltage charging flap lock 1 -F496-
– Separate electrical connector -5- on actuator.
– Unscrew bolts -4- and remove actuator -3-.
4. Charging flap unit 105

Install actuator for high-voltage charging flap lock 1 -F496-

– Bring actuator -3- into installation position.
4.2.1 Removing and installing immediate charge button -E766-
Removing immediate charge button -E766-

– Separate electrical connector -6- on immediate charge but‐
ton.
– Unscrew bolts -8- and remove button -7-.
Installing immediate charge button -E766-
– Bring button -7- into installation position.

57 – Front doors, door components, central locking

1 Door
⇒ o1.1 verview - door”, page 107
⇒ a1.2 nd installing inner door seal”, page 110
⇒ a1.3 nd installing outer door seal”, page 113
⇒ a1.4 nd installing door”, page 115
⇒ d1.5 oor”, page 118
⇒ s1.6 triker pin”, page 121
⇒ a1.7 nd installing door arrester”, page 123
1.1 Assembly overview - door
Note
♦ The illustrations show the left-hand side. The procedure for the right-hand side is basically the same.
♦ After renewal of A-pillar, the specified torque for bolts -2 and 5- as well as for -14 and 17- changes.
1. Door 107
1 - Rear door
ling ⇒ page 115
2 - Bolt
❑ Loosening once to ad‐
just the door is permit‐
ted. Always renew oth‐
erwise.
❑ 50 Nm
Note
♦ After renewal of A-pillar the

specified torque changes.
♦ Specified tightening torque after
renewal of A-pillar: 20 Nm + 90°
3 - Door hinge
❑ The hinge is split. Its upper and lower sections can be renewed individually, if necessary.
❑ Lower part is secured to hinge upper part with bolt -8-.
4 - Cover
❑ For bolt -8-
❑ Not installed in all markets
5 - Bolt
❑ Installed from inside vehicle.
❑ Loosening once to adjust the door is permitted. Always renew otherwise.
❑ For loosening and reattaching, the dash panel is not removed.
❑ To remove and install, the dash panel must be removed ⇒ General body repairs, interior; Rep. gr. 70;
Dash panel; Removing and installing dash panel.
❑ 50 Nm
108 Rep. gr.57 - Front doors, door components, central locking

Note

6 - Cover
❑ For bolts -7 and 16-
❑ Not installed in all markets
7 - Bolt
❑ 50 Nm
8 - Bolt
❑ Connects upper part of hinge -3- to bottom part of hinge -6-
❑ 23 Nm
9 - Door hinge
❑ Upper part is secured to hinge lower part with bolt -5-.
10 - Bolt
❑ 30 Nm
11 - Bolt
❑ Qty. 2
❑ 9 Nm
12 - Door arrester
13 - Door hinge
14 - Bolt
❑ For removal and installation, A-pillar lower trim must be removed ⇒ General body repairs, interior;
Rep. gr. 70; Trims, interior; Removing and installing A-pillar gap cover.
❑ 50 Nm
Note

15 - Door hinge
16 - Bolt
❑ 50 Nm
17 - Bolt
1. Door 109
❑ 50 Nm
Note

1.2 Removing and installing inner door

seal
During production, a sealant is applied to the inner door seals,
which are then placed on the door flange and rolled on.
Note
♦ When removing the seal, the sealant is distributed across

the inside of the seal. The sides are bent 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
renewed with a so-called “tap-on seal”.
♦ If a seal has been partially removed, squeeze sides of seal
together before installing.
♦ Removal and installation are described only for the left door
inner seal. The procedure for the right-hand side is basically
the same.
♦ For reasons of clarity, the front door is shown in removed
state.
Removing

– Remove sill panel trim ⇒ General body repairs, interior; Rep.

gr. 70; Trims, interior; Removing and installing sill panel trim.
– To remove inner door seal, remove pillar trims as required
⇒ General body repairs, interior; Rep. gr. 70; Trims, interior;
Overview of fitting locations – trims, interior.
– Pull off inner door seal -1- from body flange -3-.
Installing
1. Door 111
– Start installing door inner seal -1- at top radius of door aper‐
ture -arrow-.
– Align vulcanised point -2- above lower hinge.
– Install pillar trims ⇒ General body repairs, interior; Rep.
gr. 70; Trims, interior.
– Install sill panel strip ⇒ General body repairs, interior; Rep.
gr. 70; Trims, interior; Removing and installing sill panel
strip.

1.3 Removing and installing outer door

seal
⇒ a1.3.1 nd installing outer door seal”, page 113
⇒ a1.3.2 nd installing door seal”, page 114
1.3.1 Removing and installing outer door

seal
Note
♦ Removal and installation are described only for the right

door outer seal. Removal and installation of the left door
outer seal are similar.
ing temperature approx. 20°C.
Removing
– Pull door seal -1- off door.
1. Door 113
Installing
– Remove remaining adhesive residue with eraser disc for ad‐
hesive strip remover -VAS 6349-.
– Immediately before bonding outer door seal, clean bonding
surface thoroughly with adhesive remover D 002 000 10.
• Bonding surfaces must be free of dust and grease and there
should be no adhesive residues.
– Vulcanised point -2- of door seal must be in centre area of
side member.
– Pull off protective backing, and start fitting seal in upper rear
radius -arrow- of door. Do not pull door seal excessively to
avoid stretching seal.
– Press bonding surface of seal -1- firmly onto door -3- all
around using roller -3356-.
1.3.2 Removing and installing door seal
Note
♦ Removal and installation are described only for the right

door outer seal. Removal and installation of the left door

Removing
– Remove trim cover for door ⇒ page 415 .
– Pull door seal -1- off door -3-.
Installing
– Immediately before bonding outer door seal, clean bonding
surface thoroughly with adhesive remover D 002 000 10.
– Pull off protective backing -2-, and centre seal on door. Fit
seal, and press it on.
– Press bonding surface of seal -1- onto door -1- using roller
-3356-.
1.4 Removing and installing door

♦ Key (for door alignment) -3320-
♦ Universal joint for 3320 -3320/1-
1. Door 115
♦ Bit for 3320 -3320/2-

♦ Bit for 3320 -3320/3-
♦ Socket insert -3410-
♦ Removal wedge -3409-
Note
The removal and installation sequence is for the rear left door.
Removal and installation of the rear right door are similar.
Removing

– Disconnect battery earth cable with ignition switched on

⇒ Electrical system; Rep. gr. 27; Battery; Connecting and
disconnecting battery.
– Press wedge -T10383/1- between bellows -3- and locking
element -arrow a-.
– Push locking element upwards -2- with wedge -T10383/1-
-arrow b- and separate electrical connector -3- from coupling
station -arrow c-.
– Undo screws -7- from hinges.
– Unscrew bolt -4- for door arrester -5-.
– Push door arrester -5- inwards -arrow d-.
– Lift front door -1- upwards -arrow f- so that hinge -6- is
released from hinges -7-.
Installing
1. Door 117
Installation is carried out in the reverse order of removal. To this

end, the following should be observed:
• Door arrester -5- must have been pushed inwards -arrow d-.
• After installing front door, the hinge arms must be flush one
above the other.
– Adjust front door -1- ⇒ page 118 .
– Observe front door shut lines -1- ⇒ Body Repairs; Rep.
gr. 00; Body panel gaps/shut lines; Body - middle.
Specified torques
Door arrester and hinges ⇒ o1.1 verview - door”, page 107
1.5 Adjusting door

♦ Bit for 3320 -3320/2-
♦ Bit for 3320 -3320/3-


Note
♦ Only the adjustment for the left front door is described. The adjustment of the right front door is similar.
♦ Vehicle must be standing on its wheels when front door adjustment is performed.
♦ The front door is correctly adjusted when all shut lines are even when closed. it is not protruding too far
♦ For checking gaps/shut lines refer to ⇒ Body Repairs; Rep. gr. 00; Body panel gaps/shut lines; Body -
middle.
♦ After installing or alignment, carry out corrosion protection measures on hinges and screws/bolts.
1. Door 119
Adjusting shut lines

To be able to adjust shut lines correctly, bolts -2-, -3-, -5- and
-6- in A-pillar must be loosened.
– In order to gain access to bolt -3- on driver side, detach fuse
box, and lower it ⇒ Electrical system; Rep. gr. 97; Relay car‐
riers, fuse holders, E-boxes; Removing and installing relay
and fuse holder behind dash panel on driver side.
– For bolt -3-, glove compartment on front passenger side
must be removed ⇒ General body repairs, interior; Rep.
gr. 68; Compartments/covers; Removing and installing glove
compartment.
– For loosening bolt -6-, lower A-pillar trim must be removed
Removing and installing A-pillar gap cover.
Adjusting for flush fitting
In order to adjust flushness correctly, bolts -4- and -5- must be
loosened.
Use door alignment tool -3320- with appropriate bit for this.

Note
Other measures, such as raising the front door, will prove pointless. Subsequent pressure from above will
cause the door to sink again at the front.
Adjust striker pin ⇒ page 121 .
Note
After renewal of A-pillar the specified torque changes ⇒ o1.1 verview - door”, page 107 .
Specified torques
Hinges ⇒ o1.1 verview - door”, page 107
1.6 Adjusting striker pin

Note
♦ Threaded plate -1- of striker pin is secured in pillar using a method which differs from the previous
method.
♦ Bow outside of threaded plate is welded firmly to pillar. Webs to threaded plate are plastically deformable.
♦ Greater forced has to be applied so that position of striker pin -2- can be adjusted when bolts -3- are
loosened.
1. Door 121
Note
♦ The front door must lock fully when closing without any additional force being required and must not have
any play.
♦ The front door must not be pushed up or down as a result of the striker pin adjustment.
By adjusting the striker pin the alignment of the front door with
the side panel or the rear door can be adjusted -arrow a- and
-arrow b- (wind noise).
– Loosen striker pin -2- by loosening bolts -3- in B-pillar.
Note
Greater forced has to be applied so that position of striker pin -2- can be adjusted when bolts -3- are
loosened.
– Tighten bolts -3- of striker pin -2-.

Specified torques
Component Specified torques
Striker 20 Nm
1.7 Removing and installing door arrester

Note
The description of removal and installation only applies to the

left wing. The procedure for the right-hand side is basically the
same.
Removing
1. Door 123
– Remove front door trim ⇒ General body repairs, interior;

Rep. gr. 70; Front door trims; Removing and installing front
door trim.
– Remove self-adhesive cover or front loudspeaker ⇒ Commu‐
nication; Rep. gr. 91; Sound system; Overview of fitting loca‐
tions - sound system.
– Unscrew bolt -2- in A-pillar.
– Unscrew bolts -3- and remove door arrester -1- through the
opening of the loudspeaker -arrow a-.
Installing

Installation is carried out in the reverse order of removal.

Specified torques
Door arrester ⇒ o1.1 verview - door”, page 107
1. Door 125
2 Door components
⇒ o2.1 verview - door components”, page 126
⇒ o2.2 verview - window regulator”, page 128
⇒ o2.3 verview - door handle and door lock”, page 129
⇒ a2.4 nd installing window regulator motor”, page 130
⇒ a2.5 nd installing window regulator”, page 133
⇒ a2.6 nd installing inner door cover”, page 136
⇒ a2.8 nd installing cap on door handle”, page 140
⇒ a2.9 nd installing lock cylinder”, page 146
⇒ a2.10 nd installing door handle”, page 150
⇒ a2.11 nd installing mounting bracket”, page 154
⇒ a2.12 nd installing door lock”, page 156
⇒ a2.13 nd installing window channel”, page 161
⇒ a2.15 nd installing window slot outer seal”, page 165
2.1 Assembly overview - door components
Note
The illustrations show the left-hand side. The procedure for the right-hand side is basically the same.

1 - Rear door
ling ⇒ page 115
2 - Stickers
❑ Diameter 28 mm
❑ If necessary, manufac‐
ture using commercial‐
ly available textile ad‐
hesive tape.
❑ Stickers must cover the
openings completely
3 - Stickers
❑ Diameter 32 mm
hesive tape.
openings completely
4 - Dampers
❑ Self-adhesive
❑ Installing:
– Cut to size if required,
200 mm x 100 mm Po‐
sition as shown in illus‐
tration. Distance to next
insulation 10 mm.
– Warm using hot air

blower -V.A.G 1416-
and push on to outer
door panel with force.
5 - Inner door cover

6 - Door seal
7 - Stickers
❑ Diameter 40 mm
❑ If necessary, manufacture using commercially available textile adhesive tape.
❑ Stickers must cover the openings completely
8 - Dampers
❑ Self-adhesive
❑ Installing:
– Cut to size if required, 250 mm x 160 mm Position as shown in illustration.
– Warm using hot air blower -V.A.G 1416- and push on to outer door panel with force.
9 - Dampers
❑ Self-adhesive
❑ Installing:
– Cut to size if required, 250 mm x 160 mm Position as shown in illustration. Distance to next insulation
10 mm.
2. Door components 127

10 - Stickers
❑ Diameter 19 mm
11 - Window slot inner seal
12 - Window slot outer seal
13 - Window channel
14 - Stickers
❑ Qty. 3
❑ 15 mm x 50 mm
2.2 Assembly overview - window regulator

1 - Window regulator
ling ⇒ page 133
2 - Hexagon nut
❑ Qty. 4
❑ 6 Nm
3 - Bolt
❑ Qty. 3
❑ 3 Nm
4 - Window regulator motor -
V14/V15-
ling ⇒ page 130
2.3 Assembly overview - door handle and door lock
Note

1 - Door lock
ling ⇒ page 156
2 - Bolt
❑ 3 Nm
❑ For lock cylinder.
ling ⇒ page 154
4 - Lock cylinder
ling ⇒ page 146
❑ Only installed on driver
door.
5 - Carrier
6 - Cover
ling ⇒ page 140
7 - Door handle
ling ⇒ page 150
8 - Bolt
❑ 1.5 Nm
❑ Bearing plate is loos‐
ened from door when
this bolt is loosened
9 - Bowden cable
❑ From door lock -1- to
mounting bracket -3-
10 - Bowden cable
❑ From inner door handle to door lock -1-
❑ With grommet to passage on cover.
11 - Bolt
❑ Qty. 2
❑ 18 Nm
Note
The bolts are microencapsulated

and must be renewed each time
they are unscrewed.
12 - Cover
2.4 Removing and installing window regu‐

lator motor

Note
♦ Removal and installation are only described for the left win‐
dow regulator motor. Removal and installation of the right
window regulator motor are similar.
♦ The door control unit -J386/J387- -5- is separated from win‐
dow regulator motor -V14/V15- -1-.
♦ The door control unit -J386/J387- is clipped into door.
Removing


door trim.
– Tape up door window to prevent it from sliding down.
– Switch off ignition and all electrical consumers. Withdraw
ignition key.
– Disconnect connector -3-.
– Remove bolts -2- (qty. 3).
– Remove window regulator motor -1- from mounting brackets
of cable drum.
Installing

– Position window regulator motor -1- on mounting brackets of

cable drum. Move door window up and down slightly so that
the splines between window regulator motor and cable drum
engage more easily.
– A new door control unit -5- must be coded using ⇒ Vehicle
diagnostic tester.
– The work procedure and notes on the automatic window
raising and lowering system as well as on the excess-force
limitation feature can be found in ⇒ Maintenance; Booklet .
Specified torques
♦ Bolts ⇒ o2.2 verview - window regulator”, page 128

lator

Note
Removal and installation are described only for the left window
regulator. Removal and installation of the right window lifter
mechanism are similar.
Removing


door trim.
– Remove door window ⇒ page 379 .
– Remove window regulator motor ⇒ page 130 .
– If fitted, remove loudspeaker ⇒ Communication; Rep. gr. 91;
Sound system; Overview of fitting locations – sound system.
– Release locking hook of cable drum -4- and insert into door.
– Unscrew hexagon nuts -3- and insert studs of window regu‐
lator into door.
– Loosen hexagon nuts -2-, do not remove.
– Slightly push window regulator upwards in door -arrow a-,
and guide it into door.
– Turn window regulator -1- 90° -arrows b-, and remove it
through opening in door -arrow c-.
Installing
– Insert window regulator -1- through opening in door

-arrow a- and move to mounting position -arrow b-.

– Insert studs of window regulator into inner door panel, and

guide them downwards -arrow b-.
– Tighten hexagon nuts -2 and 3-.
– Press cable drum against door inner part until locking devi‐
ces -4- engage audibly.
– Install window regulator motor ⇒ page 130
– Install door window ⇒ page 379 .
Specified torques
♦ Hexagon nuts ⇒ o2.2 verview - window regulator”, page 128

cover
Note
Removal and installation are described only for the left cover.
The procedure for the right-hand side is basically the same.
Removing


door trim.
– Lift lower end of cover -1- -arrow a-.
– Pull cover -1- out of door -arrow b-.
Note
If required for subsequent work, pull cable -3- with grommet -2- out of cover -1-. Separate connector at
grommet (if there is one).
Installing

– Fit cable -3- together with grommet -2- into cover -1-.
– Attach grommet -2- to cover -1-.
– Insert cover -1- in door -arrow a-.
– Engage cover -1- around circumference -arrow b-.
Note
♦ Check proper seating of cover by pressing with fingers around circumference.

♦ If fitted, join electrical connector at grommet.


Note
Removal and installation are described only for the right door
striker pin. The procedure for the right-hand side is basically the
same.
Removing
– Unscrew bolts -2- and remove striker pin -1-.
Installing
Note
A bent striker pin (square U-shape) must be installed.
– Position striker pin -1- on B-pillar -3- with the U-shape facing
inwards. Tighten bolts -2-.

– Adjusting striker pin ⇒ page 121

Specified torques
Striker 20 Nm
2.8 Removing and installing cap on door

handle
⇒ a2.8.1 nd installing cover cap, for lock cylinder”, page 140
⇒ a2.8.2 nd installing cover cap, without lock cylinder”, page
142
2.8.1 Removing and installing cover cap, for

lock cylinder
Note
♦ When removing lock cylinder cover cap, the screwdriver

should not be turned and the screwdriver should not be used
as a lever.
♦ The lock cylinder and cover cap for lock cylinder are only
installed on the driver side.
Removing

– Pull door handle away from door.

– Push a small screwdriver -3- slightly -arrow a- into opening
on underside of lock cylinder cover cap.
– Pull lock cylinder housing cover cap -1-, together with small
screwdriver, off door lightly from underside -arrow b-.
– Push cap upwards off lock cylinder.
Installing

– Pull door handle -1- away from door.

– Push lock cylinder cover cap -2- at a slight angle from above
-arrow a- onto lock cylinder.
– Push lock cylinder cover cap -2- onto door -arrow b- until
cover cap engages in lock cylinder.
2.8.2 Removing and installing cover cap,

without lock cylinder
Note
The cover cap is installed when no lock cylinder is fitted.
Removing
♦ Assembly tool -T10539-

– Remove plugs -3-.

– Insert disassembly and assembly tool -T10539- with marking
facing upwards up to locking hook of door handle bracket.
– Pull door handle -2- off door -arrow a-.
– Push disassembly and assembly tool -T10539- approx.
5 mm towards front -arrow b- until hook is released.

There must be a gap -arrow a- between door handle -2- and

door.
Note
Do not push the door handle into the door. Otherwise the door handle bracket will be damaged.
– Pull cover cap -1- out of mounting bracket -arrow b-.

Installing

• There is a gap between door handle -2- and door -arrow a-.
– Push cover cap -1- into mounting bracket -arrow b-.

– Slightly press cover cap -1- onto door.

– Turn disassembly and assembly tool -T10539- in locking
hook by 90° -arrow a-, and pull it out by approx. 5 mm
-arrow b- until hook engages.
Door handle -2- folds down onto door automatically -arrow c-.
hook by 90° -arrow a-, and pull it out of door.
– Secure plug -3-.
2.9 Removing and installing lock cylinder


Note
♦ The removal and installation sequence is only for the left

lock cylinder. The procedure for the right-hand side is basi‐
cally the same.
♦ Door handle stops in “open” state. Try not to push door
handle in, as otherwise mounting bracket will break off and a
removed door handle can no longer be installed.
Removing

– Remove cap for lock cylinder ⇒ page 140 .

– Lift off covers -5-.
– Pull out door handle -2- as far as it will go.
– Unscrew bolt -4- onto stop.
– Press in bolt -4- with locking element -6- -arrow a-. Only then
is the lock cylinder released.
– Pull door handle -2- away from door.
– Pull out lock cylinder housing -1- perpendicular to door
-arrow b- from mounting bracket -3-.
Installing

• Door handle -2- stands off from door.

– Push lock cylinder housing -1- into mounting bracket -3- at a
right-angle -arrow a-.
– Screw bolts -4- into door handle bracket. While doing this,
the locking mechanism -6- is pulled automatically in installa‐
tion position -arrow b-.
Door handle -2- folds down onto door automatically.
Note
During installation, lock cylinder housing must be pressed against outer door panel.

• It is essential that a functional check is then performed with
the door open.
Specified torques
♦ Bolts ⇒ o2.3 verview - door handle and door lock”, page 129

2.10 Removing and installing door handle

⇒ a2.10.1 nd installing door handle”, page 150
⇒ a2.10.2 nd installing door handle with keyless entry system”,
page 152
2.10.1 Removing and installing door handle

Removing
Note
handle. The left side is similar.
For general information and work instructions for the door han‐
dle with keyless entry system refer to ⇒ Electrical system; Rep.
gr. 94; Entry and start authorisation system.
– Depending on version, remove lock cylinder cap ⇒ page 140
and lock cylinder ⇒ page 146 .
– Or just remove cap (without lock cylinder) ⇒ page 140 .

– Pull door handle -1- towards rear slightly -arrow a- until it

comes out of support for mounting bracket -2-.
– Swivel door handle in direction of -arrow b-.
– Remove door handle from mounting bracket -2-, keeping
door handle at right angles to mounting bracket -arrow c-.
On vehicles equipped with a keyless entry system, the connec‐
tor is disconnected when the door handle is being removed.
Installing
– Insert door handle -1- at right angle -arrow a- in mounting
bracket.
tor is connected when the door handle is being inserted.
– Swing door handle -1- towards door -arrow b-.
– Press door handle forwards -arrow c- into support for door
handle bracket -2-.

– It is essential that a functional check is then performed with

the door open.

with keyless entry system
Removing
Note
handle. The left side is similar.


– Open locking mechanism on connector -4- using a screw‐
driver -3- -arrow d-.
Installing
bracket.
tor is connected when the door handle is being inserted.
– Swing door handle -1- towards door -arrow b-.
handle bracket -2-.
the door open.

2.11 Removing and installing mounting

bracket
Removing
Note
Removal and installation are described only for the left mount‐
ing bracket. The procedure for the right-hand side is basically
the same.


door trim.
– Remove door handle ⇒ page 150 .
– Remove inner door cover ⇒ page 136 .
– Unscrew bolt -4-.
– Remove mounting bracket -1- from door.
Detach cable
– Slightly swing aside retainer -3- -arrow a-.
– Lift pin of cable -2- out of mounting.
Installing

Attaching cable
Note
Make sure the connector -5- for the keyless entry system is firmly seated.
– Push pin of cable -2- into mounting -arrow b-.
– Guide door handle bracket -1- into door -arrow c-.
– Tighten bolt -4-.
Specified torques
2.12 Removing and installing door lock


♦ Socket insert -T10054-
Note
lock. The procedure for the right-hand side is basically the
same.
♦ The door window must be closed for subsequent work.
♦ The bolts are microencapsulated and must be renewed each
time they are unscrewed.
Removing


door trim.
– If fitted, disconnect connector.
– Remove door lock -1- from door -arrow-.
Note
Cables can be detached if this is necessary for subsequent work.
Detach cable from mounting bracket

– Remove cover ⇒ page 159 .
– Turn cable -5- through 90° -arrow a- and take out of holder.
– Swivel cable -arrow b- upwards until cable can be threaded
out of eye in door lock -1- -arrow c-.

Detach cable from interior door handle

– Turn cable -4- by 90° and take it out of holding device.
– Swivel cable -arrow d- so far until cable can be threaded out
of eye in door lock -1- -arrow e-.
Removing cover
– Disengage hook -3- in -direction of arrow a-.

