Literatura Técnica VW POLO - CARROCERIA

Body
> General body repairs, exterior > Body front > Front panel > Tools > Special tools, workshop equipment, test and measurement devices, as well as auxiliary means necessary

Special tools, workshop equipment, test and measurement devices, as well
as auxiliary means necessary

 Guide Pins -3411-

 Hexagonal wrench 3 mm -T 10010-
Body > General body repairs, exterior > Body front > Front panel > Tools > Special tools, workshop equipment, test and measurement devices, as well as auxiliary means necessary
Body > General body repairs, exterior > Body front > Front panel > Front panel (? 2006) - Assembly overview

Front panel (► 2006) - Assembly overview

1 - Front panel with assembly components
 work position → Chapter
 remove and install → Chapter
2 - Screw
 2 units
 8 Nm
3 - Bonnet latch operating cable
4 - Wing fastening hole
5 - Radiator and condenser

 Do not leave the condenser sustained by the ducts.
 The condenser ducts cannot be bent.
6 - Front protector support

7 - Screw
 4 units
 8 Nm
8 - Screw
 6 units
 30 Nm
9 - Guide Pins -3411-

Body > General body repairs, exterior > Body front > Front panel > Front panel (? 2006) - Assembly overview
Body > General body repairs, exterior > Body front > Front panel > Front panel (? 2006) - work position

Front panel (► 2006) - work position
– Remove the front bumper cover → Chapter
– Remove the front grille → Chapter
– Remove the front bonnet latch → Chapter
– Disengage the front bonnet latch operating cable from the latch.

– Remove the screw -8- from each longitudinal member and install the guide pin -3411- rods to the longitudinal members on the right and left sizes.
– Remove the screws -8- and -2- and pull the front panel forward in the rod area of the guide pins -3411-.

Body > General body repairs, exterior > Body front > Front panel > Front panel (? 2006) - work position
Body > General body repairs, exterior > Body front > Front panel > Front panel (2007 ?) - assembly overview

Front panel (2007 ►) - assembly overview
1 - Front panel with assembly components

 work position → Chapter

2 - Screw
 2 units
 8.5 Nm
 When installing, apply to the threadanaerobic adhesive -D 000 600 A2- or low-viscosity locking adhesive→ Chemical Materials Manual
3 - Bonnet latch operating cable
4 - Wing fastening hole
5 - Radiator and condenser

 Do not leave the condenser sustained by the ducts.
 The condenser ducts cannot be bent.

7 - Screw
 4 units
 8.5 Nm
8 - Screw
 6 units
 30 Nm
9 - Guide Pins -3411-

Body > General body repairs, exterior > Body front > Front panel > Front panel (2007 ?) - assembly overview
Body > General body repairs, exterior > Body front > Front panel > Front panel (2007 ?) - work position

Front panel (2007 ►) - work position
– Remove the front bumper cover → Chapter.
– Remove the front bonnet latch → Chapter.
– Disengage the front bonnet latch operating cable from the latch.
– Remove one screw -9- from each longitudinal member and install the guide pin -3411--7- rods to the longitudinal members on the right and left sizes.
– Remove the screws -9- and -3- and pull the front panel forward in the rod area of the guide pins -3411--7-.
Note
When installing screw -3-, apply to the thread anaerobic adhesive -D 000 600 A2- or low-viscosity locking adhesive → Chemicals Manual

Body > General body repairs, exterior > Body front > Front panel > Front panel (2007 ?) - work position
ody > General body repairs, exterior > Body front > Wing > Front wing - assembly overview

Front wing - Assembly overview

Note
 The Wing of “vehicles from 07.06” has only a different contour, the fastening points remain the same.
 In vehicles with lateral flashing lights on external mirrors, no flashing light is installed on the wing.
1 - Wing
 remove and install: → Chapter
2 - Screw
 6 Nm
 10 units
3 - Support
 It is fastened facing the wheel case.
4 - Screw
 6 Nm
 2 units

Body > General body repairs, exterior > Body front > Wing > Front wing - assembly overview
Body > General body repairs, exterior > Body front > Wing > Wing - remove and install > Remove

Remove
– Remove the front bumper protector → Chapter
– Remove the wheel housing protector → Chapter.
– Remove the cover → Chapter
Vehicles up to 2006
– Remove the indicator light → Electrical system; Rep. Gr.94
All vehicles
– Remove the screws -2-.
– Heat the wing with the hot air blower -VAG 1416- in the pillar A area and remove it.

Body > General body repairs, exterior > Body front > Wing > Wing - remove and install > Remove
Body > General body repairs, exterior > Body front > Wing > Wing - remove and install > Install

Install
– Before fastening the wing, place a zinc plate -AKL 381 035 50- on the support area of the fastening points.
– Clearance dimensions → Rep. Gr.00
– Screw tightening torque: 6 Nm.
– Installation is performed in the reverse removal sequence.

Body > General body repairs, exterior > Body front > Wing > Wing - remove and install > Install
Body > General body repairs, exterior > Body front > Wing > Cover - remove and install > Remove

Remove

– Remove the wheel case