– Use the hook to pull cover -1- out of door lock -2- -arrow b-.
– Pull cover -1- upwards -arrow c- from door lock -2-.
Installing
Note
The bolts are microencapsulated and must be renewed each time they are unscrewed.

– Attach removed cables -4- and -5- to door lock -1-.

– Fit cover ⇒ page 160
– Insert door lock -1- into door.
– If fitted, connect connector.
– Clip cap -3- in.
the door open.
Only if the cables are adjusted and locked correctly, the door
lock can be unlocked and opened properly.
Specified torques
Fitting cover

– Push cover -1- onto retainer -3- on door lock -2- -arrow a-.
– Engage hook -4- with door lock -2- -arrow b-.
2.13 Removing and installing window chan‐

nel
Note

window channel. Removal and installation of the right win‐
dow channel are similar.
♦ Do not bend window channel when removing!
Removing

– Remove window slot inner seal ⇒ page 165 .

– Remove window slot outer seal ⇒ page 165 .
– Remove B-pillar trim ⇒ page 434 .
– Remove fixed front door-window ⇒ page 384 .
– Peel sealing lip of window channel -1- off the door flange
from the inside.
– Pull window channel -1- out of mountings on door
-arrows a and b-.
– Pull window channel -1- -arrows c- off flange -2- uniformly all
around it.
Installing

– Spray window channel with soapy water to facilitate installa‐

tion.
– Insert window channel -1- into mountings on door
-arrows c and b-.
– Fit window channel -1- from rear towards front onto door
flange -arrows a-.
– Fold sealing lip of window channel onto door flange -2- from
the inside -arrows-.
Note
To prevent wind noise, ensure window channel -1- seats evenly when installing.


2.14 Removing and installing window slot

inner seal
Note
Removal and installation are only described for the left window
slot inner seal. Removal and installation of the right window slot
Removing
door trim.
– Lift window slot inner seal -1- uniformly off flange -2- without
bending or distorting it -arrows a-.
Installing
– Centre window slot inner seal -1- and press it evenly onto
front door flange -2- by hand.


outer seal
Removing
Note
♦ The core of the window slot outer seal is a metal insert.

♦ If it is bent or distorted, the window slot outer seal can no
longer be straightened out. It will remain “wavy”.
♦ Therefore, the window slot outer seal must be pulled off and
pressed on evenly, without bending or distorting it.
dow slot outer seal. Removal and installation of the right
window slot outer seal are similar.
– Slightly detach window slot outer seal -1- evenly from door
flange -2- using wedge -T10039/1- -arrows a-. Make sure
not to bend the side strip.

– Pull out window slot outer seal -1- behind exterior mirror -3-
-arrow b-.
Installing
Note
♦ The use of assembly aid is allowed.

♦ The use of striking tools is not allowed for installing the window slot outer seal.
– Push window slot outer seal -1- behind exterior mirror -3-
-arrow a-.
– Align window slot outer seal -1- with B-pillar and press it
uniformly and by hand onto door flange-2- -arrows b-.

3 Central locking
⇒ o3.1 f fitting locations - central locking”, page 167
⇒ o3.2 verview - ignition key”, page 169
⇒ a3.3 nd installing bonnet contact switchF266”, page 170
⇒ a3.4 nd installing driver door control unitJ386 and front pas‐
senger door control unitJ387”, page 172
⇒ a3.5 nd installing rear left door control unitJ388 and rear right
door control unitJ389”, page 173
⇒ a3.6 nd installing tank filler flap locking motorV155”, page 174
⇒ a3.8 nd installing ignition key battery”, page 176
⇒ a3.9 nd installing cap on ignition key”, page 178
3.1 Overview of fitting locations - central locking
3. Central locking 167

1 - Alarm horn -H12-

❑ Removing ⇒ Electrical
system; Rep. gr. 96;
Anti-theft alarm system;
Removing and instal‐
ling alarm horn H12.
2 - Front passenger door con‐
trol unit -J387-
❑ Installed in door sepa‐
rated from window reg‐
ulator motor.
ling ⇒ page 172
3 - Aerial for interface for en‐
try and start system
❑ Integrated in door han‐
dle
ling door handle ⇒
page 152
4 - Front right door lock
❑ Door lock is secured to
inner part of door.
❑ Electric central locking
is integrated into door
lock.
❑ Removing ⇒ page 156
5 - Rear right door control unit
-J389-
❑ Installed in door sepa‐
rated from window reg‐
ulator motor.
ling ⇒ page 172
6 - Rear right door lock
❑ Door lock is secured to inner part of door.
❑ Electric central locking is integrated into door lock.
7 - Aerial for interface for entry and start system
❑ Integrated in door handle
❑ Door handle removed and installed ⇒ page 217
8 - Tank filler flap locking motor -V155-
9 - Rear lid lock
❑ Location: bolted to rear lid
10 - Release element
❑ Location: Bolted to rear lid.
❑ Installed behind bumper cover

❑ Door handle removed and installed ⇒ page 217
13 - Rear left door lock
14 - Rear left door control unit -J388-
❑ Installed in door separated from window regulator motor.
15 - Front left door lock
❑ Removing and installing door handle ⇒ page 152
17 - Central locking button
❑ Fitting location: in door trim
❑ Remove and install button for central closing ⇒ Electrical system; Rep. gr. 96; Controls; Overview of
fitting locations - controls in front doors.
18 - Driver door control unit -J386-
❑ Installed in door separated from window regulator motor.
19 - Onboard supply control unit -J519-
❑ Location: Under dash panel on driver side.
❑ Removing ⇒ Electrical system; Rep. gr. 97; Control units; Overview of fitting locations - control units.
20 - Bonnet contact switch -F266-
❑ Contact switch for anti-theft alarm system
❑ Location: on lid lock.
3.2 Assembly overview - ignition key

1 - Transmitter unit
❑ Adaptation ⇒ page 178
2 - Release mechanism
3 - Emergency key
4 - Cover
ling ⇒ page 178
5 - Bolt
❑ 1 Nm
6 - Battery
ling ⇒ page 176
7 - Cover for battery compart‐
ment
3.3 Removing and installing bonnet con‐

tact switch -F266-
Removing

– Remove lid lock -1- and separate electrical connector -3- ⇒

page 32 .
– Release locking hooks -arrow a-.
– Push contact switch -1- in elongated holes -arrow b-.
– Remove contact switch -1- from lid lock -2-.
Installing

– Insert contact switch -1- in elongated holes -arrow a-.

– Push contact switch -1- in elongated holes onto stop
-arrow b-.
– Install contact switch and attach electrical connector ⇒ page
32 .
3.4 Removing and installing driver door

control unit -J386- and front passenger
door control unit -J387-
Note
♦ If a new door control unit is installed, the additional functions

and the excess force limitation feature have to be coded!
♦ This description also applies to rear left/right door control
unit -J388/J389-.

Removing
– Release retaining hook from outside -arrow A-.
– Push control unit -1- downwards -arrow C-, and remove it
from door -arrow B-.
Installing
– Check seals -2- for damage, and renew them as necessary.
– Place control unit -1- in mounting holes and push upwards.
– Push retaining hook -4- into hole until it engages.
– Attach connectors -3-.
– A new control unit -1- must be coded using ⇒ Vehicle diag‐
nostic tester.
3.5 Removing and installing rear left door control unit -J388- and rear right
door control unit -J389-

Removing
– Release retaining hook from outside -arrow A-.
– Push control unit -1- downwards -arrow C-, and remove it
from door -arrow B-.
Installing
– Check seals -2- for damage, and renew them as necessary.
– Place control unit -1- in mounting holes and push upwards.
– Push retaining hook -4- into hole until it engages.
– Attach connectors -3-.
– A new control unit -1- must be coded using ⇒ Vehicle diag‐
nostic tester.
3.6 Removing and installing tank filler flap locking motor -V155-

Removing
– Remove fuel tank flap unit ⇒ page 98 .
– Separate connector -2-.
– Remove actuator -1- from tank flap unit.
Installing
– Join electrical connector -2-.
– Position actuator -1- on tank flap unit.
– Install tank flap unit ⇒ page 98 .
3.7 Removing and installing actuator for high-voltage charging flap lock 1
-F496-

Removing
– Separate electrical connector -5- on actuator.
– Unscrew bolts -4- and remove actuator -3-.
Installing
– Bring actuator -3- into installation position.
3.8 Removing and installing ignition key

battery
Removing
– Remove emergency key.
– Insert a small screwdriver -2- into the emergency key slot
-arrow a-.

– Turn screwdriver -2- -arrow b- to open catch -3-.

– Use a small screwdriver -3- to lift battery -1- -arrow a-.
– Pull battery -1- out of battery compartment -2- -arrow b-.

Installing
Note
♦ Before installing battery, always press any key once.

♦ This resets the transmitter unit so that it can detect a new
battery.
Ensure correct polarity and mounting position when installing

battery. The positive pole is marked.
– Insert battery -2- into battery compartment by pressing
slightly -arrow a-.
– Assemble cover of battery compartment -1- and transmitter

unit -3- -arrow b-.

Adapting ignition key

A new ignition key must be coded using ⇒ Vehicle diagnostic
tester.
3.9 Removing and installing cap on ignition

key
Removing
– Lift off cover for battery compartment ⇒ page 176 .

– Pull cap -1- off transmitter unit -2- -arrow-.
Installing
Note
Use the screw -2- to cut the thread in on a new cap.
– Push cap -1- onto transmitter unit -3- -arrow-.
– Install screw -2-.

– Press cover onto battery compartment
Specified torques
♦ Cap ⇒ o3.2 verview - ignition key”, page 169

58 – Rear doors, door components

1 Door
⇒ o1.1 verview - door”, page 179
⇒ a1.2 nd installing door”, page 182
⇒ d1.3 oor”, page 184
⇒ s1.4 triker pin”, page 187
⇒ a1.5 nd installing door arrester”, page 189
⇒ a1.6 nd installing inner door seal”, page 191
⇒ a1.7 nd installing outer door seal”, page 194
1.1 Assembly overview - door
Note
♦ After renewal of B-pillar, the specified torque for bolts -2 and 5- as well as for -14 and 17- changes.
1. Door 179
1 - Rear door
ling ⇒ page 182
2 - Bolt
❑ Loosening once to ad‐
just the door is permit‐
ted. Always renew oth‐
erwise.
❑ Installed from inside ve‐
hicle.
❑ To remove and install,
B-pillar lower trim must
be removed first.
❑ 50 Nm
Note

3 - Door hinge
❑ The hinge is split.
4 - Cover
❑ For bolt -8-.
5 - Bolt
❑ To remove and install, B-pillar lower trim must be removed first.
❑ 50 Nm
Note
180 Rep. gr.58 - Rear doors, door components


6 - Cover
❑ For bolt -7-.
7 - Bolt
❑ Always renew, loosening it once to adjust door is allowed.
❑ 50 Nm
8 - Bolt
❑ Connects upper part of hinge to bottom part of hinge.
❑ 23 Nm
9 - Door hinge
10 - Bolt
❑ 30 Nm
11 - Bolt
❑ Qty. 2
❑ 9 Nm
12 - Door arrester
13 - Door hinge
14 - Bolt
❑ 50 Nm
Note

15 - Door hinge
16 - Bolt
❑ Always renew, loosening it once to adjust door is allowed.
❑ 50 Nm
17 - Bolt
❑ 50 Nm
1. Door 181
Note

1.2 Removing and installing door

♦ Bit for 3320 -3320/2-
♦ Bit for 3320 -3320/3-
Note
The removal and installation sequence is described for the rear

left door only. Removal and installation of the rear right door are
similar.
Removing

– Press wedge -T10383/1- between bellows -3- and locking

element -2- -arrow a-.
– Push locking element upwards -2- with wedge -T10383/1-
-arrow b- and separate electrical connector -3- from coupling
station -arrow c-.
– If fitted, remove covers of bolts -7-.
– Loosen bolts -7- at hinges -arrow e-, but do not remove
them.
– Unscrew bolt -4- for door arrester -5-.
– Push door retaining strip -5- inwards -arrow d-.
– Lift front door -1- with upper parts of hinges -6- upwards
-arrow f- out of lower parts of hinges.
Installing
1. Door 183
Installation is carried out in the reverse order of removal. To this

end, the following should be observed:
• The door retaining strap -5- must have been pushed inwards
-arrow d-.
• After installing rear door, the hinge arms must be flush one
above the other.
– Adjust rear door -1- ⇒ page 184 .
– Observe front door shut lines -1- ⇒ Body Repairs; Rep.
gr. 00; Body panel gaps/shut lines; Body - middle.
Specified torques
♦ ⇒ o1.1 verview - door”, page 179
1.3 Adjusting door

♦ Bit for 3320 -3320/2-
♦ Bit for 3320 -3320/3-


Note
♦ Vehicle must be standing on its wheels when front door adjustment is performed.
♦ The rear door is correctly adjusted when all shut lines are even when closed. it is not protruding too far
♦ For checking gaps/shut lines refer to ⇒ Body Repairs; Rep. gr. 00; Body panel gaps/shut lines; Body -
middle.
♦ After installing or alignment, carry out corrosion protection measures on hinges and screws/bolts.
1. Door 185
Adjusting shut lines

To be able to adjust gaps correctly, bolts -2-, -3-, -6- and -7- on
B-pillar must be loosened.
– The B-pillar lower trim must be removed for bolts -3 and 7-.
Adjusting for flush fitting
In order to adjust flushness correctly, bolts -5- and -9- must be
loosened.
Use door alignment tool -3320- with appropriate bit for this.
Note
Other measures, such as raising the rear door, will prove pointless. Subsequent pressure from above will
cause the door to sink again at the back.
– Adjust striker pin ⇒ page 187 .

Specified torques

1.4 Adjusting striker pin

Note
♦ Threaded plate -1- of striker pin is secured in pillar using a method which differs from the previous
method.
♦ Bow outside of threaded plate is welded firmly to pillar. Webs to threaded plate are plastically deformable.
♦ Greater forced has to be applied so that position of striker pin -2- can be adjusted when bolts -3- are
loosened.
1. Door 187
Note
♦ The rear door must lock fully when closing without any additional force being required and must not have
any play.
♦ The rear door must not be pushed up or down as a result of the striker pin adjustment.
Striker pin can be used to align rear door flush with side panel
(to prevent wind noise) -arrows-.
– Loosen striker -2- by loosening bolts -3- in C-pillar.
Note
Greater forced has to be applied so that position of striker pin -2- can be adjusted when bolts -3- are
loosened.
– Tighten bolts -3- of striker pin -2-.


Striker 20 Nm
1.5 Removing and installing door arrester

Note
Removal and installation are described only for the left door
arrester. The procedure for the right-hand side is basically the
same.
Removing
1. Door 189
– Remove rear door trim ⇒ General body repairs, interior; Rep.

gr. 70; Rear door trims; Removing and installing rear door
trim.
– Pull off self-adhesive cover.
♦ For models without loudspeaker pull off self-adhesive cover
and remove door retaining strap through opening for loud‐
speaker -arrow c-.
♦ For models with loudspeaker detach inner door cover ⇒
page 206 and remove through this opening.
– Unscrew bolt -2- in B-pillar.
– Remove screws -3- and remove door retaining strap -1-.
Installing


Specified torques

seal
During production, a sealant is applied to the door seals, which
are then placed on the door flange and rolled on.
1. Door 191
Note
♦ When removing the door seal, the sealant is distributed

across the inside of the door seal. The sides are bent up‐
wards slightly when this is being done. If the door seal is
then refitted, sealing and firm seating are no longer guaran‐
teed.
♦ Therefore, each door seal which has been removed com‐
pletely must be replaced by a “tap-on seal”.
♦ If a door seal has been partially removed, squeeze sides of
door seal together before installing.
seal. The procedure for the right-hand side is basically the
same.
♦ For reasons of clarity, the rear door is shown removed.
Removing
– Remove sill panel trim ⇒ General body repairs, interior; Rep.

gr. 70; Trims, interior; Removing and installing sill panel trim.

– To remove inner door seal, remove pillar trims as required

Overview of fitting locations – trims, interior.
– Pull door seal -1- off body flange -2-.
Installing
Note
Do not kink vulcanised point -3-.
– Start installing door seal -1- at top radius of door aperture

-arrows-.
– Align vulcanised point -3- between hinges.
– Press door seal -1- onto body flange -2-.
– Install pillar trims ⇒ General body repairs, interior; Rep.
gr. 70; Trims, interior.
– Install sill panel strip ⇒ General body repairs, interior; Rep.
gr. 70; Trims, interior; Removing and installing sill panel
strip.
1. Door 193
1.7 Removing and installing outer door

seal
⇒ a1.7.1 nd installing outer door seal”, page 194
⇒ a1.7.2 nd installing door seal”, page 195
1.7.1 Removing and installing outer door

seal
Note
seal. Removal and installation of the right door seal are anal‐
ogous.
Removing

Installing
– Immediately before bonding door seal, clean bonding sur‐
face thoroughly with adhesive remover D 002 000 10.
side member.
– Pull off protective backing, and start fitting door seal -1- in
upper rear radius -arrows- of door. Do not pull door seal
excessively to avoid stretching seal.
– Press bonding surface of door seal firmly onto door -1- all
1.7.2 Removing and installing door seal
Note
♦ The removal and installation sequence is described only for

the right door seal. The removal and installation of the left
door seal are similar.
1. Door 195
Removing
– Remove trim cover for door ⇒ page 415 .
Installing
– Immediately before bonding door seal, clean bonding sur‐
face thoroughly with adhesive remover D 002 000 10.
side member.
– Pull off protective backing, and start fitting door seal in upper
rear radius -arrow- of door. Do not pull door seal excessively
to avoid stretching seal.
– Press bonding surface of door seal -3- firmly onto door -3- all

2 Door components
⇒ o2.1 verview - door components”, page 197
⇒ o2.3 verview - door handle and door lock”, page 199
⇒ a2.4 nd installing window regulator motor”, page 200
⇒ a2.5 nd installing window regulator”, page 203
⇒ a2.6 nd installing inner door cover”, page 206
⇒ a2.8 nd installing cap on door handle”, page 210
⇒ a2.9 nd installing door handle”, page 215
⇒ a2.10 nd installing mounting bracket”, page 219
⇒ a2.11 nd installing door lock”, page 222
⇒ a2.12 nd installing window channel”, page 226
⇒ a2.13 nd installing window slot outer seal”, page 229
⇒ a2.14 nd installing window slot inner seal”, page 231
2.1 Assembly overview - door components
Note

1 - Rear door
ling
❑ Adjusting
2 - Window slot inner seal
ling ⇒ page 231
3 - Stickers
❑ Qty. 1
❑ Diameter 28 mm
hesive tape.
4 - Dampers
❑ Self-adhesive
❑ Installing:
– Cut to size if required,
250 mm x 160 mm Po‐
sition as shown in illus‐
tration.
– Warm using hot air

blower -V.A.G 1416-
and push on to outer
door panel with force.
5 - Stickers
❑ Qty. 1
❑ Diameter 32 mm
hesive tape.
6 - Inner door cover
7 - Door seal
8 - Stickers
❑ Qty. 1
❑ Diameter 42 mm
9 - Dampers
❑ Self-adhesive
❑ Installing:
– Cut to size if required, 250 mm x 160 mm Position as shown in illustration.
10 - Stickers
❑ Qty. 2
❑ Diameter 28 mm
11 - Window slot outer seal

12 - Window channel
13 - Stickers
❑ Qty. 2
❑ 15 mm x 50 mm
2.2 Assembly overview - window regulator
ling ⇒ page 203
2 - Hexagon nut
❑ Qty. 1 top
❑ 6 Nm
3 - Hexagon nut
❑ Qty. 1 bottom
❑ 6 Nm
4 - Retaining hooks for cable
drum
❑ Qty. 3
❑ Mounting for window
regulator motor
❑ Specified torque of win‐
dow regulator motor
bolts: 3 Nm
2.3 Assembly overview - door handle and door lock
Note

1 - Door lock
ling ⇒ page 222
2 - Bolt
❑ 1.5 Nm
❑ For locking bar in
mounting bracket.
ling ⇒ page 219
4 - Carrier
5 - Cover
ling ⇒ page 210
6 - Door handle
ling ⇒ page 215
7 - Bolt
❑ 1.5 Nm
❑ Bearing plate is loos‐
ened from door when
this bolt is loosened
8 - Bowden cable
❑ From door lock -1- to
mounting bracket -3-
9 - Bowden cable
❑ From inner door handle
to door lock -1-
❑ With grommet to pas‐
sage on cover.
10 - Cover
11 - Bolt
❑ Qty. 2
❑ 18 Nm
Note
The bolts are microencapsulated

and must be renewed each time
they are unscrewed.

lator motor

Note
♦ Removal and installation are described only for the left win‐
dow regulator motor. Removal and installation of the right
window regulator motor are similar.
♦ The door control unit -6- is clipped into door separated from
window regulator motor.
Removing


trim.
– Tape up door window to prevent it from sliding down.
– Switch off ignition and all electrical consumers. Withdraw
ignition key.
– Remove bolts -4- (qty. 3).
– Remove window regulator motor -1- from mounting brackets
of cable drum -3-.
Installing

– Fit window regulator motor -1- onto mounting brackets of

cable drum -3-. Move door window up and down slightly so
that the splines between window regulator motor and cable
drum engage more easily.
– A new window regulator motor must be coded using ⇒ Vehi‐
cle diagnostic tester.
– The work procedure and notes on the automatic window
raising and lowering system as well as on the excess-force
limitation feature can be found in ⇒ Maintenance; Booklet .
Specified torques
♦ Mounting bracket ⇒ o2.2 verview - window regulator”, page
199

lator

Note
Removal and installation are described only for the left window
regulator. Removal and installation of the right window lifter
mechanism are similar.
Removing


trim.
– Detach door window from window regulator. Do not remove
it ⇒ page 382 .
– Move door window upwards, and secure it in place.
– Remove window regulator motor ⇒ page 200 .
– Release locking hook of cable drum -4- and insert into door.
– Unscrew lower hexagon nut -3- and insert threaded studs of
window regulator into door.
– Loosen upper hexagon nuts -2-, do not remove.
– Slightly push window regulator upwards in door -arrow a-,
and guide it into door.
– Turn window regulator -1- 90° -arrow b-, and remove it
through opening in door -arrow c-.
Installing
– Insert window regulator -1- through opening in door

-arrow a-, and swing it to installation position -arrow b-.

– Insert studs of window regulator into inner door panel, and

guide them downwards -arrow c-.
– Tighten hexagon nuts -2 and 3-.
– Press cable drum against door inner part until locking devi‐
ces -4- engage audibly.
– Install window regulator motor ⇒ page 200

– Installing door window
Specified torques
♦ Window regulator ⇒ o2.2 verview - window regulator”, page
199

cover
Note
Removal and installation are described only for the left cover.
The procedure for the right-hand side is basically the same.
Removing


trim.
– Lift cover -1- at front -arrow a-.
– Pull cover -1- downwards out of door -arrow b-.
Note
If required for subsequent work, pull cable -3- with grommet -2- out of cover -1-. Separate connector at
grommet (if there is one).
Installing

– Fit cable -3- together with grommet -2- into cover -1-.
– Attach grommet -2- to cover -1-.
– Insert cover -1- in door -arrow a-.
– Engage cover -1- around circumference -arrow b-.
Note
♦ Check proper seating of cover by pressing with fingers around circumference.

♦ If fitted, join electrical connector at grommet.


Note
striker pin. The procedure for the right-hand side is basically the
same.

Removing
– Unscrew bolts -2- and remove striker pin -1-.
Installing
– Fit striker pin -1- to C-pillar and tighten bolts -2-.
– Adjusting striker pin ⇒ page 187
Component Specified tor‐
ques
Striker 20 Nm
2.8 Removing and installing cap on door

handle
♦ Assembly tool -T10539-
Removing

– Remove plugs -3-.

– Pull door handle -2- off door -arrow b-.
– Push disassembly and assembly tool -T10539- approx.
5 mm towards front -arrow b- until hook is released.

– There must be a gap -arrow a- between door handle -2- and

door.
Note
Do not push the door handle into the door. Otherwise the door handle bracket will be damaged.
– Pull cover cap -1- out of mounting bracket -arrow b-.

Installing

– There is a gap between door handle -2- and door -arrow a-.
– Push cover cap -1- into mounting bracket -arrow b-.

– Slightly press cover cap -1- onto door.

hook by 90° -arrow a-, and pull it out by approx. 5 mm
-arrow b- until hook engages.
Door handle -2- folds down onto door automatically -arrow c-.
hook by 90° -arrow c-, and pull it out of door.
– Secure plug -3-.

2.9 Removing and installing door handle

⇒ a2.9.1 nd installing door handle”, page 215
⇒ a2.9.2 nd installing door handle with keyless entry system”,
page 217
Note
handle. The procedure for the right-hand side is basically the
same.
Removing
– Remove cap ⇒ page 210 .

– Pull out door handle -1- backwards slightly -arrow a- from
support for mounting bracket.

– Pull door handle -1- out of door handle bracket -2- -arrow c-.
Installing

bracket.
– Swing door handle -1- into door -arrow b-.
handle bracket -2-.
Installing cover cap ⇒ page 210
the door open.


with keyless entry system
Note
The removal and installation sequence is only for the left door
handle. The procedure for the right-hand side is basically the
same.
Removing
– Remove cap ⇒ page 210 .
– Open locking mechanism on connector -4- using a screw‐
driver -3- -arrow d-.


Installing
bracket.
The connector for the keyless entry system is connected when
the door handle is being inserted.
– Swing door handle -1- into door -arrow b-.
handle bracket -2-.
Installing cover cap ⇒ page 210
the door open.

2.10 Removing and installing mounting

bracket
Note
Removal and installation are described only for the right mount‐
ing bracket. The procedure for the right-hand side is basically
the same.
Removing


trim.
– Push door handle bracket -1- slightly towards rear, and re‐
move it from door.
Detach cable
– Lift pin of cable -2- out of mounting.
Installing

Note
Make sure the connector -5- for the keyless entry system is firmly seated.
Attaching cable
– Push pin of cable -2- into mounting -arrow b-.
– Guide door handle bracket -1- into door -arrow c-.
– Tighten bolt -4-.
Specified torques
♦ Mounting bracket ⇒ o2.3 verview - door handle and door
lock”, page 199

2.11 Removing and installing door lock

♦ Socket insert -T10054-
Note
lock. The procedure for the right-hand side is basically the
same.
♦ The door window must be closed for subsequent work.
♦ The bolts are microencapsulated and must be renewed each
time they are unscrewed.
Removing


trim.
– If fitted, disconnect connector.
– Remove door lock -1- from door -arrow-.
Note
Cables can be detached if this is necessary for subsequent work.
Detach cable from mounting bracket

– Remove cover ⇒ page 224 .
– Turn cable -5- 90° and take out of holder -arrow a-.
– 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 -4- by 90° and take it out of holding device.
– Swivel cable -arrow d- so far until cable can be threaded out
of eye in door lock -1- -arrow e-.
Removing cover
– Disengage hook -3- in -direction of arrow a-.

– Use the hook to pull cover -1- out of door lock -2- -arrow b-.
– Pull cover -1- upwards -arrow c- from door lock -2-.
Installing
Note
The bolts are microencapsulated and must be renewed each time they are unscrewed.

– Attach removed cables -4- and -5- to door lock -1-.

– Fit cover ⇒ page 225
– Insert door lock -1- into door -arrow f-.
– If fitted, connect connector.
– Clip cap -3- in.
– It is essential to perform a functional check.
• Only if the cables are adjusted and locked correctly, the door
lock can be unlocked and opened properly.
Specified torques
♦ ⇒ o2.3 verview - door handle and door lock”, page 199
Fitting cover

– Push cover -1- onto retainer -3- on door lock -2- -arrow a-.
– Engage hook -4- with door lock -2- -arrow b-.
2.12 Removing and installing window chan‐

nel
Note

window channel. Removal and installation of the right win‐
dow channel are similar.
♦ Do not bend window channel when removing!
Removing

– Remove window slot inner seal ⇒ page 231 .

– Detach window channel -1- at rear end from door -arrow a-.
– Peel sealing lip of window channel -1- off the door flange -2-
from the inside.
– Pull window channel -1- out of mountings on door -arrows c-.
– Pull window channel -1- -arrows b- evenly all around off door
flange -2-.
Installing

– Spray window channel with soapy water to facilitate installa‐

tion.
– Push window channel -1- into mountings on door -arrows a-.
– Attach window channel at rear end to door -arrow c-.
– Fit window channel -1- all around onto door flange -2-
-arrows b-, and press it on.
– Fold sealing lip of window channel onto door flange from the
inside.
Note
To prevent wind noise, ensure window channel -1- seats evenly when installing.



outer seal
Note
♦ The core of the window slot outer seal is a metal insert.

♦ If it is bent or distorted, the window slot outer seal can no
longer be straightened out. It will remain “wavy”.
♦ Therefore, the window slot outer seal must be pulled off and
pressed on evenly, without bending or distorting it.
dow slot outer seal. Removal and installation of the right
window slot outer seal are similar.
Removing
– Slightly detach window slot outer seal -1- evenly from door
flange -2- using wedge -T10039/1- -arrows a-. Make sure
not to bend the side strip.

– Push window slot outer seal -1- towards front out of door
-arrow b-.
Installing
Note
♦ The use of assembly aid is allowed.

♦ The use of striking tools is not allowed for installing the window slot outer seal.
– Push window slot outer seal -1- at front end into door
-arrow a-.
– Press window slot outer seal -1- evenly onto door flange -2-
by hand.


inner seal
Note
Removal and installation are only described for the left window
slot inner seal. Removal and installation of the right window slot
Removing
trim.
– Lift window slot inner seal -1- evenly off flange -2- without
bending or distorting it -arrows-.
Installing
– Centre window slot inner seal -1- and press it evenly onto
front door flange -2- by hand.

60 – Sunroof
1 Sliding sunroof
⇒ o1.1 verview - sliding sunroof”, page 232
⇒ o1.2 verview - sunroof roller blind”, page 234
⇒ a1.3 nd installing sunroof panel”, page 235
⇒ a1.4 nd installing rear sunroof panel”, page 239
⇒ s1.5 unroof panel”, page 243
⇒ a1.6 nd installing sliding sunroof frame”, page 247
⇒ a1.7 nd installing wind deflector”, page 249
⇒ a1.8 nd installing sunroof motorV1”, page 251
⇒ a1.9 nd installing sunroof roller blind motorV260”, page 253
⇒ a1.10 nd installing sunroof roller blind control unitJ394”, page
255
⇒ a1.11 nd installing sliding sunroof adjustment control
unitJ245”, page 256
⇒ a1.12 nd installing sliding sunroof seals”, page 258
⇒ a1.13 nd installing sunroof roller blind”, page 263
⇒ s1.14 liding sunroof adjustment control unit J245”, page 266
⇒ s1.15 unroof roller blind control unit J394”, page 266
⇒ a1.16 nd installing rear part”, page 266
⇒ a1.17 nd installing tilt mechanism for sliding sunroof”, page
271
⇒ a1.18 nd installing sunroof roller blind cable”, page 273
⇒ w1.19 ithout current”, page 275
1.1 Assembly overview - sliding sunroof
232 Rep. gr.60 - Sunroof

1 - Exterior seal
ling ⇒ page 258
2 - Front sunroof panel
ling ⇒ page 235
3 - Bolt
❑ Micro-encapsulated
bolt, always renew
❑ Qty. 6
❑ 7 Nm
4 - Rear sunroof panel
ling ⇒ page 239
ling rear sunroof panel
seals ⇒ page 261
5 - Inner seal
❑ Positioned on assembly
frame.
6 - Sunroof roller blind
ling ⇒ page 263
7 - Bowden cable
❑ For sun blind
ling ⇒ page 273
8 - Bolt
❑ Qty. 4
❑ 7 Nm
9 - Rear part
❑ Part of assembly frame
10 - Sliding sunroof adjustment control unit -J245-
❑ Comprises sunroof roller blind control unit -J394-
❑ Initialising ⇒ page 266 .
11 - Bolt
❑ For securing motors.
❑ Qty. 2 per engine
❑ 8 Nm
12 - Motor for sliding roller blind -V260-
13 - Wire
14 - Spring
15 - Bolt
1. Sliding sunroof 233

❑ For securing sliding sunroof frame
❑ Qty. 18
❑ 8 Nm
16 - Sliding sunroof motor -V1-
17 - Sliding roof frame
18 - Wind deflector
19 - Bolt
❑ Micro-encapsulated bolt, always renew
❑ Qty. 6
❑ 7 Nm
20 - Tilting mechanism
❑ For front glass panel, with Bowden cables.
1.2 Assembly overview - sunroof roller blind

1 - Sunroof roller blind

ling ⇒ page 263
2 - Support
❑ For sunroof roller blind
fabric.
3 - Bolt
❑ Qty. 2
❑ 2 Nm
4 - Yoke
5 - Tension bow
6 - Sliding roof frame
1.3 Removing and installing sunroof panel

Removing

– Open sunroof panel -2- until trims -1- are accessible.

– Push interior trims -1- slightly towards rear -arrow a-.
Note
To unscrew bolts, use a magnetic tool so that bolts do not fall into mechanism of panoramic sliding roof.

– Pull seal off assembly frame.

– Remove bolts -2- from sunroof panel -1- on left and right.
– Take out sunroof panel upwards.
Installing
Note
♦ Micro-encapsulated bolts must always be renewed.

♦ To screw in bolts, use a magnetic tool so that bolts do not fall into panoramic sliding roof guide.

– Insert sunroof panel -1- from above a into tilting mechanics.

Screw bolts -2- in; do not tighten.
– Adjust front sunroof panel ⇒ page 245 .
Specified torques
♦ Bolts ⇒ o1.1 verview - sliding sunroof”, page 232

– Place trim -1- onto glass panel -1- and push onto fasteners.
– Slide trim towards front as far as stop.
– After completing all work, carry out normalisation run for
sliding roof motor ⇒ page 266 .
1.4 Removing and installing rear sunroof

panel

Removing
Note
To unscrew bolts, use a magnetic tool so that bolts do not fall into panoramic sliding roof guide.
– Pull seal -3- from assembly frame.

– Remove bolts -2- from sunroof panel -1- on left and right.

– Slide rear sunroof panel -1- slightly under front sunroof panel
-3- -arrow a-.
– Lift rear sunroof panel -1- out of roof cut-out -2- in rear area
only -arrows b-.
– Guide rear sunroof panel -1- angled upwards -arrow c- over
roof -2- and pull out from beneath front sunroof panel -3-.
Installing
Note
♦ Micro-encapsulated bolts must always be renewed.

♦ To screw in bolts, use a magnetic tool so that bolts do not fall into panoramic sliding roof guide.


– Insert rear sunroof panel -1- at an angle from above under
front sunroof panel -3-.
– Insert rear sunroof panel -1- downwards into roof cut-out -2-
in rear area and slide to rear.

– Insert bolts -2-; do not tighten.

– Adjust sunroof panel -1- ⇒ page 246 .
– After adjusting rear sunroof panel, tighten bolts.
Specified torques
1.5 Adjusting sunroof panel

⇒ h1.5.1 eight adjustment”, page 243
⇒ f1.5.2 ront sunroof panel”, page 245
⇒ r1.5.3 ear sunroof panel”, page 246
1.5.1 Checking height adjustment


Note
♦ The front sunroof panel is now adjusted at the front edge only and the rear sunroof panel at the rear edge
only.
♦ To achieve the best possible optical appearance, ensure that adjustments on left and right are uniform
(symmetrical).
♦ The arrow points in direction of normal travel.

Checking height adjustment

– Check adjustment of front sunroof panel -1- and rear sunroof
panel -2- with a depth gauge.
♦ Dimension -a-: 1.5 ± 1 mm
♦ Dimension -b-: 1 ± 1 mm
♦ Dimension -c-: 1 ± 1 mm
If measured values differ from specifications, the respective
sunroof panel must be adjusted.
♦ Adjust front sunroof panel ⇒ page 245
♦ Adjust rear sunroof panel ⇒ page 246
1.5.2 Adjusting front sunroof panel
Note
♦ The sunroof panel height adjustment is performed after the sunroof panel has been closed from slide
open position.
♦ -Arrow d- points in direction of normal travel.

– Remove trim ⇒ page 235 .

– Pull seal off assembly frame.
– Loosen only both front bolts -4- on left and right for front
sunroof panel -2-.
– Adjust front sunroof panel -3- according to dimensions ⇒
page 245 .
– Tighten bolts on left and right -4-.
– Installing trim ⇒ page 235 .
– Position seal on assembly frame.
Specified torques
1.5.3 Adjusting rear sunroof panel
Note
The arrow points in direction of normal travel.

– Pull off inner seal -5-.

– Loosen bolts -4- for rear sunroof panel -3-.
– Adjust rear sunroof panel -3- according to dimensions ⇒
page 245 .
– Tighten bolts on left and right -4-.
– Position seal -5- on assembly frame.
Specified torques
1.6 Removing and installing sliding sunroof

frame
Note
A second mechanic is required for removing and installing as‐

sembly frame.
Removing

– Remove moulded headliner ⇒ General body repairs, interior;

Rep. gr. 70; Roof trim.
– Pull water drain hoses from fittings.
– Disconnect connector to wiring harness on sliding roof mo‐
tor.
– Unscrew bolts -2- except for the centre bolts on right and left
side.
Note
Now, two other persons are required to hold the frame.
– Only now, the last bolts can be removed.

– Remove assembly frame -1- from vehicle.
Installing
– Lift assembly frame -1- into vehicle with the help of 2 other
persons.

– When bolting on assembly frame -1-, use 2 cylindrical pins

(reversed 10 mm drill bits) to align assembly frame relative
to front and rear centring holes -arrows a and b- and to roof.
– Screw in bolts -2-, but do not tighten.
– Connect all water drain hoses -arrow c-.
– Connect connectors -3-.
– Tighten numbered bolts alternately in the specified se‐

quence -1 to 4-.
– Tighten remaining bolts -arrows- in any sequence.
Specified torques
1.7 Removing and installing wind deflector

Removing

– Open front glass panel completely.

– Using a screwdriver -2-, lift out retaining hook from frame
-arrow a-.
– Push wind deflector -1- towards front as far as stop
-arrows b-.
– Lift out wind deflector from installation frame.
Installing

– Position wind deflector -1- with retaining hooks in holes.

– Push wind deflector backwards until retaining hooks engage
audibly in frame.
1.8 Removing and installing sunroof motor

-V1-

Removing
Note
Remove or install drive for panorama tilting sunroof glass panel

only when sunroof is closed (“0” position ).
– Remove front lights and operating unit ⇒ General body re‐

pairs, interior; Rep. gr. 68; Compartments/covers; Removing
and installing storage compartment in roof headliner.
– Switch off ignition, remove key, and open door.
• This situation must be maintained until drive has been instal‐
led.
• Remove or install drive for panorama tilting sunroof glass
panel only when sunroof is closed (“0” position ).
– Lower sliding roof motor -1- slightly and tilt out to rear.

Installing
– Install sliding roof motor -1- and tighten bolts -3-. Specified
torque: 3.5 Nm.
– Install front lights and operating unit ⇒ General body repairs,
interior; Rep. gr. 68; Compartments/covers; Removing and
installing storage compartment in roof headliner.
Specified torques
1.9 Removing and installing sunroof roller

blind motor -V260-
Removing


– Disconnect connector -2- on sun blind motor -1-.
– Remove sunroof roller blind motor -1-.
Installing
– Before installing roller blind motor, roller blind must be
aligned parallel.
– Measure and adjust distance -dimension a- between blind
brace -1- and blind cassette -2-.

– On completion of all work, carry out normalisation run for

sun blind motor ⇒ page 266 .
Specified torques
Sun blind housing 3.5 Nm

blind control unit -J394-
Note
The sunroof roller blind control unit -J394- is integrated in the

sliding sunroof adjustment control unit -J245-.


– Release retaining hooks -3- -arrows a-.
– Slightly lift control unit -1-, and pull it out of bracket -2-
-arrows b-.
– Disconnect connectors -4- from control unit -1-.
– Code new control unit ⇒ Vehicle diagnostic tester.

adjustment control unit -J245-
Note
Integrated in the sliding sunroof adjustment control unit -J245-

is the sunroof roller blind control unit -J394-.

Removing
– Release retaining hooks -3- -arrows a-.
– Slightly lift control unit -1-, and pull it out of bracket -2-
-arrows b-.
– Disconnect connectors -4- from control unit -1-.
Installing
Install in reverse order.
– Code new control unit. ⇒ Vehicle diagnostic tester


seals
⇒ a1.12.1 nd installing seal for sliding sunroof frame”, page 258
⇒ a1.12.2 nd installing glass panel seal”, page 261
1.12.1 Removing and installing seal for sliding

sunroof frame
♦ Roller -T10563-
♦ Adhesive residue remover -VAS 6349-
♦ Hot-air blower -V.A.G 1416-
Fitting instructions
♦ If a seal is installed for the first time on a new vehicle or
a newly painted surface, the procedure described in the
⇒ Paintwork manual ⇒ Paintwork repairs ⇒ Paint finish ⇒
Mouldings & film should be observed.
♦ Remove existing adhesive residue of adhesive tape using
adhesive strip remover -VAS 6349-.

♦ If a seal is removed and reinstalled, only use adhesive re‐

mover to remove the adhesive remains in installation area.
♦ The drying time of the adhesive remover is 5 minutes.
♦ Ensure that the bonding surfaces are free of dust and
grease.
♦ Seal must be bonded in place immediately after cleaning.
♦ Remove protective film immediately before installation.
♦ Working temperature is approx. 18°C.
Minimum drying time
Note
♦ There are special requirements for renewing seals with dou‐

ble-sided adhesive tape.
♦ Further work in the area of the seal may be carried out after
the maximum adhesive strength has been reached.
For the double-sided adhesive tape of the seal, the minimum

drying time is 3 hours.
The minimum drying time is the period from bonding in the seal
until the installation of the assembly frame. During this time, the
vehicle must be kept at room temperature (at least 18°C).
Removing
Note
Seal cannot be removed without damage.

– Remove assembly frame ⇒ page 247 .

– Pull exterior seal -1- with bonding area -3- from roof -2-.
Installing

– Follow fitting instructions ⇒ page 258 .

– Centre new exterior seal -1- with joint -arrows- to centre of
rear roof cut-out.
– Pull off protective film from adhesive tape -3- in sections and
press seal onto roof -2-.
Note
Do not stretch or puncture seal.
– Using roller -T10563- -4-, press on exterior seal firmly and

evenly around circumference twice -arrow a-.
– Observe minimum drying time ⇒ page 259 .
– Install assembly frame ⇒ page 247 .
1.12.2 Removing and installing glass panel

seal
Removing

– Open front glass panel completely via the convenience posi‐

tion.
– Pull seal -2- off rear glass panel -1-.
Installing

– Follow fitting instructions ⇒ page 258 .

– Pull protective film -4- off adhesive tape of new seal -2- and
press seal on at ends.
– If the seal is excessively long, any excess length is evenly
compressed.
– Press seal on evenly all round using roller -3356-.
– Observe minimum drying time ⇒ page 259 .

blind

Removing
Note
♦ In the event of power failure, the sunroof sun blind can be moved by turning the sunroof sun blind motor
with a commercially available hexagon key to removal position (fully open). ⇒ page 275
♦ The greatest possible cleanliness must be ensured when working on fabric of sun blind. If necessary,
parts of it must be covered. Wear gloves in case of need.

Removing
– Move sunroof sun blind -1- to fully open position.
– Remove front sunroof panel ⇒ page 235 .
– Remove rear sunroof panel ⇒ page 239
– Remove sunroof frame ⇒ page 247 .
– Remove roller blind motor ⇒ page 253 .
– Push sunroof sun blind -1- in parallel completely towards
rear -arrow a-.
– Tilt sunroof sun blind -1- in front area evenly on left and right
-arrow b-.
– Pull sunroof sun blind -1- out of assembly frame -arrow c-.
Installing
– Guide sunroof sun blind -1- evenly on left and right into
assembly frame -arrow a-.
– Insert sunroof sun blind -1- into assembly frame -arrow b-.

– Align mountings of sunroof sun blind -3- on left and right with
guides in assembly frame -4- -arrows c-.
Specified torques
Sun blind 3 Nm
1.14 Programming sliding sunroof adjust‐

ment control unit -J245-
Note
♦ The sunroof roller blind control unit -J394- is integrated in

the sliding sunroof adjustment control unit -J245-.
♦ If a glass panel, motor or tilt mechanism have been re‐
newed, adaption needs to be performed.
♦ Programming function is switched off when establishing ref‐
erence points.
Establishing reference points of sliding sunroof motor

Ignition is switched on.
– Push knob for “closing” and hold in this position during entire
programming process (approx. 20 sec).
– When establishing reference points, glass panel first closes
and then moves approx. 200 mm towards the rear.
– Once panel has closed again, normalisation is finished and
button can be released.
– Adapting is also done through ⇒ Vehicle diagnostic tester.
1.15 Adapting sunroof roller blind control

unit -J394-
Note
♦ Integrated in the sliding sunroof adjustment control unit -

J245- is the sunroof roller blind control unit -J394-.
♦ If a glass panel, motor or tilt mechanism have been re‐
newed, adaption needs to be performed.
♦ Programming function is switched off when establishing ref‐
erence points.
Ignition is switched on.

– Push knob for “closing” and hold in this position during entire
programming process (approx. 20 sec).
The sunroof roller blind is completely closed.
– Adapting is also done through ⇒ Vehicle diagnostic tester.
1.16 Removing and installing rear part


Removing

– Remove front glass panel ⇒ page 235 .
– Remove rear glass panel ⇒ page 239 .
– Remove sunroof roller blind ⇒ page 263 .

– Remove sunroof frame ⇒ page 247 .

– Release wiring harness from rear section.
– Separate bonded joint -5- with a knife.
– Pull entire rear section -1- with followers -4- from assembly
frame -3- in -direction of arrow-.
Installing
– Remove existing adhesive residues with adhesive strip re‐

mover -VAS 6349-.
– Thoroughly clean bonded areas on rear section -1- and on
assembly frame -3- with cleaning solution -D 009 401 04-.
– Insert a 3.5 mm butyl adhesive sealing cord -AKD 497 010
04 R10- ∅ into bonding channel -5- on rear section -1-.
– Push rear section -1- with followers -4- onto assembly frame
-3-.


Rear part 2 Nm
Follower -1- and cable for roller blind -3- are located in lower
guide channel.
Cable for glass panel -2- is located in upper guide channel.

Note
Before installation, checking assembly frame for leaks is recommended.
– Seal water drain fitting -3-.

– Fill marked area -4- between rear section -2- and assembly
frame -5- with water.
– Wait for at least 5 minutes and check for leaks.
– Seal any leaks with butyl adhesive sealing cord -AKD 497
010 04 R10-.
– Install sun blind ⇒ page 263 .
– Install roller blind motor ⇒ page 255 .
– Install assembly frame ⇒ page 247 .
– On completion of all work, carry out a normalisation run for
all panoramic sliding roof drives ⇒ page 266 .

1.17 Removing and installing tilt mechanism

for sliding sunroof
Removing
Note
Observe the position of the Bowden cables before removal to avoid any errors when installing.

– Remove sun blind ⇒ page 263 .
– Remove sliding roof motor ⇒ page 255 .
– Remove rear section from assembly frame ⇒ page 266 .
– Slide tilting mechanism -1- out to rear -arrows- together with
Bowden cables and followers -3-.

Note
Tilting mechanism must not tilt during sliding.
Installing
Note
♦ Clean and lubricate guide rails ⇒ Maintenance; Booklet ; Panorama tilting/sliding roof with rear panorama
roof: Check function, clean and grease guide rails, and clean wind deflector.
♦ Do not grease cables.
♦ Bowden cables and tilting mechanism must only be renewed in pairs.
– Slide tilting mechanism -1- into guide rails -5- together with
Bowden cables and followers -3-.
– Attach rear section to assembly frame ⇒ page 266 .

– Install sliding roof motor ⇒ page 256 .

– Install assembly frame in vehicle ⇒ page 247 .
– Install rear glass panel ⇒ page 239 .
– Install front glass panel ⇒ page 235 .
– On completion of all work, carry out a normalisation run for
all panoramic sliding roof drives ⇒ page 266 .

blind cable
Removing
Note
Observe the position of the Bowden cables before removal to avoid any errors when installing.

– Remove roller blind ⇒ page 263 .


– Remove roller blind motor ⇒ page 255 .
– Remove rear section from assembly frame ⇒ page 266 .
– Pull Bowden cables -2- out of rear section -3- together with
followers -1- -arrows-.
Installing
Note
♦ Clean and lubricate guide rails ⇒ Maintenance; Booklet ; Panorama tilting/sliding roof with rear panorama
roof: Check function, clean and grease guide rails, and clean wind deflector.
♦ Do not grease cables.
♦ Bowden cables must only be renewed in pairs.
– Slide Bowden cables -2- into guide rails together with follow‐
ers -1-.

– Attach rear section to assembly frame ⇒ page 266 .

– Install roller blind motor ⇒ page 255 .
– Install assembly frame in vehicle ⇒ page 247 .
– Install rear glass panel ⇒ page 239 .
– Install front glass panel ⇒ page 235 .
– On completion of all work, carry out a basic setting for all
panoramic sliding roof drives ⇒ page 266 .
1.19 Operating without current
Note
♦ In the event of power failure, the sliding/tilting sunroof with glass panel can be moved using a commer‐
cially available hexagon key directly on the drive.
♦ Considerable force must be used to turn the key because the drive is not decoupled from the gears.
– Insert hexagon key into the bolt -4- of the drive -1-.
– Turn the bolt -4- to close the glass panel.

2 Water drain hoses

⇒ o2.1 verview - water drainage hoses”, page 276
⇒ w2.2 ater drain hoses”, page 276
⇒ a2.3 nd installing water drain hoses”, page 278
2.1 Assembly overview - water drainage hoses
1 - Front water drain hose

❑ Left and right
❑ Cleaning ⇒ page 276 .
ling ⇒ page 278
2 - Front drain grommet
3 - Marking
❑ The water drain hose
must be pushed up to
the marking into the
drain grommet.
4 - Clip
❑ Other fasteners may be
used
5 - Rear water drain hose
❑ Left and right
❑ Cleaning ⇒ page 276 .
ling ⇒ page 278
6 - Clip
7 - Hose retainer
❑ Other fasteners may be
used
8 - Marking
❑ The water drain hose
must be pushed up to
the marking into the
drain grommet.
9 - Rear drain grommet
2.2 Cleaning water drain hoses


♦ Cleaning and fitting tool -VAS 6620-
Front water drain hose

The front water drain hoses -1- are routed in the A-pillars and
end in the plenum chamber.
– Cleaning is carried out from bottom drain grommet -4- with
the cleaning and pull-in cable -VAS 6620-.
2. Water drain hoses 277

Rear water drain hose

The rear water drainage hoses -2- run through the C-pillars and
end in the rear wheel housings.
– Remove wheel housing liner ⇒ page 486 .
– Cleaning for all models is carried out from bottom drain
grommet -5- with the cleaning and pull-in cable -VAS 6620-.
2.3 Removing and installing water drain hoses
Removing front water drain hose

– Remove A-pillar trim ⇒ General body repairs, interior; Rep.
gr. 70; Trims, interior; Removing and installing A-pillar trim.
Rep. gr. 70; Roof trims; Removing and installing moulded
headliner.
– Pull front water drain hose -1- out of clips -3- and out of drain
grommets -4-.
Removing rear water drain hose
– Remove C-pillar trim ⇒ General body repairs, interior; Rep.
gr. 70; Trims, interior; Removing and installing C-pillar trim.

– Detach right luggage compartment side trim ⇒ General body

repairs, interior; Rep. gr. 70; Luggage compartment trims;
Removing and installing luggage compartment side trim.
Rep. gr. 70; Roof trims; Removing and installing moulded
headliner.
– Pull rear water drain hose -2- out of clips -3- and out of drain
grommets -5-.
Installing water drain hose
– Push water drain hoses -1 and 2- into drain grommets
-2 and 8- up to markings -3 and 9-.
2. Water drain hoses 279

63 – Bumpers
1 Bumper, front
⇒ o1.1 verview - bumper cover”, page 280
⇒ o1.2 verview - add-on parts”, page 284
⇒ o1.3 verview - impact bar”, page 292
⇒ a1.4 nd installing bumper cover”, page 293
⇒ a1.5 nd installing add-on parts”, page 297
⇒ b1.6 umper cover”, page 314
⇒ b1.7 rackets for parking aid system”, page 314
⇒ b1.8 rackets for park assist steering”, page 319
1.1 Assembly overview - bumper cover

⇒ o1.1.1 verview - bumper cover”, page 280
⇒ o1.1.2 verview – bumper cover, R-Line models as of
07.2019”, page 282
1.1.1 Assembly overview - bumper cover
Note
Minor differences may be encountered in respect of bumper cover, depending on vehicle model.
280 Rep. gr.63 - Bumpers

1 - Bumper cover
❑ Material PP/EPDM
ling ⇒ page 293
Note
♦ On a new bumper cover, there

are transportation struts in area
of ventilation grille.
♦ The transportation struts must
be cut out before attachments
parts are installed.
2 - Bolts 07/2019 ►
❑ Qty. 4
❑ 2 Nm
3 - Bolts
❑ Left and right
❑ Points upwards.
❑ 2 Nm
4 - Bolts
❑ Up to 4 on each side depending on version
❑ Bolted to wheel housing liner.
❑ 2 Nm
1. Bumper, front 281

5 - Bolts
❑ Qty. up to 3, depending on version
❑ Bolted to wheel housing liner.
❑ 2 Nm
6 - Bolts
❑ Qty. 3
❑ Bolted to lock carrier.
❑ 2 Nm
❑ Bolts ► 06/2019
❑ Spreader rivets 07/2019 ►
8 - Guide profile
❑ Left and right
1.1.2 Assembly overview – bumper cover, R-Line models as of 07.2019

1 - Bumper cover
ling ⇒ page 293
❑ Repairing ⇒ page 314
2 - Connecting strip
ling ⇒ page 297
3 - Support members
❑ Qty. 2
ling ⇒ page 297
4 - Bolts
❑ Qty. 8
❑ 2 Nm
5 - Bolts
❑ Qty. 12
❑ 2 Nm
6 - Trim strip
ling ⇒ page 297
7 - Trim
❑ For fog light
ling ⇒ page 297
8 - Ventilation grille
9 - Number plate carrier
❑ Installing ⇒ page 297
10 - Cover parts
11 - Clips
❑ Qty. 4
12 - Trim strip
13 - Decorative trims
❑ Qty. 2
14 - Caps
❑ Qty. 2
❑ Qty. 2
16 - Trims
❑ Qty. 2
17 - Trim strip

18 - Spoiler
19 - Bolts
❑ Qty. 4
❑ 2 Nm
20 - Spreader rivets
❑ Qty. 3
21 - Cover
❑ For towing eye.
1.2 Assembly overview - add-on parts

⇒ o1.2.1 verview - add-on parts”, page 284
⇒ o1.2.2 verview – add-on parts, GTE”, page 286
⇒ o1.2.3 verview - add-on parts, Alltrack”, page 288
⇒ o1.2.4 verview – add-on parts, R-Line models up to 06.2019”,
page 290
1.2.1 Assembly overview - add-on parts
Note
The attachments may be slightly different, depending on vehicle model, and these differences must be taken
into account.

1 - Bumper cover
ling ⇒ page 293
2 - Headlight washer system
cover
❑ Left and right
3 - Reinforcing member
❑ Left and right
❑ Engaged in front bump‐
er cover
❑ Can only be removed
with front bumper cover
removed
4 - Bolts
❑ For securing bumper
cover
❑ 2 Nm
❑ Installed only in selec‐
ted models available in
selected markets
ling ⇒ page 297
Note
♦ The wires can run behind the

holes for the clips -6- in the
bumper cover.
♦ Holes for bolts must be drilled
before installing the lines.
6 - Clip
❑ Different number for securing.
Note
♦ The electrical wires can be rout‐

ed behind the holes for the clips
in the bumper cover.
♦ Holes for clips must be drilled
7 - Centre air intake grille

❑ Different versions, allocation ⇒ Electronic parts catalogue “ETKA”
8 - Trim strip

❑ Left and right
❑ Can only be removed with front bumper cover removed
9 - Fog light trim
❑ Left and right
❑ Pull forwards out of detent.
10 - Bolt
❑ 2 Nm
❑ Bolt ► 06/2019
❑ Spreader rivet 07/2019 ►
11 - Spoiler
12 - Clip
❑ For securing spoiler
13 - Trim strip
14 - Cover for towing eye
1.2.2 Assembly overview – add-on parts, »GTE«

1 - Bumper cover
ling ⇒ page 293
2 - Headlight washer system
cover
❑ Left and right
3 - Bolts
❑ 2 Nm
❑ Left and right
❑ Engages in front side of
bumper cover and bol‐
ted
removed
5 - Daytime running lights
ling
6 - Bolts
❑ 2 Nm
❑ For securing daytime
running lights
7 - Bolts
❑ 2 Nm
cover
8 - Cover ► 06/2019
er cover
9 - Trim strips ► 06/2019
❑ Engaged in front bumper cover
10 - Clip
Note


❑ Installed only in selected models available in selected markets.

Note


13 - Trim strip
❑ Left and right
14 - Rivets
❑ Qty. 10
15 - Spoiler
16 - Clip
17 - Clip
❑ For securing the attachment
18 - Attachment
19 - Headlight washer system cover
❑ Left and right
1.2.3 Assembly overview - add-on parts, Alltrack

1 - Front bumper cover

ling ⇒ page 293
❑ Left and right
❑ Engaged in bumper
cover
❑ Only remove when
bumper cover is re‐
moved
3 - Trim
❑ Extension of wheel
arch trim, left and right
cover -1-.
bumper cover -1- is re‐
moved.
4 - Cover for headlight washer
system
❑ Left and right
❑ Instructions and work
specifications for the
headlight washer sys‐
tem ⇒ Electrical sys‐
tem; Rep. gr. 92; Head‐
light washer system
er cover
removed
6 - Side air intake grille
❑ Engaged in bumper cover -1-.
❑ To remove:
– Release from catches from the middle
– Pull out of side insert to centre.
7 - Trim strip
❑ Engaged in air intake grille -5-
❑ Can only be removed with front bumper cover removed and air intake grilles removed
8 - Trim strip
❑ Engaged in side air intake grille -6-
❑ Only remove when side air intake grille -6- is removed
❑ Installed only in selected models available in selected markets.
Note


10 - Clip
❑ Or bolts, depending on vehicle equipment
❑ Qty. 4
Note

11 - Skid plate
❑ Engaged on spoiler -12-.
❑ Can only be removed if front bumper cover and spoiler are removed
12 - Spoiler
1.2.4 Assembly overview – add-on parts, R-Line models up to 06.2019

1 - Bumper cover
ling ⇒ page 293
Note
♦ On a new bumper cover, there

are transportation struts in area
of ventilation grille.
♦ The transportation struts must
be cut out before attachments
parts are installed.
2 - Headlight washer system cover

❑ Left and right
❑ Installed only in selected models available in selected markets
Note


4 - Clip
Note

5 - End plate
❑ Left and right
❑ Left and right
7 - Fog light cover
❑ Left and right
❑ Pull forwards out of detent.
8 - Centre trim strip
9 - Trim strip
❑ Left and right
❑ Can only be removed when fog light cover is removed
❑ Cannot be removed without being damaged
10 - Trim for fog light cover
❑ Left and right
11 - Lower centre trim strip
12 - Lower trim strip
❑ Left and right
13 - End plate
❑ Left and right
14 - Spoiler
1.3 Assembly overview - impact bar


1 - Impact bar
2 - Centre hex studs
3 - Guide profile
❑ Left and right
4 - Nuts
❑ 2 Nm
5 - Bolts
❑ 8 Nm
6 - Bolts
❑ 55 Nm
8 - Bolts
❑ Qty. 4
❑ 8 Nm
9 - Foam element
❑ Is fitted onto impact bar
❑ Not installed in all mod‐
el versions
10 - Pedestrian protection
❑ Not installed in all mar‐
kets
11 - Pop rivet
❑ Left and right
❑ Insert with special pop
rivet pliers -V.A.G 1753A-
1.4 Removing and installing bumper cover


Note
♦ The removal and installation procedures for front bumper

cover may have to be revised slightly depending on model
variations.
♦ On vehicles ► 06/2019, the bumper cover can be removed
together with the radiator grille.
Removing
– On vehicles ► 06/2019, unscrew radiator grille bolts ⇒ page

392 .
– On vehicles 07/2019 ►, remove radiator grille ⇒ page 392 .
– On vehicles 07/2019 ►, unscrew bolts -2-.
– Undo bolts -3- in wheel housing (pointing upwards) on left
and right.
– Unscrew bolts -4- on left and right.
– Unscrew bolts -5- from underneath.

– On vehicles ► 06/2019, unscrew bolts -6- from below.

– On vehicles 07/2019 ►, unscrew spreader rivets -6- from
below.
chanic.
– Pull bumper cover -1- out of guide fasteners on left and right
of wing -arrows a-.
– Pull bumper cover -1- out of fasteners in centre guide
-arrows b-.
– Pull bumper cover -1- off vehicle in parallel movement
-arrow c-.
– Detach washer fluid line hose couplings (if there are any)
⇒ Electrical system; Rep. gr. 92; Headlight washer system;
Assembly overview - headlight washer system.
– Disconnect connectors of electrical components (if present).
tions for parking aid ⇒ Electrical system; Rep. gr. 94; Parking
aid.
tions for park assist steering ⇒ Electrical system; Rep. gr. 94;
Park assist steering.
tions for overhead view camera ⇒ Communication; Rep. gr. 91;
Overhead view camera; Overview of fitting locations - overhead
view camera.
On vehicles 07/2019 ►, observe instructions and work specifica‐
tions for parking aid, park assist steering and overhead view
camera ⇒ Driver assist systems; Rep. gr. 98; Fitting locations;
Overview of fitting locations - senders, sensors and control units
in front area of vehicle.
Installing

Install in reverse order of removal, observing the following:

Further installation requires the assistance of a second me‐
chanic.
– Connect connectors of all installed electrical components.
Note
When positioning the bumper cover, make sure that the front wheel housing liner is correctly seated.
– Guide bumper cover -1- onto lock carrier -arrows a- in a

parallel movement until locking devices engage.
– Press bumper cover -1- onto guides -8- on left and right of
wing until they engage -arrows b-.
– Observe gaps/shut lines ⇒ Body Repairs; Rep. gr. 00; Panel
gaps; Body – front.
Specified torques
♦ ⇒ o1.1 verview - bumper cover”, page 280

1.5 Removing and installing add-on parts

⇒ f1.5.1 ront number plate carrier”, page 297
⇒ a1.5.2 nd installing reinforcement – R-Line models as of
07.2019”, page 298
⇒ a1.5.3 nd installing connecting strip, R-Line models as of
07.2019”, page 299
⇒ a1.5.4 nd installing fog light trim, R-Line models as of
07.2019”, page 300
⇒ a1.5.5 nd installing trim cover, R-Line models as of 07.2019”,
page 302
⇒ a1.5.6 nd installing cover section, R-Line models as of
07.2019”, page 303
⇒ a1.5.7 nd installing outer trim strip end piece, R-Line models
as of 07.2019”, page 304
⇒ a1.5.8 nd installing cap of trim strip end piece, R-Line models
as of 07.2019”, page 305
⇒ a1.5.9 nd installing outer trim strip, R-Line models as of
07.2019”, page 306
⇒ a1.5.10 nd installing centre trim strip, R-Line models as of
07.2019”, page 308
⇒ a1.5.11 nd installing spoiler, R-Line models as of 07.2019”,
page 309
⇒ a1.5.12 nd installing ventilation grille, R-Line models as of
07.2019”, page 310
⇒ a1.5.13 nd installing centre trim strip for ventilation grille,
R-Line models as of 07.2019”, page 311
⇒ a1.5.14 nd installing upper trim strip for ventilation grille, R-
Line models as of 07.2019”, page 312
1.5.1 Installing front number plate carrier
Note
♦ Number plate carrier is not installed in all models or in all markets.

♦ Number plate carriers of different sizes are fitted in various markets.
♦ The height of the number plate carrier is specified by the contour to the bumper.
♦ The electrical wires can be routed behind the holes for the clips in the bumper cover.
♦ Holes for bolts must be drilled before installing the lines.
♦ Adherence to a depth of 12 mm is required when drilling holes.

Holes exist
– Fit number plate carrier -3- to front bumper cover -2- and
press in clips -4-.
Holes do not exist
– Centre number plate carrier -3- on front bumper cover -2-
relative to emblem -1-.
– Set bit stop of drill to 12 mm and drill holes.
– Fit number plate carrier -3- to front bumper cover -2- and
press in clips -4-.
1.5.2 Removing and installing reinforcement

– R-Line models as of 07.2019

Removing
– Remove bumper cover ⇒ page 293 .

– Remove fog light ⇒ Electrical system; Rep. gr. 94; Fog
lights; Removing and installing fog lights.
– Disconnect electrical connector -1-.
• The following work steps must be performed by a second
mechanic.
– Have a second mechanic secure bumper cover.
– Release catches -3- with removal wedge -3409-. When do‐
ing this, hold reinforcement -4- under tension.
– Remove reinforcement -4-.
Installing
Torque settings
♦ ⇒ o1.1.2 verview – bumper cover, R-Line models as of
07.2019”, page 282
1.5.3 Removing and installing connecting

strip, R-Line models as of 07.2019

Removing

mechanic.
ing this, hold connecting strip -2- under tension.
– Remove connecting strip -2-.
Installing
Torque settings
07.2019”, page 282
1.5.4 Removing and installing fog light trim,

R-Line models as of 07.2019

Removing

– Remove reinforcement ⇒ page 298 .
mechanic.
ing this, hold fog light trim -2- under tension.
– Remove fog light trim -2-.
Installing

Torque settings
07.2019”, page 282
♦ Fog lights; Assembly overview – fog lights ⇒ Electrical sys‐
tem; Rep. gr. 94; Fog lights; Assembly overview – fog lights
1.5.5 Removing and installing trim cover, R-

Line models as of 07.2019
Removing



mechanic.
ing this, hold trim cover -2- under tension.
– Remove trim cover -2-.
Installing
Torque settings
07.2019”, page 282
1.5.6 Removing and installing cover section,

R-Line models as of 07.2019

Removing

mechanic.
ing this, hold cover section -2- under tension.
– Remove cover section -2-.
Installing
Torque settings
07.2019”, page 282
1.5.7 Removing and installing outer trim

strip end piece, R-Line models as of
07.2019

Removing
– Remove front section of front wheel housing liner ⇒ page

484 .
ing this, hold trim strip -2- under tension.
– Remove trim strip -2-.
Installing
Torque settings
♦ ⇒ o8.1 verview - front wheel housing liner”, page 483
1.5.8 Removing and installing cap of trim

strip end piece, R-Line models as of
07.2019

Removing
– Remove outer trim strip end piece ⇒ page 304 .

– Release catch -1- using removal wedge -3409-. Hold cap -2-
under tension when doing this.
– Remove cap -2-.
Installing
Torque settings
♦ ⇒ o8.1 verview - front wheel housing liner”, page 483


Removing
– Remove fog light trim ⇒ page 300 .

– Remove spoiler ⇒ page 309 .
mechanic.
Installing

Torque settings
07.2019”, page 282
1.5.10 Removing and installing centre trim

Removing
– Remove outer trim strips ⇒ page 306 .

mechanic.


Installing
Torque settings
07.2019”, page 282
1.5.11 Removing and installing spoiler, R-Line

models as of 07.2019
Removing
– Remove connecting strip ⇒ page 299 .


mechanic.
– Release catches -1- with removal wedge -3409-. Hold spoil‐
er -2- under tension when doing this.
– Remove spoiler -2-.
Installing
Torque settings
07.2019”, page 282
1.5.12 Removing and installing ventilation

grille, R-Line models as of 07.2019

Removing
– Remove spoiler ⇒ page 309 .

– Remove outer trim strips ⇒ page 306 .
– Remove cover sections ⇒ page 303 .
– Unclip wiring harness -1-.
mechanic.
ing this, hold ventilation grille -2- under tension.
– Remove ventilation grille -2-.
Installing
Torque settings
07.2019”, page 282
1.5.13 Removing and installing centre trim

strip for ventilation grille, R-Line mod‐
els as of 07.2019

Removing
– Remove trim cover ⇒ page 302 .

mechanic.
Installing
Torque settings
07.2019”, page 282
1.5.14 Removing and installing upper trim

strip for ventilation grille, R-Line mod‐
els as of 07.2019

Removing
– Remove number plate carrier.

– Remove trim covers ⇒ page 302 .
– Unclip wiring harness -1-.
mechanic.
Installing

Torque settings
07.2019”, page 282
1.6 Repairing bumper cover
Note
If bumper cover is damaged, determine whether plastic can be

repaired before renewing bumper.
Description under: ⇒ General Information; Body Repairs, Gen‐

eral Body Repairs; Plastic repair procedures
1.7 Installing brackets for parking aid sys‐

tem
♦ Installation tool for PDC bracket -VAS 6614-
Materials
♦ Cleaning solution ⇒ Electronic parts catalogue
“ETKA”
Note
Observe manufacturer's instructions enclosed in the packaging.
Installing brackets
Note
The brackets are installed after the bumper cover has been painted.

The 4 markings for brackets -1- can be found on the inside of

the bumper cover.
– If there are no markings, the centre point -2- must be deter‐
mined.
– The holes must be drilled from the inside to the outside with
the drill bit -VAS 6614/4- -3- from the supplied tool kit.

– Fit screw-hole punch -VAS 6614/9--1-, washer -2- and coun‐

ter-support -3- from inside of bumper cover -5-.
– Screw on punch -4-, not quite as far as bumper cover.
– Press punch -4- against bumper cover.
– Tighten screw-hole punch -1-.
Note
Do not permit the punch -4- to turn on the paint of the bumper cover.
– Pull punch -4- through material of bumper cover -5- -arrows-

by turning bolt head -1-.
– Remove screw-hole punch and make next holes.
– Thoroughly clean bumper cover and bracket with cleaning
solution.

Alignment of brackets
– Brackets -1- must be aligned in such a way that sensor
connections -arrows- point to centre of vehicle.

– Thoroughly clean bonding surfaces on bumper cover -4-.

– Push bracket -2- onto centring pin -VAS 6614/3- -1-.
– Pull off backing from double-sided adhesive tape -3- on re‐
tainer.
– Insert centring pin -1- into hole until the bracket is touching
the bumper cover -4-.
– Press bracket forcefully against bonding surface -3-.
– Removing centring pin and repeat the procedure for all
brackets.
– Further work can carried out on bumper cover only after
minimum curing period 1)
.
1) Minimum drying time
Do not carry out any further work on the bumper cover or brack‐
ets until the minimum curing period of 2 hours has expired.
The minimum curing period must be observed so that the adhe‐
sive tape can develop its full adhesive strength.
In this time, the bumper cover must remain where it is. Do not
move it.

1.8 Installing brackets for park assist steer‐

ing
♦ Assembly tool for park assist steering sensors -VAS 895
003-
Materials
♦ Cleaning solution -D 009 2) 1
401 04-
2) Observe manufacturer's instructions enclosed in the packaging.
Installing brackets
Note
The brackets are installed after the bumper cover has been
painted.

The markings for the bracket -1- can be found on the inside of
the bumper cover.
mined.
the drill in the tool kit -3-.
– Set hole puncher in position with bolt head -1-, washer -2-
and thrust bearing -3- from inside bumper cover -5-.
– Tighten hole puncher -1-.
Note


– Remove hole punch and make next holes.

– Push bracket -2- onto centring pin -1-.
tainer.
brackets.
minimum curing period ⇒ page 321 .
Minimum drying time

move it.

2 Bumper, rear
⇒ o2.1 verview - bumper cover”, page 323
⇒ o2.2 verview - guides for bumper cover”, page 325
⇒ o2.3 verview - add-on parts”, page 326
⇒ o2.4 verview - impact bar”, page 329
⇒ a2.5 nd installing bumper cover”, page 330
⇒ a2.6 nd installing add-on parts”, page 334
⇒ a2.7 nd installing impact bar”, page 342
⇒ b2.8 umper cover”, page 344
⇒ b2.9 rackets for parking aid system”, page 345
⇒ b2.10 rackets for park assist steering”, page 350
2.1 Assembly overview - bumper cover

⇒ o2.1.1 verview - bumper cover”, page 323
⇒ o2.1.2 verview – bumper cover, R-Line models as of
07.2019”, page 324
2.1.1 Assembly overview - bumper cover
Note
Minor differences may be encountered in respect of bumper cover, depending on vehicle model.
2. Bumper, rear 323

1 - Bumper cover
ling ⇒ page 330
2 - Bolts
❑ Left and right
❑ Points upwards.
❑ Bolted to side panel.
❑ 2 Nm
3 - Bolts
❑ Bolted to wheel hous‐
ing liner.
❑ 2 Nm
4 - Bolts
❑ Bolted to spoiler
❑ 2 Nm
5 - Bolts
❑ Bolted to underbody
covers
❑ 2 Nm
6 - Spreader rivets
❑ Qty. 3 or 5, depending
on type
8 - Guide profile
❑ Left and right
9 - Guide profile
❑ For tail light on left and right
2.1.2 Assembly overview – bumper cover, R-Line models as of 07.2019

1 - Bumper cover
ling ⇒ page 330
2 - Cover
❑ For towing eye.
3 - Bolts
❑ Qty. 8
❑ 2 Nm
4 - Spreader rivets
❑ Qty. 5
5 - Caps
❑ Qty. 2
ling ⇒ page 334
❑ Qty. 2
ling ⇒ page 334
7 - Trim strip
ling ⇒ page 334
8 - Reflector
❑ Qty. 2
ling ⇒ page 334
9 - Trim
❑ Qty. 2
10 - Trim strip
11 - Diffuser
2.2 Assembly overview - guides for bump‐

er cover
Note
Different versions; for allocation refer to ⇒ Electronic parts catalogue “ETKA”
2. Bumper, rear 325

1 - Impact bar
2 - Bolts
❑ Qty. 3 left
❑ Qty. 4 right
❑ 55 Nm
3 - Nuts
❑ Qty. 2 on each side for
guide bracket with tail
light
❑ 3.5 Nm
4 - Guide profile
❑ Left and right
❑ Is installed together
with tail light
5 - Bracket
❑ Not fitted on all ver‐
sions
6 - Bolts
❑ Only when bracket -5-
is installed
❑ Qty. 2
❑ 6 Nm
7 - Bolts
❑ For lateral guide.
❑ 6 Nm
8 - Guide profile
❑ Left and right
9 - Expanding nuts
11 - Nuts
❑ Qty. 4 for centre guide bracket
❑ 3.5 Nm
2.3 Assembly overview - add-on parts

⇒ o2.3.1 verview - add-on parts”, page 326
⇒ o2.3.2 verview - add-on parts, Alltrack”, page 327
⇒ o2.3.3 verview – add-on parts, R-Line models up to 06.2019”,
page 328
2.3.1 Assembly overview - add-on parts

1 - Bumper cover
ling ⇒ page 330
2 - Bolts
cover
3 - Bolts
cover
4 - Expanding nuts
5 - Towing eye cap
cover
6 - Spoiler
❑ Material PC/ABS
cover
moved
7 - Bolts
8 - Spreader rivets
9 - Cover
❑ Left and right
cover
❑ Only remove when bumper cover is removed
10 - Trim strip
❑ 3 parts, left, right and centre
❑ Engaged in bumper cover
11 - Cover
❑ Left and right
12 - Frame
❑ Left and right
13 - Dampers
❑ Cut to size according to template
2.3.2 Assembly overview - add-on parts, Alltrack
2. Bumper, rear 327

1 - Rear bumper cover

ling ⇒ page 330
2 - Dampers
❑ Cut to size according to
template
3 - Trim
❑ Extension of wheel
arch trim, left and right
❑ Engaged in rear bump‐
er cover -1-
❑ Remove only when rear
moved.
4 - Towing eye cap
❑ Engaged in rear bump‐
er cover -1-
5 - Trim strip
❑ Left and right
moved.
6 - Reflector
❑ Left and right
moved.
7 - Trim
❑ Left and right
❑ Remove only when rear bumper cover -1- is removed.
8 - Spoiler
❑ Material PC/ABS
❑ Engaged in rear bumper cover -1-
9 - Skid plate
❑ Material PC/ABS
❑ Engaged in rear bumper cover -1-
10 - Trim strip
❑ Centre
2.3.3 Assembly overview – add-on parts, R-Line models up to 06.2019

1 - Bumper cover
❑ Material: PP+EPDM-
TD10
ling ⇒ page 330
2 - Dampers
❑ Left and right
❑ Cut to size according to
template
3 - Towing eye cap
cover
4 - Bumper brackets
❑ Left and right
5 - Trim strip
❑ Left and right
cover
moved
6 - Centre trim strip
cover
moved
7 - Spoiler bracket
❑ Left and right
8 - Spoiler
❑ Material: PP+EPDM-
TD10
❑ Engaged in bumper cover
9 - Rear trim panel
❑ Left and right
10 - Rear spoiler trim
❑ Material: PP+EPDM-TD10
❑ Engaged in spoiler
2.4 Assembly overview - impact bar

2. Bumper, rear 329

1 - Impact bar
ling ⇒ page 342
❑ Vehicles with towing
bracket ⇒ page 506
2 - Cross panel
3 - Bolts
❑ Qty. 4 right
❑ Qty. 3 left
❑ 20 Nm +90°
2.5 Removing and installing bumper cover

Note
The removal and installation procedures for the bumper cover

may vary slightly, depending on vehicle model.

Removing
– Remove tail lights in side panel ⇒ Electrical system; Rep.

gr. 94; Tail lights; Removing and installing tail light.
– Undo bolts -3- in wheel housing (pointing upwards) on left
and right.
– Remove bolts -4- on left and right sides in area of wheel
housing liner.
2. Bumper, rear 331


– Remove spreader rivets -7- from underneath.
chanic.
– Pull bumper cover -1- out of guide fasteners on left and right
-2- of side panel -arrows a-.
– Detach rear bumper cover -1- from catches below tail lights
and in centre -arrows b-.
– Pull bumper cover -1- off vehicle in parallel movement
-arrows b-.
– Disconnect connectors from installed electrical components.
tions for parking aid ⇒ Electrical system; Rep. gr. 94; Parking
aid.
tions for park assist steering ⇒ Electrical system; Rep. gr. 94;
Park assist steering.
On vehicles 07/2019 ►, observe instructions and work specifica‐
tions for parking aid and park assist steering ⇒ Driver assist
systems; Rep. gr. 98; Fitting locations; Overview of fitting loca‐
tions - senders, sensors and control units in rear area of vehi‐
cle.
Installing


Further installation requires the assistance of a second me‐
chanic.
– If present, connect connectors to electrical components.
– Guide bumper cover -1- onto vehicle in a parallel movement
-arrows a-.
– Press bumper cover -1- onto guide brackets in centre as well
as on left and on right below tail lights -2- until it engages in
guide brackets -arrow b-.
– Press bumper cover -1- onto guides on left and right -5- of
side panel until they engage with each other -arrow b-.
– Observe gaps/shut lines ⇒ Body Repairs; Rep. gr. 00; Panel
gaps; Body – rear.
– Clip in spreader rivets -8- from underneath.
– On vehicles ► 06/2019 with lane change assist, the rear
radar system must be calibrated following every removal and
installation ⇒ Electrical system; Rep. gr. 96; Lights, bulbs,
switches – interior, anti-theft protection; Lane change assist.
– On vehicles 07/2019 ► equipped with lane change assist,
the rear radar system must be calibrated following each re‐
moval and every installation ⇒ Driver assist systems; Rep.
2. Bumper, rear 333

gr. 98; Fitting locations; Overview of fitting locations – send‐

ers, sensors and control units in rear part of vehicle.
Specified torques
♦ ⇒ o2.1 verview - bumper cover”, page 323
2.6 Removing and installing add-on parts

⇒ a2.6.1 nd installing diffuser, R-Line models as of 07.2019”,
page 334
⇒ a2.6.2 nd installing diffuser trim ,R-Line models as of
07.2019”, page 335
⇒ a2.6.3 nd installing upper centre trim strip, R-Line models as
of 07.2019”, page 336
⇒ a2.6.4 nd installing lower centre trim strip, R-Line models as
of 07.2019”, page 338
⇒ a2.6.5 nd installing outer trim strip, R-Line models as of
07.2019”, page 339
⇒ a2.6.6 nd installing end piece of trim strip, R-Line models as
of 07.2019”, page 340
⇒ a2.6.7 nd installing reflector, R-Line models as of 07.2019”,
page 341
2.6.1 Removing and installing diffuser, R-


Removing

mechanic.
ing this, hold diffuser -2- under tension.
– Remove diffuser -2-.
Installing
Torque settings
07.2019”, page 324
2.6.2 Removing and installing diffuser

trim ,R-Line models as of 07.2019
2. Bumper, rear 335

Removing
– Remove diffuser ⇒ page 334 .

mechanic.
ing this, hold trim -2- under tension.
– Remove trim -2-.
Installing
Torque settings
07.2019”, page 324
2.6.3 Removing and installing upper centre

trim strip, R-Line models as of 07.2019

Removing
– Remove trim strips ⇒ page 339 .

mechanic.
Installing
Torque settings
07.2019”, page 324
2. Bumper, rear 337

2.6.4 Removing and installing lower centre

Removing
– Remove diffuser trims ⇒ page 335 .

mechanic.

Installing
Torque settings
07.2019”, page 324

Removing

mechanic.
2. Bumper, rear 339


Installing
Torque settings
07.2019”, page 324
2.6.6 Removing and installing end piece of


Removing
– Remove outer trim strip ⇒ page 339 .

– Release catch -1- using removal wedge -3409-. When doing
this, hold end piece of trim strip -2- under tension.
– Remove end piece of trim strip -2-.
Installing
Torque settings
07.2019”, page 324
2.6.7 Removing and installing reflector, R-

2. Bumper, rear 341

Removing

ing this, hold reflector -2- under tension.
– Remove reflector -2-.
Installing
Torque settings
07.2019”, page 324
2.7 Removing and installing impact bar


Removing

– Lift impact bar -1- upwards -arrow- out of tabs in cross panel
-2-.
Installing
2. Bumper, rear 343

– Guide guides of impact bar -1- from top to bottom -arrow-

into tabs in cross panel -2-.
Specified torques
♦ ⇒ o2.4 verview - impact bar”, page 329
2.8 Repairing bumper cover
Note
♦ If bumper cover is damaged, determine whether plastic can

be repaired before renewing bumper.
♦ On vehicles with lane change assist, lane change assist
control units -J769 / J770- are located behind bumper cover.
♦ With this equipment, the bumper cover may not be repaired
in this area. The bumper cover must be renewed in this
instance.
Description under: ⇒ General Information; Body Repairs, Gen‐

eral Body Repairs; Plastic repair procedures

2.9 Installing brackets for parking aid sys‐

tem
♦ Installation tool for PDC bracket -VAS 6614-
Materials
♦ Cleaning solution ⇒ Electronic parts catalogue
“ETKA”
Note
Observe manufacturer's instructions enclosed in the packaging.
Installing brackets
Note
The brackets are installed after the bumper cover has been painted.
2. Bumper, rear 345

The 4 markings for brackets -1- can be found on the inside of

the bumper cover.
mined.
the drill bit -VAS 6614/4- -3- from the supplied tool kit.

– Fit screw-hole punch -VAS 6614/9- with bolt head -1-, wash‐
er -2- and counter-support -3- from inside of bumper cover
-5-.
– Tighten screw-hole punch -1-.
Note

– Remove screw-hole punch and make next holes.
– Thoroughly clean bumper cover and bracket with cleaning
solution.
2. Bumper, rear 347

Alignment of brackets
– Brackets -1- must be aligned in such a way that exterior
sensor connections -arrows- point to centre of vehicle.
– Connections of interior sensors -arrows- point outwards.
Note
♦ The centring pin has a diameter of 18.2 mm, the hole has a diameter of 18.4 mm.
♦ Nevertheless, the centring pin is suitable for centring the support.


– Push bracket -2- onto centring pin -VAS 6614/3- -1-.
tainer.
brackets.
minimum curing period 3)
.
3) Minimum drying time
move it.
2. Bumper, rear 349

2.10 Installing brackets for park assist steer‐

ing
♦ Assembly tool for park assist steering sensors -VAS 895
003-
Materials
♦ Cleaning solution -D 009 4) 1
401 04-
4) Observe manufacturer's instructions enclosed in the packaging.
Installing brackets
Note
The brackets are installed after the bumper cover has been
painted.

The markings for the bracket -1- can be found on the inside of
the bumper cover.
mined.
the drill in the tool kit -3-.
– Set hole puncher in position with bolt head -1-, washer -2-
and thrust bearing -3- from inside bumper cover -5-.
– Tighten hole puncher -1-.
Note

2. Bumper, rear 351

– Remove hole punch and make next holes.

– Push bracket -2- onto centring pin -1-.
tainer.
brackets.
minimum curing period ⇒ page 352 .
Minimum drying time

move it.
2. Bumper, rear 353

64 – Glazing
1 Repair instructions
⇒ c1.1 uring periods for bonded windows”, page 354
⇒ r1.2 epair”, page 354
⇒ i1.3 nstructions for bonded windows”, page 355
⇒ o1.4 ld undamaged windows for fitting”, page 356
⇒ n1.5 ew windows for installing”, page 357
⇒ b1.6 ody flange for fitting”, page 357
⇒ o1.7 ff excess adhesive”, page 359
1.1 Minimum curing periods for bonded

windows
Note
♦ There are special requirements for renewing bonded win‐

dows.
♦ The vehicle is safe to use only after the minimum curing
period has elapsed.
2-pack window adhesive

The minimum curing period for 2-pack window adhesive is 2
hours for all windows.
The specified minimum curing period remains the same even if
1-pack window adhesive needs to be used for additional residu‐
al work or for sealing purposes.
Minimum curing period is the time from bonding the window
until vehicle may be used. During this time, the vehicle must be
standing on a level surface at room temperature (at least 15°C).
1-pack window adhesive
The minimum curing period for 1-pack window adhesive is 6
hours for all windows.
Minimum curing period is the time from bonding the window
until vehicle may be used. During this time, the vehicle must be
standing on a level surface at room temperature (at least 15°C).
1.2 Window repair
Note
♦ Before renewing windscreen, explore possibilities of repair‐

ing damage to glass.
♦ Damaged windscreens can be repaired with the window re‐
pair kit -VAS 6092-.
♦ This damage must remain within a certain size or position.
♦ Each window repair kit comes with a set of instructions.
354 Rep. gr.64 - Glazing

♦ Window repair kit -VAS 6092-
1.3 Installation instructions for bonded win‐

dows
⇒ i1.3.1 nstructions”, page 355
⇒ 1.3.2 , page 355
1.3.1 Fitting instructions

– Apply adhesive sealing material -1- in continuous bead,
holding applicator at right angle to window -2-.
♦ Adhere to the specified dimensions for the adhesive beads.

♦ Using 2 suction lifters -V.A.G 1344-, install glass pane in
window aperture, align to centre and press in onto spacing
lip.
♦ Replace stickers (e.g. for airbag) if there were any.
1.3.2 Materials
Note
The current material numbers for the chemical materials listed

should be gleaned from the Electronic parts catalogue “ETKA”.
♦ 2-pack window adhesive 1) 2) 3)
1. Repair instructions 355

♦ 1-pack window adhesive 1) 2)
♦ Activator 1)
♦ Primer 1)
♦ Cleaning solution 1)
♦ Primer applicator
♦ Adhesive remover 1)
♦ Cutting cord 357 853 999 4
♦ Wire reel 4
VAS 6452/1
♦ Cutting cord 4
6888/1
1)Observe instructions for use on the information sheet provi‐

ded by the manufacturer.
2) Observe minimum curing period ⇒ page 354 .
3)Double cartridge gun -VAS 5237- must be used to apply
these materials.
4) The cutting cords stated above can be used alternatively to
the cutting wires, and vice versa. They are designated for single
use.
1.4 Preparing old undamaged windows for

fitting
Cutting back adhesive bead
♦ If an undamaged window is being re-used, cut back the re‐
sidual adhesive sealant to 1 to 2 mm shortly before bonding
it back in.
♦ Do not damage primer and ceramic coating when doing this.
♦ Keep bonding surface free of dirt and grease.

♦ Do not treat bonding surface with activator, glass/paint pri‐
mer or cleaning solution immediately after cutting back.
♦ The remaining material is required as a base for better adhe‐
sion of the new adhesive sealing material to be applied.
• Exception: if bonding is performed later than one day after
cutting back adhesive bead, the remaining residual material
must be activated with activator.

– Apply activator evenly in one stroke using applicator.
NOTICE
Risk of damage to paintwork from activator.
– Apply activator neatly onto adhesive bead, do not spill.
Allow to air dry for approx. 10 minutes.
1.5 Preparing new windows for installing
Note
♦ The application area for the adhesive bead is not precoated

or primed.
♦ The relevant area is a ceramic coating.
♦ No windows are precoated.
♦ The sealing lip is included with a new windscreen.
– Using cleaning solution, clean edge of window all round to a

width of 20 mm.
– Then rub edge of window dry using a lint-free cloth.
– Using applicator -2-, apply primer -3- evenly in one pass
onto ceramic coating -1-.
♦ Allow to air dry for approx. 10 minutes.
1.6 Preparing body flange for fitting

♦ Cut back residual adhesive sealant to 1 … 2 mm shortly
before bonding window back in.
♦ Do not damage primer and paintwork structure when doing
this.

♦ Keep bonding surface free of dirt and grease.

♦ Do not treat bonding surface with activator, glass/paint pri‐
mer or cleaning solution immediately after cutting back.
♦ The remaining material is required as a base for better adhe‐
sion of the new adhesive sealing material to be applied.
– Cut back remaining material on body flange with U-shaped
blade -V.A.G 1561/3-, but do not remove completely.
• Exception: if bonding is performed later than one day after
cutting back adhesive bead, the remaining residual material
must be activated with activator.
– Apply activator evenly in one stroke using applicator.
NOTICE
Risk of damage to paintwork from activator.
– Apply activator neatly onto adhesive bead, do not spill.
♦ If the window flange has been repaired or partially renewed,

the area concerned must be cleaned and primed again after
painting.
– Clean metal flange all around using cleaning solution.
– Then rub edge of window dry using a lint-free cloth.
– Apply glass/paint primer evenly in one pass onto paintwork
structure using applicator.
Note
It is possible that a laser weld seam lies outside the area of the
adhesive bead. In this case, the exposed weld seam must be
sealed with glass adhesive before bonding the window.
– If laser weld seam -3- on metal flange -4- is not covered by

existing adhesive bead -1-, coat laser weld seam -3- with
primer -3-. Then fill laser weld seam with glass adhesive -1-.

Touching up paint damage

Paint structure must be restored after damage to the paintwork
according to specifications in the “Paint” workshop manual.
1.7 Cleaning off excess adhesive

– Use adhesive remover as cleaning agent. Safety precau‐
tions must be observe for all work procedures.
Note
♦ When cleaning the vehicle interior, do not press freshly in‐

stalled window outwards.
♦ Otherwise, the window will be detached.
– First, clean the painted surface roughly with a dry cloth.

Remove residue using adhesive remover.
– Cleaning plastic trim: Allow adhesive sealant to cure (ap‐
prox. 1 hour) and then peel off.

2 Windscreen
⇒ o2.1 verview - windscreen”, page 360
⇒ a2.2 nd installing windscreen”, page 361
2.1 Assembly overview - windscreen
1 - Windscreen
ling ⇒ page 361
2 - Water deflector
3 - PUR adhesive sealant
❑ Cross section of
bead: width = 7 mm
-dimension a-, height =
10 mm -dimension b-
(including precoating,
residual material on
window glass and win‐
dow flange).
❑ Minimum curing period
⇒ page 354 .
❑ Adhesive bead starts
and ends at -arrow-
4 - Body flange
❑ Touch up paintwork
damage.
5 - Gaps/shut lines
❑ Must be uniform.
6 - Seal
7 - Windscreen adjuster
❑ 443 845 631 A
❑ Remove 2 hours af‐
ter installation of wind‐
screen.
8 - Windscreen seal
❑ Is part of windscreen
ling plenum chamber cover ⇒ page 17

2.2 Removing and installing windscreen

⇒ a2.2.1 nd installing windscreen”, page 361
⇒ b2.2.2 roken windscreen”, page 368
2.2.1 Removing and installing windscreen
Note
♦ The removal of a bonded window is described using the

Removal kit for flush bonded windows -V.A.G 1474 A-.
♦ Alternatively, you can also use the cutting tool for bonded
windows -VAS 6452-.
♦ Another alternative is to use the window removal set -VAS
6888-.

♦ Removal kit for flush bonded windows -V.A.G 1474 A- or
Removal kit for flush bonded windows -VAS 6452-
♦ Suction lifter -V.A.G 1344-
♦ Cutting tool -V.A.G 1351-
♦ Windscreen removal kit -V.A.G 1755-
♦ Hand-cartridge gun -V.A.G 1628-
♦ Cartridge heater -V.A.G 1939-
♦ Electric cutter -V.A.G 1561 A-

♦ Blade, offset -V.A.G 1561/2-
2. Windscreen 361
♦ Double cartridge gun -VAS 5237-
Removing
– Remove A-pillar upper trims on left and right ⇒ General body
repairs, interior; Rep. gr. 70; Trims, interior; Removing and
installing A-pillar trim.
– Remove left and right sun visors ⇒ General body repairs,
interior; Rep. gr. 68; Equipment; Removing and installing
sun visor.
– Remove interior mirror ⇒ General body repairs, interior; Rep.
gr. 68; Interior mirror; Removing and installing interior mirror.
– On vehicles ► 06/2019 with front camera for driver assist
systems -R242-, remove front camera ⇒ Electrical system;
Rep. gr. 96; Front camera for driver assist systems; Remov‐
ing and installing front camera for driver assist systems.
– On vehicles 07/2019 ► equipped with a front camera for
driver assist systems -R242-, remove front camera ⇒ Driver
assist systems; Rep. gr. 98; Fitting locations; Overview of fit‐
ting locations – senders, sensors and control units in centre
part of vehicle.
– Lower moulded headliner in area of windscreen ⇒ General
body repairs, interior; Rep. gr. 70; Roof trims; Removing and
installing moulded headliner.
– Moulded headliner can now be lowered sufficiently to allow
windscreen to be cut out without damage occurring to moul‐
ded headliner.
– Removing plenum chamber cover ⇒ page 17 .

Only for vehicles with windscreen heater

– Unscrew securing nut -6-.
– Bond cable -5- to windscreen.
– Separate electrical connectors -1 and 3-.
– Bond cables -2 and 4- to windscreen.
2. Windscreen 363
– Slide suitable covering film -V.A.G 1474/8- between wind‐

screen and dash panel.
– Pull end of cutting cord -1- through adhesive sealing material
into inside of vehicle using awl -V.A.G 1474/2-.
– Secure inside end of cutting cord against falling out using
Pull toggle -V.A.G 1351/1- -3-.

– Insert cutting cord -2- into window flange using tube -1-.
– Place cutting cord around the front windscreen.
– Ensure that cutting cord lies under front windscreen in cor‐
ners.
2. Windscreen 365
– Attach the ends of cords -4- on removal kit for flush bonded
windows -VAS 6452- -1-.
– Put cutting cord around suction cups of reel device -arrow-.
– Use plastic wedge -2- to press cutting cord against wind‐
screen while cutting in order to have clearance at window
flange and dash panel.

– Position removal kit for flush bonded windows -VAS 6452- at

lower corners of windscreen.
– Change permanently position of left removal kit for flush
bonded windows -VAS 6452- from “position I”to “position III”
and cut windscreen free.
– Change position of right removal kit for flush bonded win‐
dows -VAS 6452- from “position IV”to “position VI” and cut
windscreen free.
– Use 2 suction lifters -V.A.G 1344- to lift off windscreen from
vehicle.
Installing
– On vehicles ► 06/2019 with front camera for driver assist
systems -R242-, install front camera ⇒ Electrical system;
Rep. gr. 96; Front camera for driver assist systems; Remov‐
ing and installing front camera for driver assist systems, and
calibrate front camera ⇒ Running gear, axles, steering; Rep.
gr. 44; Front camera for driver assist systems; Calibrating
front camera for driver assist systems.
– On vehicles 07/2019 ► equipped with a front camera for
driver assist systems -R242-, install and calibrate front cam‐
era ⇒ Driver assist systems; Rep. gr. 98; Fitting locations;
2. Windscreen 367
Overview of fitting locations – senders, sensors and control

units in centre part of vehicle.
– Preparing old undamaged window for glazing ⇒ page 356 .
– Preparing new window for glazing ⇒ page 357 .
– Preparing body flange for glazing ⇒ page 357 .
– Installation instructions ⇒ page 355
– Minimum curing period ⇒ page 354
– After inserting, secure windscreen on roof using adhesive
tape.
2.2.2 Removing broken windscreen

Removal of a broken windscreen is performed in the same
manner as the removal a broken rear window ⇒ page 373 .

3 Rear windscreen
⇒ o3.1 verview - rear window”, page 369
⇒ a3.2 nd installing rear window”, page 370
3.1 Assembly overview - rear window
1 - Rear windscreen
ling ⇒ page 370
❑ Cross section of
bead: width = 7 mm
-dimension a-, height =
10 mm -dimension b-
dow flange).
⇒ page 354 .
and ends at -arrow-
3 - Spacer
4 - Body flange
5 - Connection for rear win‐
dow heating
6 - Aerial connection
3. Rear windscreen 369

3.2 Removing and installing rear window

⇒ a3.2.1 nd installing rear window”, page 370
⇒ b3.2.2 roken rear window”, page 373
3.2.1 Removing and installing rear window
Note

windows -VAS 6452-.
6888-.

Removing
Note
If the rear window is reused, make sure that the electrical connections for the rear window heating are not
damaged.

– On vehicles with side spoiler, remove side spoiler ⇒ page

398 .
– Pull off connectors for rear window heating and window aer‐
ial.
– Using the awl -V.A.G 1474/2- pull cutting cord -1- inwards
through adhesive sealant at the location -arrow- shown in
the illustration.
– Use the pull toggle -V.A.G 1351/1- to secure end of cutting
cord before pulling it out.
– Lay cutting cord around rear window and guide second end
of cord inwards.
– Attach end of cutting cord to removal kit for flush bonded
windows -VAS 6452- or reel device -V.A.G 1654 A-.
Note
It is essential to use the protective film or the plastic strip -V.A.G 1474/15- in order to protect the metal
flange.

– Carefully guide protective film -4- or plastic strip -V.A.G

1474/15- between rear window and metal flange.
– Place reel device -V.A.G 1654 A- in indicated position.
– Cut rear window free by appropriate movement of reel de‐
vice -V.A.G 1654 A-.
– Use wedge -V.A.G 1474/5- to press cutting cord -3- against
rear window glass while cutting in order to have clearance at
body flange.
– Hold rear window on 2 suction lifters while cutting free.
– Pull rear window off rear lid using the 2 suction lifters.
Installing
– On vehicles with side spoiler, install side spoiler ⇒ page
398 .

3.2.2 Removing broken rear window

– Protect body and interior from glass splinters.
– Remove pieces of glass up to adhesive sealing material.
– Pull off connections for rear window heating and aerial.
– Cover flange -2- all round with textile-reinforced adhesive
tape.
CAUTION
Risk of injury to hands and eyes caused by glass splinters.
Risk of cuts.
– Wear protective gloves!
– Cut through adhesive sealant (with glass remains) in window

opening using electric cutter -V.A.G 1561 A- and U-shaped
blade -V.A.G 1561-.

4 Side window
⇒ o4.1 verview - rear side windows”, page 374
⇒ a4.2 nd installing rear side window”, page 375
4.1 Assembly overview - rear side windows
1 - Side window
❑ Removing side window
⇒ page 375 .
❑ Cross section of bead:
height = 10 mm
-dimension a-, width =
6.5 mm -dimension b-
dow flange).
⇒ page 354 .
and ends at -arrow-
3 - Body flange
4 - Clip
❑ Qty. 2
❑ Are part of side win‐
dow.

4.2 Removing and installing rear side win‐

dow
⇒ a4.2.1 nd installing rear side window”, page 375
⇒ b4.2.2 roken rear side window”, page 377
4.2.1 Removing and installing rear side win‐

dow
Note

windows -VAS 6452-.
6888-.

Removing
Note
♦ Removal and installation are described only for the left side
window. Removal and installation of the right window are
similar.
♦ Instead of reel device -V.A.G 1654- -3-, reel device -V.A.G
1654 A- -3- can be used.
4. Side window 375

– Remove side trim ⇒ General body repairs, interior; Rep.

gr. 70; Trims, interior; Fitting location overview - trims, interi‐
or.
Protect surrounding parts against damage.

– Using the awl -V.A.G 1474/2-, pull cutting cord -1- through
the adhesive sealant at the place shown in the illustration.
– Press seal aside so that it is not damaged.
– Insert cutting cord -3- behind seal in window flange with aid
of tube -1-.
– Secure one end of cord -3- to pull handle -V.A.G 1351/1- -2-
to counterhold.
– Pull other end of cord -2- through adhesive sealant as well.

– Secure other end of cord to reel device -V.A.G 1654 A- -3-.

Note
♦ In the area of the clips -4- greater force may need to be

applied.
♦ In the case of windows with a trim strip, the retaining hooks
of the trim strip might become damage during the cutting
process.
♦ If the retaining hooks are damaged, a new window must be
installed.
– Turn reel device -V.A.G 1654 A- -3- accordingly and cut

window free.
– Press cutting cord against window glass with plastic wedge
during cutting process, in order to have clearance at window
flange.
– Instead of reel device -V.A.G 1654- -3-, reel device -V.A.G
1654 A- -3- can be used.
– One suction cup can be removed from the reel device -

V.A.G 1654- -3- as shown in illustration. This ensures that
the reel device -V.A.G 1654 A- -3- roller can be guided clos‐
er to the window flange.
Installing
– Insert side window with seal -1- in guide -3- -arrow-, and
press it on.
– Secure side window using adhesive tape.
4.2.2 Removing broken rear side window

Removing a broken side window is performed in the same man‐
ner as removing a broken rear window ⇒ page 373 .
4. Side window 377

5 Door windows
⇒ o5.1 verview - front door window”, page 378
⇒ o5.2 verview - rear door window”, page 378
⇒ a5.3 nd installing front door window”, page 379
⇒ a5.4 nd installing rear door window”, page 382
⇒ a5.5 nd installing fixed front door window”, page 384
⇒ a5.6 nd installing fixed rear door window”, page 386
5.1 Assembly overview - front door window
1 - Door window
ling ⇒ page 379
2 - Locking lug
❑ Component part of
fixed door window
3 - Fixed door window
ling
4 - Bolt
❑ Qty. 3
❑ 3 Nm
5 - Stickers
❑ Diameter 28 mm
hesive tape.
openings completely
6 - Locking lug
❑ Part of mounting for
door window
❑ Qty. 2
❑ For securing the door
window on window reg‐
ulator
5.2 Assembly overview - rear door window

1 - Door window
ling ⇒ page 382
2 - Spreader pin
❑ Together with spreader
plug for securing door
window.
3 - Spreader plug
❑ Together with spreader
pin for securing door
window.
ling ⇒ page 203
5 - Window regulator motor
ling ⇒ page 200
6 - Bolt
❑ Qty. 3
❑ 3 Nm
7 - Bolt
❑ Qty. 2
❑ 6 Nm
8 - Stickers
❑ Qty. 2
❑ Diameter 28 mm
hesive tape.
openings completely
9 - Locking lug
❑ Qty. 2
❑ Component part of fixed door window
10 - Fixed door window
5.3 Removing and installing front door win‐

dow
5. Door windows 379

Note
window. The left side is similar.
Removing


door trim.
– Remove door inner cover -3- ⇒ page 136 .
– Lower door window -1- until retaining hooks -2- for door
window are accessible.
Note
♦ If this part of the work cannot be done due to a fault in the window regulator motor, the window regulator
motor can be removed -4-.
♦ The window can then be pushed to required working position.
– Carefully press locking hooks -2- through opening in the win‐

dow. Lift door window slightly to prevent it from falling back
again in retaining hook.
– Lift rear of door window -1- and swing forwards out of win‐
dow channels -arrows b-.
Installing
5. Door windows 381

– Swing door window -1- into window channels -3- -arrows a-.
Note
Ensure that door window is properly located in window channel.
– Guide door window without force into mounting for door win‐
dow of window regulator -3-.
– Align door window with rear window frame.
– Press door window -1- into mounting for door window until
the retaining hooks -2- in the door window engage.
– Before the inner door cover, the cable feed and the door trim
are installed, carry out a functional check.
5.4 Removing and installing rear door win‐

dow
Removing


trim.
– Lower door window -1- until spreader pin -2- and spreader
plug -3- in cut-out of window regulator -5- are accessible.
Note
If work is not possible due to a malfunction caused by the electric window regulator, the window regulator
motor -4- must be unbolted. Window can then be pushed to required working position.
– Screw a 5 mm bolt (approx. 70 mm long) into spreader pin

-2-, and pull bolt with spreader pin out of spreader plug -3-
-arrow a-.
– Screw an 8 mm bolt (approx. 80 mm long) into spreader plug
-3-.
Note
When screwing bolt into spreader plug, do not apply excessive pressure on plug. It otherwise falls inwards
into door.
– Pull spreader plug -3- out of window regulator guide -5- and
thus out of door window -arrows b-.
– Remove B-pillar trim ⇒ page 434 .
– Pull door window -1- upwards at an angle -arrow c- to vehi‐
cle exterior out of window slot.
Installing
Note
♦ When installing door window, always renew spreader plug

and spreader pin.
♦ Before inserting spreader plug -2- and spreader pin -3-,
check window glass -1- for damage.
5. Door windows 383

– Insert spreader plug -3-, and centre it in the middle with the
window glass -1- removed -arrows a-.
– Push spreader pin -2- flush -arrows b- into spreader plug -3-.
– Insert door window -1- into door -arrows d-, and push it into
window regulator guide -4-.
– Engage door window -1- in window regulator by pressing
slightly from above.
– Then perform remaining installation in reverse order of re‐
moval.
– Carry out functional check before fitting door trim.
5.5 Removing and installing fixed front

door window
Removing


door trim.
– Pull off sticker -5-, and unscrew bolt -4-.
– Pull inner seal off metal flange.
– Guide release tool -T10236- one after the other under both
clips -2-.
– Push door window -1- outwards slightly when doing this
-arrows a- until clips -2- are pressed out of door -3-.
– Then, pull door window -1- with web upwards -arrow b- out
of door -3-.
Installing
5. Door windows 385

– Slide door window -1- into door -arrow a-.

– Push door window -1- against door until clips -2- engage
audibly -arrow b-.
– Door window seal must be seated firmly in door frame -3-.
– Tighten bolts -5-, and attach sticker -4-.
Specified torques
♦ Fixed front door window ⇒ page 378
5.6 Removing and installing fixed rear door

window
Removing

– Remove door trim panel ⇒ General body repairs, interior;

Rep. gr. 70; Rear door trim panels; Removing and installing
rear door trim panel.
– Remove window slot seal ⇒ page 229 .
– Pull off sticker -2-, and unscrew bolts -3-.
– Pull inner seal off metal flange.
– Guide release tool -T10236- one after the other under both
clips -4-.
– When doing this, push door window -1- outwards slightly
-arrow a- until clips -4- are pushed out of door.
– Then, pull door window -1- with web upwards -arrow b- out
of door.
Installing
5. Door windows 387

– Slide door window -1- into door -arrow a-.

– Push door window against door until clips -2- engage audibly
-arrows b-.
– Tighten bolts -4-, and attach sticker -5-.
– Pull inner seal around flange.
Specified torques
♦ Fixed rear door window ⇒ o5.2 verview - rear door window”,
page 378 .

66 – Exterior equipment
1 Radiator grille and front trim
⇒ o1.1 verview - radiator grille”, page 389
⇒ a1.2 nd installing radiator grille”, page 392
⇒ a1.3 nd installing radiator grille seal, R-Line models as of
07.2019”, page 394
1.1 Assembly overview - radiator grille

⇒ o1.1.1 verview - radiator grille”, page 389
⇒ o1.1.2 verview - radiator grille GTE (hybrid)”, page 390
⇒ o1.1.3 verview – radiator grille, R-Line models as of 07.2019”,
page 391
1.1.1 Assembly overview - radiator grille
Note
Depending on the respective model, optical differences and dif‐

ferent versions must be taken into account; for allocation refer
to ⇒ Electronic parts catalogue “ETKA”
1. Radiator grille and front trim 389

1 - Radiator grille
ling ⇒ page 392
2 - Bolt
❑ Qty. 4
❑ 2 Nm
3 - Bumper cover
ling ⇒ page 293
4 - Badge
ling ⇒ page 494
1.1.2 Assembly overview - radiator grille »GTE« (hybrid)
390 Rep. gr.66 - Exterior equipment

1 - Radiator grille
ling ⇒ page 392
2 - Seal
❑ Clipped into radiator
grille.
3 - Removing and instal‐
ling actuator for high-voltage
charging flap lock 1 -F496-
ling ⇒ page 175
4 - Bolts
❑ Qty. 3
❑ 2 Nm
5 - Immediate charging button
-E766-
ling ⇒ page 106
6 - Bolts
❑ Qty. 2
❑ 2 Nm
7 - Bolts
❑ Qty. 4
❑ 2 Nm
8 - Charging flap unit
ling ⇒ page 104
9 - Cover
10 - Tailgate
11 - Badge
12 - Badge
1.1.3 Assembly overview – radiator grille, R-Line models as of 07.2019

1 - Seal
ling ⇒ page 394
2 - Bolts
❑ Qty. 4
❑ 2 Nm
3 - Radiator grille
ling ⇒ page 392
4 - Adaptive cruise control
unit -J428-
ling ⇒ Driver as‐
sist systems; Rep.
gr. 98; Senders/sen‐
sors/control units; Re‐
moving and installing
adaptive cruise control
unit -J428-
5 - Badge
ling ⇒ page 494
6 - Badge
❑ Model designation R-
Line
ling ⇒ page 494
1.2 Removing and installing radiator grille

Removing


– Slightly pull off radiator grille -1- on top -arrows a- to detach
radiator grille from catches -3-.
– Pull radiator grille -1- out of catches -4- on bumper cover
-arrows b-.
– On vehicles with charging socket, separate electrical con‐
nectors for actuator and immediate charge button -E766- ⇒
page 106 .
Installing

– On vehicles with charging socket, join electrical connectors

for actuator and immediate charge button -E766- ⇒ page
106 .
– Insert radiator grille -1- in front bumper cover, and centre it.
– With slight pressure, push radiator grille -1- into lower catch‐
es of bumper cover -arrows a-.
– With slight pressure, push radiator grille -1- into upper catch‐
es of bumper cover -arrows b-.
Specified torques
♦ ⇒ o1.1 verview - radiator grille”, page 389
1.3 Removing and installing radiator grille

seal, R-Line models as of 07.2019

Removing
– Using removal wedge -3409- -2-, lever out seal -1- at catch‐
es -3-.
Installing

2 Spoiler
⇒ o2.1 verview - spoiler”, page 396
⇒ a2.2 nd installing spoiler”, page 398
2.1 Assembly overview - spoiler

⇒ i2.2.1 nstructions for bonded spoilers”, page 398
⇒ o2.1.1 verview - side spoiler”, page 396
⇒ o2.1.2 verview - roof spoiler, R-Line”, page 396
2.1.1 Assembly overview - side spoiler
1 - Side spoiler
❑ With adhesive tape.
ling ⇒ page 398
2 - Seal
❑ Part of side spoiler
3 - Pull-off tab
❑ Part of adhesive tape
on side spoiler
4 - Bonding surface
❑ Primer area
2.1.2 Assembly overview - roof spoiler, »R-Line«

1 - Roof spoiler
❑ Bonded with double-si‐
ded adhesive tape and
3.5 mm bead of PUR
adhesive; for allocation
refer to ⇒ Electronic
Parts Catalogue “ET‐
KA”
ling ⇒ page 403
2 - Right side spoiler
❑ Secured with double-si‐
ded adhesive tape
ling ⇒ page 398
3 - Trim, roof spoiler
❑ For high-level brake
light
ling ⇒ page 403
4 - Left side spoiler
❑ Secured with double-si‐
ded adhesive tape
ling ⇒ page 398
2. Spoiler 397
2.2 Removing and installing spoiler

⇒ i2.2.1 nstructions for bonded spoilers”, page 398
⇒ a2.2.2 nd installing side spoiler”, page 398
⇒ a2.2.3 nd installing side spoiler, R-Line”, page 401
⇒ a2.2.4 nd installing roof spoiler, R-Line”, page 403
2.2.1 Installation instructions for bonded

spoilers
Note
♦ The part numbers of the materials can be found in the

⇒ Electronic parts catalogue “(ETKA)”.
♦ The spoilers are bonded in the factory using double-sided
adhesive tape.
♦ The spoilers are primed by the supplier and delivered with
double-sided adhesive tape.
♦ Do not use cutting wire to remove the spoilers.
♦ The temperatures of the room, work bay and vehicle must

be approximately the same (at least 15°C).
♦ Remove existing adhesive tape residues with adhesive re‐
mains remover -VAS 6349-.
♦ Always use a clean, lint-free cloth for cleaning.
♦ Immediately before attaching special add-on parts, clean
exterior areas using adhesive remover and then carefully
remove dirt, grease, wax and other impurities using plastic
cleaner.
♦ Remove backing only immediately before installation.
2.2.2 Removing and installing side spoiler


Removing
Note
♦ The illustrations show the left-hand side. The right side is analogous.
♦ When the side spoiler is removed the adhesive sections are damaged, meaning that the side spoiler
cannot be re-used.
♦ Always install a new side spoiler.
– Apply hot air to side spoiler -1- in area of adhesive strips -2-
using hot air blower -V.A.G 1416-.
– Pull side spoiler -1- off rear window -arrow a-, and pull it off
downwards -arrow b-.
2. Spoiler 399
Installing
Note
♦ The illustrations show the left-hand side. The right side is analogous.
♦ The side spoiler -1- is bonded with double-sided adhesive tape -2-.
Adhere to the installation instructions for bonded spoilers.

– Clean bonding area of rear lid with cleaning solution.
– Allow cleaning solution to evaporate.
• (At least 5 minutes).
– Pull backing off upper double-sided adhesive tape.
– Slide side spoiler -1- under roof spoiler -arrows a-, and align
side spoiler.
– Firmly press side spoiler -1- onto roof spoiler.
– Align side spoiler on rear lid.

– Pull backing off double-sided adhesive tape using removal

aid -arrows b-.
– Firmly press side spoiler -1- onto rear lid -arrows c-.
2.2.3 Removing and installing side spoil‐

er, »R-Line«
Note
♦ The removal and installation procedure is for the left side. The right side is analogous.
♦ The side spoiler cannot be removed without damage.
2. Spoiler 401
Removing
– Apply hot air to side spoiler -1- in area of adhesive strips -2-
– Carefully pull side spoiler -1- off rear window, and carefully
pull off roof spoiler in -direction of arrow-.

Installing
Adhere to the installation instructions for bonded spoilers ⇒
page 398 .
– Pull backing off upper double-sided adhesive tape.
– Slide side spoiler -1- under roof spoiler -arrows a-, and align
side spoiler.
– Firmly press side spoiler -1- onto roof spoiler.
– Align side spoiler on rear lid.
– Pull backing off double-sided adhesive tape using removal
aid -arrows b-.
– Firmly press side spoiler -1- onto rear lid -arrows c-.
2.2.4 Removing and installing roof spoil‐

er, »R-Line«
2. Spoiler 403
♦ Pull handle -V.A.G 1351/1-
♦ Hand cartridge gun -V.A.G 1628-
Note
♦ The roof spoiler cannot be removed without being damaged.

♦ Clean dirt from all joints so that no paintwork is damaged when roof spoiler is removed.
♦ Mask of adjoining paintwork using adhesive tape to prevent damage.

Removing
– Remove right and left side spoilers ⇒ page 401 .
– Carefully release roof spoiler trim -2- from fasteners of roof
spoiler -1-.
– Thread cutting cord in at one corner between rear lid and
roof spoiler -1-.
– Cut through adhesive sealants up to middle of roof spoil‐
er using a “sawing” motion with both pull handles -V.A.G
1351/1- -2-.
– Also cut through sealant materials on other side.
– Remove roof spoiler -1-.
2. Spoiler 405
Installing
Adhere to the installation instructions for bonded spoilers ⇒
page 398 .
– Apply glass/paint primer evenly in one pass onto bonding
area of 1-component window adhesive using applicator.
– Observe drying time according to the safety data sheet.
– Using hand-cartridge gun -V.A.G 1628-, apply 1-component
window adhesive -2- in a bead of 3.5 mm in diameter on
inside of roof spoiler -1-.
– With the assistance of a second mechanic, fit roof spoiler -1-
in -direction of arrow- to rear lid.
Pull protective film off adhesive tape -3-, verify correct align‐
ment, and press on roof spoiler -1-.

– After brake light has been installed, fit roof spoiler trim -4-,
and engage it in roof spoiler -1-.
– Install side spoiler ⇒ page 401 .
2. Spoiler 407
3 Mouldings, trims, extensions

⇒ o3.1 verview - trim strip and covers”, page 408
⇒ o3.2 verview - side member trim”, page 410
⇒ o3.3 verview - water deflector”, page 412
⇒ o3.4 verview - heat shield”, page 413
⇒ a3.5 nd installing cover”, page 415
⇒ a3.7 nd installing side member trim”, page 428
⇒ a3.8 nd installing water deflector”, page 433
⇒ a3.9 nd installing B-pillar trim on door”, page 434
⇒ a3.10 nd installing trim strip”, page 436
⇒ a3.11 nd installing entry moulding”, page 442
⇒ a3.12 nd installing underbody heat shield”, page 445
3.1 Assembly overview - trim strip and cov‐

ers
⇒ o3.1.1 verview - door covers”, page 408
⇒ o3.1.2 verview - door covers (Alltrack)”, page 409
3.1.1 Assembly overview - door covers

1 - Rear trim cover for door

ling ⇒ page 415
ling trim strip ⇒ page
440
2 - Adhesive tape
❑ Part of moulding.
3 - Front door moulding
ling ⇒ page 415
ling trim strip ⇒ page
440
4 - Clip
❑ Qty. 6 for trim strip on
front door
rear door
5 - Seal
❑ Part of covers
6 - Clip
❑ Qty. 2 for each cover
7 - Trim
8 - Bolt
❑ Qty. 2 for each door
trim strip
❑ Specified torque:
1.5 Nm
9 - Grommet
❑ Qty. 6 for front door
❑ Qty. 4 for rear door
3.1.2 Assembly overview - door covers (Alltrack)
3. Mouldings, trims, extensions 409


ling ⇒ page 415
ling ⇒ page 415
3 - Adhesive tape
❑ Part of trim strip
4 - Clip
front door
rear door
5 - Protective sheet
❑ Covers adhesive tape.
6 - Clip
❑ Qty. 2 for each cover
7 - Bolt
❑ Qty. 2 for each door
trim strip
1.5 Nm
8 - Grommet
❑ Qty. 6 for front door
❑ Qty. 4 for rear door
9 - Bonding surface
3.2 Assembly overview - side member trim

⇒ o3.2.1 verview - side member trim”, page 410
⇒ o3.2.2 verview - side member trim, Alltrack”, page 411
3.2.1 Assembly overview - side member trim

1 - Side member trim

ling ⇒ page 428
2 - Clip
❑ Qty. 2
3 - Adhesive tape
5 - Clip
❑ Qty. 2
6 - Clip
❑ Qty. 6
7 - Bolt
❑ Qty. 2
1.5 Nm
8 - Spreader rivet
❑ Qty. 6
9 - Wing cover
10 - Grommet
❑ Qty. 8 for clip -2 and 6-
11 - Grommet
❑ Qty. 6 for spreader rivet
-8-
12 - Bonding surface
13 - Bonding surface
3.2.2 Assembly overview - side member trim, Alltrack

1 - Side member trim

ling ⇒ page 428
2 - Trim
3 - Adhesive tape
4 - Clip
❑ Qty. 2
6 - Spreader rivet
❑ Qty. 6
7 - Wheel housing trim
8 - Wheel housing liner
3.3 Assembly overview - water deflector
Note
The right side is shown. The left side is similar.

1 - Water deflector
ling ⇒ page 433
2 - Retaining strip
– During removal, drill out
rivet heads and chop
through rivet shanks.
3 - A-pillar
4 - Pop rivet
❑ Qty. 5
❑ Insert with pop rivet pli‐
ers -VAS 5072-
5 - Clip
❑ Position clip in wing
hole and press for‐
wards, afterwards turn
through 90°.
6 - Wings
ling ⇒ page 10
3.4 Assembly overview - heat shield

1 - Underbody heat shield

ling ⇒ page 445
2 - Dampers
❑ Additional, not fitted on
all models
3 - Clamping washer
4 - Left heat shield for centre
exhaust system
ling ⇒ page 445
5 - Heat shield for left rear si‐
lencer
ling ⇒ page 445
6 - Heat shield for centre ex‐
haust system
ling ⇒ page 445
7 - Heat shield for spare
wheel well
ling ⇒ page 445
8 - Heat shield for right rear
silencer
ling ⇒ page 445
9 - Additional underbody heat
shield
ling ⇒ page 445
❑ Not fitted on all models

3.5 Removing and installing cover

⇒ a3.5.2 nd installing door cover”, page 415
⇒ a3.5.3 nd installing door cover, Alltrack”, page 418
Note
♦ Before removing the trim strip, heat it up with a hot air blow‐
er -V.A.G 1416-.
grease.
♦ Letterings, films or emblems must be bonded in place imme‐
diately after cleaning.
♦ Remove protective foil immediately before installation.
♦ The working temperature is approx. 21°C.
Removing
3.5.2 Removing and installing door cover
Note
♦ The removal and installation sequence is for the front and rear door mouldings on the left only. Removal
and installation of the front and rear door mouldings on the right is analogous.
♦ Mouldings cannot be removed without damage.

Front door moulding

– Unscrew bolts -7- on inner side of door.
– Heat up trim strip in area of adhesive tape -3- using hot air
blower -V.A.G 1416-.
– Pull off cover -2- forcibly from door.
Rear trim cover for door
Installing

Front door moulding

– Check all grommets -8- and clips -4- for damage, and renew
them if necessary.
– Fit cover -2- with clips -4- into grommets -8-, and push it on.
– Pull off backing -5- from adhesive tape -3-.
– Press trim strip in area of adhesive tape -3- firmly onto door.
them if necessary.
Specified torques
♦ Bolts ⇒ page 408

3.5.3 Removing and installing door cover, Alltrack
Note
♦ The removal and installation sequence is for the front and rear door mouldings on the left only. Removal
and installation of the front and rear door mouldings on the right is analogous.
♦ Mouldings cannot be removed without damage.
Front door moulding



Installing
Front door moulding

them if necessary.
– Guide cover with seal -5- up to edge of door.
– Pull off backing from adhesive tape -2-.
them if necessary.
– Guide cover with seal -5- up to edge of door.

Specified torques
3.6 Removing and installing wheel arch

covers
⇒ a3.6.2 nd installing front wheel arch trims”, page 421
⇒ a3.6.3 nd installing rear wheel arch trims”, page 424

Preparing body component for bonding
– Remove existing adhesive residues of double-sided adhe‐
sive tape with adhesive remains remover -VAS 6349-.
– The cleaning guidelines for surrounding components are to
be observed ⇒ page 421 .
– New special add-on parts may be attached immediately at
the prescribed positions with the adhesive points.
If the body part has been repaired or partially replaced, the area
concerned must be cleaned again after painting.
Note
♦ Gaps/shut lines should be kept to an absolute minimum.

♦ Use adhesive tape to secure add-on parts in position during
minimum curing time.
♦ The surfaces to be bonded must be free from impurities
♦ If no cleanser is named in the repair procedure, use silicone
remover -LSE 020 100 A3-.
– Remove adhesive residue using adhesive remover -D 002

000 10-.
– Clean bonding surface for adhesive tape twice thoroughly
using cleaning solution and allow to flash-off.
♦ Allow to air dry for approx. 10 minutes.
Minimum drying time
Note
The vehicle is safe to use only after the minimum curing period
has elapsed.
The minimum curing period for newly bonded attachments is 3

hours.
The minimum curing time is the time from bonding the add-on
parts until the vehicle may be used. During this time, the vehicle
must be standing on a level surface at room temperature (at
least 15°C).

Touching up paint damage

Paint structure must be restored according to specifications in
the ⇒ “Paint” workshop manual.
Cleaning guidelines
– Carry out cleaning immediately before installation.
– First, clean the outer metal surface with adhesive remover
-D 002 000 10-.
– Then use plastic cleaner -D 195 850 A1- to carefully remove
dirt, grease, wax and other contaminants.
• Always use a clean, lint-free cloth for cleaning.
3.6.2 Removing and installing front wheel

arch trims
Note
♦ Installation of the wheel arch trim is described only for the

left side. The right side is analogous.
♦ The wheel arch trim cannot be removed without damaging it.
Removing

– Unscrew bolts -3- in wheel housing.

– Warm front wheel housing trim -1- using the hot air blower
-V.A.G 1416-.
– Pull off front wheel arch trim -1- starting at side member
-arrow a-.
– If wheel arch trim cannot be lifted off, use cutting cord to cut
through adhesive tape -5-.
– Pull out wheel arch trim from below trim on bumper cover -2-
-arrow b-.
Installing

– Prepare wheel housing -1- for bonding ⇒ page 420 .

– Clean bonding surface -5-.
– Apply 2-pack adhesive between adhesive tape -5-, width =
6 mm, height = 10 mm.

– Guide front wheel arch trim -1- under trim on bumper cover
-arrow a-.
– Engage wheel arch trim in wing and side member extension
-4- -arrows c-.
– Fit trim to wheel housing and pull off protective backing us‐
ing removal aids -6- -arrow b-.
– Press on front wheel arch trim firmly in area of adhesive
tapes -2-.
– Tighten bolts -5- to specified torque of 2 Nm.
– Minimum curing period ⇒ page 420 .
3.6.3 Removing and installing rear wheel

arch trims
Note
♦ Installation of the wheel arch trim is described only for the

left side. The right side is analogous.
♦ The wheel arch trim cannot be removed without damaging it.

Removing
– Warm rear wheel arch trim -1- in area of adhesive tapes -4-,
using hot air blower -V.A.G 1416- to do so.
– Lift off rear wheel arch trim -1- from side member -3- using
removal wedge -3409- -arrow a-.
– Pull rear wheel arch trim -1- firmly off wheel housing
-arrow a-.
– If wheel arch trim cannot be raised, use cutting cord to cut
through adhesive tape.
– Pull out rear wheel arch trim -1- from below trim on bumper
cover -2- -arrow b-.
Installing

– Prepare wheel housing -4- for bonding ⇒ page 420 .

– Apply 2-pack adhesive between adhesive tape -3-, width =
6 mm, height = 10 mm.

– Guide rear wheel arch trim -1- under trim on bumper cover
-4- -arrow a-.
– Align rear wheel arch trim -1- with side member trim -5-, and
pull protective backing off adhesive strip using removal aids
-6-.
– Firmly press on rear wheel arch trim -1- in area of adhesive
strips -2-.
– Minimum curing period ⇒ page 420 .

3.7 Removing and installing side member

trim
⇒ a3.7.2 nd installing side member trim”, page 428
⇒ a3.7.3 nd installing side member trim, Alltrack”, page 431

Note
♦ Before removing the side member trim, heat it up with a hot

air blower -V.A.G 1416-.
grease.
♦ Letterings, films or emblems must be bonded in place imme‐
diately after cleaning.
♦ Remove protective foil immediately before installation.
♦ The working temperature is approx. 21°C.

3.7.2 Removing and installing side member trim
Note
♦ Removal and installation are described only for the left side member trim. The removal and installation of
the right side member trim are similar.
♦ The side member trims cannot be removed without being damaged.

Removing
– Unscrew bolts -7- on wing.
– Unscrew spreader rivets -8-, and pull them out of grommets.
– Heat up side member trim -1- in area of adhesive tape -3-
– Pull side member trim -1- firmly off side member.

Installing
– Check all grommets -8-, clips -4- and spreader rives -8- for
damage, and renew them if necessary.
– Fit side member trim -1- with clips -2 and 6- into grommets
-10-, and push it on.
– Press side member trim in area of adhesive tape -3- firmly
onto side member.
Specified torques

3.7.3 Removing and installing side member trim, Alltrack
Note
♦ Removal and installation are described only for the left side member trim. The removal and installation of
the right side member trim are similar.
♦ The side member trims cannot be removed without being damaged.
Removing
– Remove front door ⇒ page 115 and rear door ⇒ page 182 .
– Unscrew spreader rivets -6-, and pull them out of grommets.
– Heat up side member trim -1- in area of adhesive tape -3-
– Starting from front wheel arch trim, pull off side member trim
-1- forcibly from side member.
– Detach side member trim -1- from fasteners of sill cover -8-.
– Pull out side member trim -1- from under rear wheel arch
trim -7-.

Installing

– Check all grommets, clips and spreader rivets -6- for dam‐
age and renew if necessary.
– Guide side member trim -1- under rear wheel arch trim
-arrow a-.
– Engage side member trim -1- in sill cover -8- -arrow b-.
– Guide side member trim -1- with clips into grommets and
firmly press into position -arrow b-.
– Press side member trim in area of adhesive tape -3- firmly
onto side member.
– Tighten spreader rivets -6-.

3.8 Removing and installing water deflector
Note
Removal and installation are described only for the left side. Removal and installation of the right side are
similar.
Removing
– Starting at bottom end, pull water deflector -1- out of clip -3-
and retaining strip -2-.
Installing
– Position upper inner edge of water deflector -1- on upper
edge of windscreen.
– Press water deflector -1- from above into retaining strip -2-
and clip -3-.
– Fit contact lip between water deflector and windscreen be‐
hind window.

3.9 Removing and installing B-pillar trim on

door
⇒ a3.9.1 nd installing B-pillar trim on front door”, page 434
⇒ a3.9.2 nd installing B-pillar trim on rear door”, page 435
3.9.1 Removing and installing B-pillar trim on front door
Note
similar.
Removing
– Run door window down to bottom position.
– Pull window channel -3- in area of B-pillar trim-1- out of door
frame.
– Unclip spreader rivets -2-.
– Push B-pillar trim -1- downwards and pull off door frame.

– Pull out B-pillar trim -1- upwards.

Installing
– Position B-pillar trim -1- on door frame.
– Guide in B-pillar trim -1- at bottom and fit it in place.
– Push B-pillar trim -1- upwards until it is in contact with win‐
dow channel -3-.
– Hook in spreader rivet -2- from top to bottom and insert
window channel -3- into B-pillar trim.
3.9.2 Removing and installing B-pillar trim on rear door
Note
similar.
Removing
– Run door window down to bottom position.

– Pull window channel -3- in area of B-pillar trim-1- out of door

frame.
– Unclip spreader rivets -2-.
– Push B-pillar trim -1- downwards and pull off door frame.
– Pull out B-pillar trim -1- upwards.
Installing
– Insert B-pillar trim -1- on door frame.
– Fit B-pillar trim -1- in longitudinal holes -4- in frame section.
– Position B-pillar trim -1- and push until stop.
– Push B-pillar trim -1- upwards until it is in contact with win‐
dow channel -3-.
– Hook in spreader rivet -2- from top to bottom and insert
window channel -3- into B-pillar trim.
3.10 Removing and installing trim strip

⇒ a3.10.1 nd installing window channel trim strip of front door”,
page 436
⇒ a3.10.2 nd installing window channel trim strip of rear door”,
page 438
⇒ a3.10.3 nd installing trim strip cover on doors”, page 440
3.10.1 Removing and installing window chan‐

nel trim strip of front door
Removing

– Starting at front, detach trim strip -1- evenly from window

channel -2- -arrows b-.
– Push trim strip -1- towards rear out of window channel -2-
-arrow a-.
Installing

– Push trim strip -1- towards front into window channel -2-
-arrow a-.
– Press trim strip -1- evenly into window channel -2-
-arrows b-.
3.10.2 Removing and installing window chan‐

nel trim strip of rear door
Removing

– Detach trim strip -1- evenly from window channel -2-

-arrows-.
Installing

– Align trim strip -1- with B-pillar trim -arrow a-.

– Press trim strip -1- into window channel -2- -arrows b-.
3.10.3 Removing and installing trim strip cov‐

er on doors
♦ Adhesive strip remover -VAS 6349-

♦ If a trim strip is installed for the first time on a new vehicle
or on newly painted surfaces, the procedure in ⇒ Workshop
manual “Paint”; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒ Mould‐
ings & film should be observed.
♦ If a trim strip is removed and reinstalled, use only adhesive
remover to remove the adhesive residue in the installation
area.
grease.
♦ The trim must be bonded in place immediately following
cleaning.
♦ Working temperature is approx. 21 °C.
Note
♦ The trim strip cannot be removed without it being damaged.

♦ Different versions depending on model version; for allocation refer to ⇒ Electronic parts catalogue ETKA
♦ Removal and installation are described only for the left side. Removal and installation of the right side are
similar.

Removing
– Heat trim strip -1- using hot air blower -V.A.G 1416-, and pull
it off sill.
– Use removal wedge -3409- -2- to facilitate separation of ad‐
hesive strips -5-.
Installing
– Fitting notes ⇒ page 441 .
– Align rear end of trim strip -1- to rear end of door cover -4-.
– Firmly press on trim strip -1- over whole area.
3.11 Removing and installing entry mould‐

ing

♦ If a step moulding is installed for the first time on a new ve‐
hicle or on newly painted surfaces, the procedure in ⇒ Work‐

shop manual “Paint”; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒

Mouldings & film should be observed.
♦ If step moulding is removed and reinstalled, only use adhe‐
sive remover -D 002 000 10- to remove adhesive residue in
installation area.
grease.
♦ The entry moulding must be bonded in place immediately
following cleaning.
3.11.2 Removing and installing outer step

moulding
Note
Entry moulding cannot be removed without damage.

Removing
– Heat step moulding -1- using hot air blower -V.A.G 1416-
and pull off from entrance area.
Installing
– Assembly notes ⇒ page 442
– Pull off backing.
– Align front end of outer step moulding -1- to front end of
inner step moulding -arrows-.
– Ensure that dimension -a- of 12 mm between metal flange
and step moulding is adhered to.
– Smooth down using plastic scraper with paper towel wrap‐
ped around it.

3.12 Removing and installing underbody

heat shield
⇒ a3.12.1 nd installing underbody heat shield”, page 445
⇒ a3.12.2 nd installing heat shield for centre exhaust system”,
page 447
⇒ a3.12.3 nd installing heat shield for rear silencer”, page 448
3.12.1 Removing and installing underbody heat shield
Note
Slight discrepancies may need to be allowed for depending on the type of engine.
Removing
– Removing centre underbody panel ⇒ page 459 .
– Remove tunnel cross-piece at front -3- and rear -2- ⇒ page
464 .

– Remove rear exhaust system ⇒ Rep. gr. 26; Exhaust sys‐

tem/silencer; Assembly overview - silencers.
Only for vehicles with all-wheel drive
– On vehicles with all-wheel drive, remove propshaft ⇒ Rep.
gr. 39; Propshaft; Assembly overview - propshaft.
“GTE” only
– On hybrid vehicles, detach high-voltage heater (PTC) -Z115-
⇒ Heating, air conditioning; Rep. gr. 87; Coolant circuit; Re‐
moving and installing high-voltage heater (PTC) Z115/high-
voltage heater (PTC) control unit J848.
All vehicles
– Detach lock washers -4- (qty. 6) and remove tunnel heat
shield -1- to the back.
Installing

Vehicles with all-wheel drive
CAUTION
Risk of injury from sharp edges.
Cut injury to hands and eyes possible.
– Wear safety goggles.
– Cut new heat shield -1- at marked points -2- prior to instal‐
ling, and bend it open in direction of -arrow-.
3.12.2 Removing and installing heat shield for centre exhaust system
Note
Removing
– Remove rear exhaust system ⇒ Rep. gr. 26; Exhaust sys‐
tem/silencer; Assembly overview - silencers.

– Loosen lock washers -2-.

– Remove heat shield -1-.
Installing
3.12.3 Removing and installing heat shield for

rear silencer
♦ Engine and gearbox jack -V.A.G 1383 A-
Note

Removing
– Loosen bracket for rear silencer and slightly lower using the
engine and gearbox jack -V.A.G 1383 A- ⇒ Rep. gr. 26;
Exhaust pipes/silencers; Assembly overview - silencer.
– Loosen lock washers -2-.
– Remove heat shield -1-.
Installing

4 Noise insulation
⇒ o4.1 verview - noise insulation”, page 450
4.1 Assembly overview - noise insulation

⇒ o4.1.1 verview - short noise insulation”, page 450
⇒ o4.1.2 verview - long noise insulation”, page 451
⇒ o4.1.3 verview - skid plate”, page 451
4.1.1 Assembly overview - short noise insulation
Note
1 - Short noise insulation

❑ To remove:
– Unscrew bolts -2- and
-3-
– Pull out noise insulation

off lock carrier to the
back.
2 - Bolt
❑ Qty. 3 left
❑ Qty. 4 right
❑ 2.0 Nm
3 - Bolt
❑ 1 on lock carrier
❑ 1 Nm

4.1.2 Assembly overview - long noise insulation
Note
1 - Short noise insulation

❑ To remove:
– Remove bolts -2-, -3-
and -4-.

back.
2 - Bolt
❑ Qty. 3 left
❑ Qty. 4 right
❑ 2.0 Nm
3 - Bolt
❑ Micro-encapsulated; re‐
new after each removal
❑ Qty. 3
❑ 6.0 Nm
4 - Bolt
❑ 1 on lock carrier
❑ 1 Nm
4.1.3 Assembly overview - skid plate
Note
4. Noise insulation 451

1 - Skid plate
❑ To remove:
– Remove bolts -2-, -3-
and -4-.

back.
2 - Bolt
❑ Qty. 2 each on left and
right
❑ 20 Nm
3 - Bolt
❑ Qty. 3 left
❑ Qty. 4 right
❑ 2.0 Nm
4 - Bolt
❑ Qty. 3
❑ 20 Nm
5 - Skid plate bracket
❑ Left and right
6 - Bolt
❑ 20 Nm

5 Underbody cladding
⇒ o5.1 f fitting locations - trim”, page 453
⇒ o5.2 verview - bracing on underbody”, page 458
⇒ a5.3 nd installing underbody cladding”, page 459
⇒ a5.4 nd installing tunnel cross-piece”, page 464
5.1 Overview of fitting locations - trim

⇒ o5.1.1 verview - underbody cladding”, page 453
⇒ o5.1.2 verview – underbody cladding GTE (hybrid)”, page 454
⇒ o5.1.3 verview - low-noise underbody cladding 1/3”, page 455
5.1.1 Assembly overview - underbody cladding
5. Underbody cladding 453

1 - Front underbody cover

❑ Left and right
ling ⇒ page 459
2 - Nut
❑ Captive
❑ 2.0 Nm
3 - Panel nut
4 - Left underbody cladding
extension
ling ⇒ page 459
5 - Bolt
❑ (2 Nm)
6 - Clamping washer
7 - Insert nut
8 - Rear left underbody cover
❑ Unscrew bolts -5- and
nuts -2-
9 - Rear right underbody clad‐
ding
❑ Unscrew bolts -5- and
nuts -2-
10 - Right underbody cladding
extension
ling ⇒ page 459
11 - Cover
12 - Spreader rivet
❑ Qty. 4
13 - Centre underbody cover
❑ Left and right
14 - Plugs
❑ Left and right
5.1.2 Assembly overview – underbody cladding »GTE« (hybrid)

1 - Underbody cladding, front

right
ling ⇒ page 459
2 - Nut
❑ Captive
❑ 2.0 Nm
3 - Bolt
❑ (2 Nm)
4 - Underbody cladding, front
left
ling ⇒ page 459
5 - Nut
❑ Captive
❑ 2.0 Nm
6 - Bolt
❑ (8 Nm)
7 - Cover
❑ Left and right
❑ Engaged with under‐
body cladding
8 - Left underbody cladding
extension
❑ Pushed into underbody
cladding and screwed
in place
9 - Right underbody cladding extension
❑ Pushed into underbody cladding and screwed in place
10 - Bolt
❑ (2 Nm)
5.1.3 Assembly overview - low-noise underbody cladding 1/3

1 - Low-noise underbody
cladding
2 - Insert nut
❑ Qty. 5
3 - Bolt
❑ (2 Nm)
❑ Qty. 5

cladding
2 - Clamping washer
❑ Qty. 1
3 - Insert nut
❑ Qty. 6
4 - Bolt
❑ (2 Nm)
❑ Qty. 9

cladding
2 - Insert nut
❑ Qty. 8
3 - Bolt
❑ (2 Nm)
❑ Qty. 15
4 - Clamping washer
❑ Qty. 1
5.2 Assembly overview - bracing on underbody

1 - Front tunnel cross-piece

2 - Rear tunnel cross-piece
3 - Hexagon nut
❑ Qty. 2
❑ 20 Nm
4 - Bolt
❑ Qty. 2
❑ 20 Nm
5.3 Removing and installing underbody

cladding
⇒ a5.3.1 nd installing underbody cladding”, page 459
⇒ a5.3.2 nd installing centre underbody cladding”, page 461
⇒ a5.3.3 nd installing short centre underbody cladding”, page
462
⇒ a5.3.4 nd installing underbody cover extension”, page 463
5.3.1 Removing and installing underbody

cladding

Note
Removing
– Remove centre underbody panels ⇒ page 459 .

– Release retaining tab and pull out front cover -2- or -5- in
direction of travel backwards off catches.
– Unscrew nuts -3-.
– Remove underbody panel -1- or -4-.
Installing
Specified torque
• Nuts ⇒ page 453
5.3.2 Removing and installing centre underbody cladding
Note
Removing
Unclip spreader river -2- and remove centre underbody panels.

Installing
5.3.3 Removing and installing short centre underbody cladding
Note
Removing
Unclip spreader river -2- and remove centre underbody panels.
Installing
Specified torques
• Bolt ⇒ page 453

5.3.4 Removing and installing underbody

cover extension
Note

– Loosen lock washer -3-.

– Unclip spreader rivet -2- and remove bolt -4-.
– Remove rear underbody panel -1-.
Installing
Specified torques
• Bolt ⇒ page 453
5.4 Removing and installing tunnel cross-

piece
Removing

Front tunnel cross-piece

– Detach underbody covers, and push them slightly down‐
wards ⇒ page 459 .
– Remove front tunnel cross-piece -1-.
Rear tunnel cross-piece
– Detach underbody covers, and push them slightly down‐
wards ⇒ page 459 .
– Unscrew nuts -3-.
– Remove front tunnel cross-piece -2-.
Installing

Front tunnel cross-piece

– Fit tunnel cross-piece -1-.
– Install underbody cover ⇒ page 459 .
Rear tunnel cross-piece
– Fit tunnel cross-piece -2-.
– Tighten nuts -3-.
– Install underbody cover ⇒ page 459 .
Specified torques
♦ Nuts ⇒ page 458

6 Roof moulding and roof railing

⇒ o6.1 verview - roof railing”, page 467
⇒ a6.2 nd installing roof railing”, page 467
6.1 Assembly overview - roof railing
1 - Roof railing
❑ Left and right
ling ⇒ page 467
2 - Seal
❑ Self-adhesive
ling ⇒ page 469
3 - Seal
❑ Self-adhesive
4 - Hexagon nut
❑ 9 Nm
6.2 Removing and installing roof railing

Removing
6. Roof moulding and roof railing 467


– Unscrew hexagon nuts -2- at front and rear.
– Remove roof railing -1- straight upwards.
Installing

– Check seal for damage and ensure proper seating.

– Fit roof rail -1- starting at front -arrows a- and working to‐
wards rear -arrows b-.
– Tighten hexagon nuts -2- at front and rear.
Specified torques
♦ Nuts ⇒ Item 4 (page 467)
6.2.1 Removing and installing seal for roof

railing
♦ If a seal is removed and reinstalled, only use adhesive re‐
mover -D 002 000 10- to remove adhesive residue in instal‐
lation area.
grease.
♦ Seal must be bonded in place immediately after cleaning.


Removing and installing seal
Removing
– Roof railing is removed ⇒ page 467 .
– Heat seal -1- using hot air blower -V.A.G 1416-, and pull it
off roof railing.

Installing
– Follow installation instructions ⇒ page 469 .
– Align front end of seal -2- with front end of roof railing -1-.
– Do not stretch or puncture seal. The rear end of the seal
must lie against the rear end of the roof railing.
– Press seal firmly onto roof railing.

7 Exterior mirror
⇒ o7.1 verview - exterior mirror”, page 472
⇒ a7.2 nd installing exterior mirror”, page 474
⇒ a7.3 nd installing mirror glass”, page 476
⇒ a7.4 nd installing mirror adjustment unit”, page 478
⇒ a7.5 nd installing mirror cover”, page 480
⇒ a7.6 nd installing mirror frame”, page 481
7.1 Assembly overview - exterior mirror
Note
The illustrations show the left-hand side. The right side is similar.

1 - Mirror mounting
ling ⇒ page 474
2 - Turn signal
ling ⇒ Electrical sys‐
tem; Rep. gr. 94; Lights
in exterior mirror; Re‐
turn signal
3 - Bolt
❑ Qty. 2
❑ 1.0 Nm
4 - Camera
5 - Camera bracket
6 - Bolt
❑ Qty. 2
❑ 1.0 Nm
7 - Mirror cover
❑ Material: ABS
ling ⇒ page 480
8 - Ambient light
tem; Rep. gr. 94; Lights
in exterior mirror; Re‐
entry light in exterior
mirror
9 - Bolt
❑ Qty. 1
❑ 12 Nm
10 - Connector
11 - Seal
❑ Between cover and outer door panel
❑ until 9.2016 installed at mirror base
❑ from 10.2016 installed at outer door panel
12 - Adjuster unit
13 - Bolt
❑ Qty. 1
❑ 1.0 Nm
14 - Mirror frame
15 - Bolt
❑ Qty. 2
❑ 1.0 Nm
16 - Mirror glass
7. Exterior mirror 473

7.2 Removing and installing exterior mirror

Note
♦ The removal and installation sequence is for the left exterior mirror only. The right side is similar.
♦ The cables and connectors in a new exterior mirror are always ready for the highest equipment level.
♦ Any superfluous connectors are secured to prevent noise.

Removing
door trim.
– Detach door control unit ⇒ page 172 .
– Disconnect connector for exterior mirror -4-.
– Detach wire from retainers -5- and guide it through opening
-6- in door.
– Remove sticker -3-, and unscrew bolt -2-.
– Remove exterior mirror -1-, and guide out wire through
opening in door.
Installing
– The seal at mirror base or outer door panel must be correctly
fitted.
– Grommet -6- must be inserted properly.
– Attach sticker -3- free of creases. The opening must be cov‐
ered completely.

– Then check function.

Specified torques
♦ Bolts ⇒ Item 9 (page 473)
7.3 Removing and installing mirror glass

♦ Assembly lever -80-200-
Note
Removal and installation are described only for the left mirror
glass. The right side is similar.
Removing

CAUTION
Risk of injury to hands and eyes caused by glass splinters.
Risk of cuts.
– Protect housing edges e.g. with textile-reinforced tape to

prevent damage to paintwork.
– Press bottom of mirror glass -1- into mirror housing.
– Press mirror glass -1- off adjuster unit -2- using the removal
lever -80-200-.
– Swivel mirror glass -1- to side and detach connectors -3- for
electric mirror heating on back of mirror glass -1-.
Installing
– Fit connector contacts -3- on mirror glass -1-.
– Push mirror glass -1- centrally onto adjustment unit -2- in
housing.
Mirror glass engages audibly.

Note
When fitting the mirror glass, only press on the centre of the
mirror.
7.4 Removing and installing mirror adjust‐

ment unit
Note
The removal and installation sequence is only for the left adjustment unit with motor. The right side is similar.

Removing
– Remove mirror glass ⇒ page 476 .
– Unscrew bolt -2- (qty. 1), and remove adjustment unit -1-
from mirror mounting.
– Swivel adjustment unit together with motor -1- to the side
and pull off connector -3-.
Installing
– Attach connector -3- to adjusting unit -1-.
– Fit adjustment unit -1- to mirror mounting, and secure it by
tightening bolt -2- (qty. 1).
– Install mirror glass ⇒ a7.3 nd installing mirror glass”, page
476 .
Specified torques
♦ Bolts ⇒ Item 13 (page 473)

7.5 Removing and installing mirror cover
Note
Removal and installation are described only for the left mirror cover. The right side is similar.
Removing
– Release locking hooks -arrows A-.
– Pull mirror cover -1- in -direction of arrow B- off mirror
mounting.
Installing
– Position mirror cover -1- and press on until locking hooks
engage audibly.
– Install mirror glass ⇒ a7.3 nd installing mirror glass”, page
476 .

7.6 Removing and installing mirror frame

Note
Removal and installation are described for the left mirror frame only. The right side is similar.

Removing
– Remove mirror cover ⇒ page 480 .
Installing
Specified torques

8 Wheel housing liner

⇒ o8.1 verview - front wheel housing liner”, page 483
⇒ o8.2 verview - rear wheel housing liner”, page 484
⇒ a8.3 nd installing front wheel housing liner”, page 484
⇒ a8.4 nd installing rear wheel housing liner”, page 486
8.1 Assembly overview - front wheel housing liner
Note
♦ Minor differences may be encountered in respect of front wheel housing liner, depending on vehicle
model.
♦ The illustrations show the left-hand side. Adapt accordingly for the right-hand side.
1 - Front wheel housing liner

ling ⇒ page 484
2 - Bolt
❑ 2.0 Nm
3 - Speed nut
4 - Wheel housing liner front
part
5 - Expansion nut
6 - Locking element
8. Wheel housing liner 483

8.2 Assembly overview - rear wheel housing liner
Note
♦ Minor differences may be encountered in respect of front wheel housing liner, depending on vehicle
model.
1 - Rear wheel housing liner

ling ⇒ page 486
2 - Bolt
❑ Qty. 9 on each side, for
wheel housing liner
❑ Qty. 4 on each side, for
side member cover
❑ 2.0 Nm
3 - Side member cover
ling ⇒ page 486
4 - Expanding nuts
5 - Speed nuts
6 - Expansion nut
❑ Gas-tight.
❑ The expanding nut
seals the interior
against exhaust gases
and must always be re‐
newed in the event of
damage.
7 - Adapter
❑ On right side only, not
for petrol engines
❑ Mounting prior to in‐
stalling the rear wheel
housing liner -1-
8.3 Removing and installing front wheel

housing liner

Note
♦ Removal and installation is described for the front left wheel housing liner only. The procedure for the
right-hand side is basically the same.
♦ The removal and installation procedures may have to be modified slightly depending on model variants.
♦ For reasons of clarity of bolt illustration, the wheel is not shown.

Removing
– Pull wheel housing liner -1- and front section of wheel hous‐
ing liner -4- out of wing.
Installing
Note
Check expanding nuts for damage and renew if necessary.
– Push front section of wheel housing liner -4- and front wheel
housing liner -1- into wing.
– Align wheel housing liners -1 and 4-.
Specified torques
♦ Bolts ⇒ o8.1 verview - front wheel housing liner”, page 483 .
8.4 Removing and installing rear wheel

housing liner
Removing
Note
♦ Removal and installation are described for the rear left wheel housing liner only. The procedure for the

– Remove wheel ⇒ Running gear, axles, steering; Rep. gr. 44;

Wheels, tyres; Specified torque for wheel bolts.
Wheel housing liner
– Pull rear wheel housing liner -1- out of wheel housing.
Side member cover
Detach rear wheel housing liner -1-.
Unscrew bolts -2- and remove sill panel cover downwards.
Note
Check spreader nuts for damage, and renew them if necessary ⇒ Item 6 (page 484) .

Installing
Note
♦ Removal and installation are described for the rear left wheel housing liner only. The procedure for the
Note
Check spreader nuts for damage, and renew them if necessary ⇒ Item 6 (page 484) .
Wheel housing liner

– Insert rear wheel housing liner -1- in wheel housing without
kinking the liner.
– Mount wheel ⇒ Running gear, axles, steering; Rep. gr. 44;

Side member cover

Position and bolt sill panel cover.
– Mount wheel ⇒ Running gear, axles, steering; Rep. gr. 44;
Specified torques
♦ Bolts ⇒ o8.2 verview - rear wheel housing liner”, page 484 .

9 Lettering and emblems

⇒ -9.1 lettering and emblems on rear”, page 490
⇒ -9.2 lettering and emblems on sides”, page 494
⇒ a9.3 nd installing badges at front”, page 494
⇒ a9.4 nd installing lettering”, page 499
9.1 Dimensions - lettering and emblems on

rear
⇒ –9.1.1 lettering on rear lid ► 06/2019”, page 490
⇒ –9.1.2 lettering on rear lid 07/2019 ►”, page 491
⇒ a9.1.3 nd installing manufacturer emblem at rear”, page 492
9.1.1 Dimensions – lettering on rear lid ► 06/2019
Note
When fitting the lettering, observe the fitting notes ⇒ page 499 .

1 - Lettering
❑ Height dimension -d-:
12 ± 1 mm from low‐
er edge of lettering to
edge in rear lid
❑ Side dimension -b-: 20
± 1 mm from outer
edge of rear lid to let‐
tering
2 - Badge
❑ Additional model desig‐
nation
er edge of emblem to
edge in rear lid.
❑ Side dimension -c-: 8 ±
1 mm from lettering to
emblem
3 - Lettering
❑ Engine designation
without technical de‐
scription
er edge of lettering to
edge in rear lid
❑ Side dimension -e-
= 20 ± 1 mm from outer
tering
4 - Badge
❑ Technical designation
12 ± 1 mm from lower edge of emblem to edge in rear lid.
❑ Side dimension -e- = 20 ± 1 mm from outer edge of rear lid to emblem
5 - Lettering
❑ Engine designation with technical description
❑ Height dimension -d-: 12 ± 1 mm from lower edge of lettering to edge in rear lid
❑ Side dimension -f-: 8 ± 1 mm from lettering to emblem
9.1.2 Dimensions – lettering on rear lid 07/2019 ►
Note
When fitting the lettering, observe the fitting notes ⇒ page 499 .
9. Lettering and emblems 491

1 - Badge
❑ Height dimension -b-
= 13 ± 1 mm from lower
edge of emblem to low‐
er edge of rear lid
❑ Side dimension -c-
edge of rear lid to em‐
blem
2 - Badge
❑ Height dimension -d-
edge of emblem to low‐
er edge of rear lid
❑ Side dimension -c-
edge of rear lid to em‐
blem
3 - Lettering
❑ Additional model desig‐
nation
❑ Height dimension -f-
edge of lettering to low‐
er edge of rear lid
❑ Side dimension -e-
tering
4 - Lettering
❑ Height dimension -h-
edge of lettering to edge in rear lid
❑ Side dimension -g- = 212 ± 1 mm, from centre line -6- of rear lid to start of lettering
❑ The width dimension -I- = 416 ± 1 mm indicates the total width of the lettering.
5 - Brand badge
❑ To determine the centre
6 - Vertical line
❑ To align the lettering
7 - Lettering
❑ Engine designation with torque indication
❑ Height dimension -j- = 13 ± 1 mm from lower edge of lettering to lower edge of rear lid
❑ Side dimension -k- = 29 ± 1 mm from outer edge of rear lid to lettering
9.1.3 Removing and installing manufacturer emblem at rear
Note
The badge cannot be removed without damage.

Removing
– Use a screwdriver -3- to carefully lever manufacturer em‐
blem -1- off swivel badge -2- in -direction of arrow A-.
Installing
– Press manufacturer emblem -1- onto swivel badge -2- until it
engages audibly.

9.2 Dimensions - lettering and emblems on

sides
Note
♦ Follow the fitting notes when removing or applying the letter‐

ing ⇒ page 499 .
♦ The dimensions are indicated only for the left wing. The
dimensions for the right wing are analogous.
♦ The dimensions are applicable for any lettering.
♦ The lettering cannot be removed without damage.
Dimension -a-: 4 mm, from character line in wing to upper edge

of lettering.
Dimension -b-: 5 mm, from character line in wing to upper edge
at rear of lettering.
Dimension -c-: 1 mm, from edge of wing to lower edge of letter‐
ing.
9.3 Removing and installing badges at

front
⇒ a9.3.1 nd installing brand badge, vehicles > 08.2019 without
adaptive cruise control unit”, page 494
⇒ a9.3.2 nd installing brand badge, vehicles > 08.2019 with
adaptive cruise control unitJ428”, page 495
⇒ a9.3.3 nd installing brand badge, vehicles 09.2019 >”, page
496
⇒ a9.3.4 nd installing emblem with model designation”, page
497
⇒ a9.3.5 nd installing emblem with model designation, R-Line”,
page 498
9.3.1 Removing and installing brand badge, vehicles > 08.2019 without adap‐
tive cruise control unit

Removing
– Remove radiator grille -2- ⇒ page 392 .
– Release the two retaining hooks -3- on the rear -arrow a-.
– Push badge -1- out of radiator grille -2- slightly.
– Pull emblem -1- upwards out of radiator grille -2- -arrow b-.
Installing
– Push badge -1- into radiator grille -2- until retaining hooks
-3- can be heard to engage.
9.3.2 Removing and installing brand badge, vehicles > 08.2019 with adaptive
cruise control unit -J428-

Removing
– Push seal -3- slightly to one side.
– Guide screwdriver -4- through opening -arrow a-.
– While doing this, push screwdriver -4- towards rear
-arrow b-. Screwdriver -4- is thereby guided onto locking
device -5-.
– Release locking device -5- -arrow a-.
– Pull emblem -1- slightly towards front out of radiator grille
-arrow c-. Locking devices -6- will disengage autonomously
while doing this.
– Pull emblem -1- upwards out of radiator grille -2- -arrow d-.
Installing
– Push emblem -1- into radiator grille -2- until retaining hooks
-5 and 6- can be heard to engage.
9.3.3 Removing and installing brand badge,

vehicles 09.2019 >

♦ Removal and assembly tool -T10389-
Removing
– Guide removal and assembly tool -T10389- -4- behind lock‐
ing device -3-.
– Release locking devices -3- -arrow b-, and pull badge -1- out
of radiator grille -2- -arrow c-.
Installing
– Push badge -1- into radiator grille -2- -arrow a- until locking
devices -3- engage audibly.
9.3.4 Removing and installing emblem with model designation

Removing
– Carefully unclip emblem -3- from radiator grille -1- from in‐
side -arrows-.
Installing
– Push emblem -3- into radiator grille -1- until retaining hooks
-arrows- can be heard to engage.
9.3.5 Removing and installing emblem with model designation, »R-Line«
Note
Do not remove unless radiator grille -1- is removed.

Removing
– Working from the inside, carefully unclip emblem -2- from
radiator grille -1-.
Installing
9.4 Removing and installing lettering


Note
♦ The vertical and horizontal dimensions of lettering for the

different engines are identical.
♦ When fitting the decals, observe the fitting notes as follows.
♦ Heat lettering or emblem with hot air blower -V.A.G 1416-
before removing.
♦ If the lettering or emblem is removed and reinstalled, only
use adhesive remover -D 002 000 10- to remove the adhe‐
sive remains.
grease.
♦ The lettering or emblem must be bonded in place immedi‐
ately after cleaning.
♦ Lettering or emblem cannot be removed without being dam‐
aged.

10 Decorative film / protective film
10.1 Removing and installing protective film

Note
♦ The description applies to all models. Only optical differen‐

ces exist depending on the model.
♦ When fitting the lettering, observe the assembly instructions
as follows.
♦ Heat up film before removing using a hot air blower -V.A.G
1416-.
♦ If film is removed, only use adhesive remover -D 002 000
10- to remove adhesive residue.
grease.
♦ The film must be applied immediately after cleaning.
♦ The bonded film cannot be removed without being damaged.
10. Decorative film / protective film 501

Note
Renewing scuff protection film is described for the left-hand side only. The right side is analogous.
Removing
– Heat up front scuff protection film -1- or rear scuff protection
film -2- using a hot air blower -V.A.G 1416- and pull off scuff
protection film from side members.
Installing
– Follow installation instructions ⇒ page 501 .
Note
Film is aligned between pillar curves.

– Position front scuff protection film -1- or rear scuff protection

film -2- and press it smooth using a plastic blade wrapped in
a soft paper towel -arrow- in centre first.
– Check position.
– Smooth down scuff protection film at front and rear -arrows-,
forcing out any bubbles.
10. Decorative film / protective film 503

11 Special add-on parts
11.1 Assembly overview – special add-on

parts
⇒ o11.1.1 verview – special add-on parts, Alltrack”, page 504
⇒ o11.1.2 verview – special add-on parts, R-Line”, page 504
11.1.1 Assembly overview – special add-on parts, Alltrack

ling
2 - Trim on front bumper
ling
3 - Front wheel housing trim
ling ⇒ page 421
ling ⇒ page 409
5 - Side member extension
❑ Left and right
ling ⇒ page 431
ling ⇒ page 409
7 - Rear wheel housing trim
ling ⇒ page 424
8 - Trim on rear bumper
ling
ling ⇒ page 330
10 - Lettering
ling ⇒ page 490
11.1.2 Assembly overview – special add-on

parts, R-Line

1 - Model designation »R-

Line«
ling ⇒ page 494
2 - Roof spoiler
ling ⇒ page 403
ling ⇒ page 330
4 - Side member extension
❑ Left and right
ling ⇒ page 428
5 - Lettering on wing
❑ Left and right
ling ⇒ page 494
ling ⇒ page 293
11. Special add-on parts 505

12 Towing bracket
⇒ o12.1 verview - towing bracket”, page 506
⇒ a12.2 nd installing towing bracket”, page 507
12.1 Assembly overview - towing bracket
Note
♦ Minor differences will be encountered on removal and installation, depending on version.

♦ The specified torques refer only to factory-installed towing brackets.
♦ Request torque specifications for other towing brackets from the manufacturers.

1 - Towing bracket
❑ Swivel-mounted towing
bracket
2 - Bolt
❑ Sealing plugs
❑ The bolts function as
plugs and seal the pas‐
senger compartment
against exhaust fumes,
and must be installed
without fail
❑ Qty. 3
❑ 20 Nm + 90°
❑ From towing bracket to
control unit
4 - Bolt
❑ Qty. 1
❑ 2.5 Nm
5 - Trailer detector control unit
tem; Rep. gr. 94; Trail‐
er detector control unit;
Removing and instal‐
ling trailer detector con‐
trol unit -J345-
6 - Expansion nut
❑ Qty. 1
❑ From control unit to ve‐
hicle
8 - Bolt
Note
Note different bolts and specified

torques.
❑ Bolt -N 911 784 01- (M10x38) 50 Nm + 90°
❑ Bolt -N 911 730 01- (M10x45) 50 Nm + 180°
❑ Always renew bolts after loosening
12.2 Removing and installing towing bracket

Note
Minor differences will be encountered on removal and installa‐

tion, depending on version.
12. Towing bracket 507

Removing
Remove lock carrier trim ⇒ General body repairs, interior; Rep.
lock carrier trim.
– Remove luggage compartment side trim on left ⇒ General
body repairs, interior; Rep. gr. 70; Luggage compartment
trims; Removing and installing luggage compartment side
trim.
– Separate electrical connector on control unit -3-.
– If present, remove reducing agent tank ⇒ Rep. gr. 26; SCR
system (selective catalytic reduction), Assembly overview -
reducing agent tank.
– Pull towing bracket -1- in a parallel movement out of longitu‐
dinal members.

Installing
Note
The bolts -2- function as plugs and seal the passenger compartment against exhaust fumes. They must be
installed without fail.
Ensure that the grommet of wire -3- is properly secured in the

cross panel.
– Perform functional check after installation of towing bracket.
Specified torques
♦ Bolts ⇒ o12.1 verview - towing bracket”, page 506
12.3 Removing and installing trigger unit
12. Towing bracket 509

Removing
– Remove towing bracket -4- ⇒ page 507 .
– Detach cover -2-.
– Remove drive -1-.
Installing
Note
♦ Before fitting cover, the area where the seal touches it must be cleaned.
♦ Under no circumstances must water be allowed to enter the trigger unit -1-.
Specified torques
Cover 1 Nm

VW Passat b8 Var Body Repairs Exterior Eng

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Service

Service Department. Technical Information

55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 107

58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

2.10 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

1.1 Minimum curing periods for bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

6.2 Removing and installing roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467

1.1 Assembly overview – lock carrier

1.1.1 Assembly overview – lock carrier

Different versions; for allocation refer to ⇒ Electronic parts catalogue “ETKA”

1 - Lock carrier with add-on

2 Rep. gr.50 - Body - front

1.2 Removing and installing lock carrier

♦ Torque wrench -V.A.G 1331-

♦ Torque wrench -V.A.G 1332-

4 Rep. gr.50 - Body - front

– Remove guide pins -T10093- from left and right longitudinal

♦ Do not hang condenser and hydraulic oil cooler from lines.

♦ Always fit lock carrier on the bolting points at the foremost

1.3 Moving to and back from service posi‐

♦ Guide pins -T10093-

♦ Torque wrench -V.A.G 1331-

♦ Torque wrench -V.A.G 1332-

6 Rep. gr.50 - Body - front

Moving to service position

– Remove front bumper cover ⇒ page 293 .

– Remove cable on mounting bracket of electrically operated

8 Rep. gr.50 - Body - front

– Remove special tool adapter -T10467- on left and right from

Further installation is carried out in reverse order of removal.

– Adjust headlights ⇒ Electrical system; Rep. gr. 94; Head‐

2.1 Assembly overview - wing

2.2 Removing and installing wing

10 Rep. gr.50 - Body - front

♦ Torque wrench -V.A.G 1783-

– Remove front wheel housing liner ⇒ page 484 .

– Remove front bumper cover ⇒ page 293 .

Install wing -1- without subjecting it to tensile stress.

12 Rep. gr.50 - Body - front

Install in the reverse order of removal observing the following:

– Thoroughly wax area -1- of wing in which insulation -2- is

14 Rep. gr.50 - Body - front

3.1 Assembly overview - plenum chamber bulkhead

3.2 Assembly overview - plenum chamber cover

1 - Plenum chamber cover

3.3 Removing and installing plenum cham‐

16 Rep. gr.50 - Body - front

3.4 Removing and installing plenum chamber cover

– Remove wiper arms ⇒ Electrical system; Rep. gr. 92; Wind‐

18 Rep. gr.50 - Body - front

– Spray windscreen seal -6- with a soapy solution so that ple‐

– Fit seal -5- on plenum chamber covers -1- and -2-.

20 Rep. gr.50 - Body - front

55 – Bonnet, rear lid

1.1 Assembly overview - bonnet

The threads of the adjusting buf‐

22 Rep. gr.55 - Bonnet, rear lid

1.2 Assembly overview - Bowden cable

1.3 Assembly overview - gas strut

Volkswagen Technical Site: http://vwts.ru http://vwts.info 1. Bonnet 23

1.4 Removing and installing bonnet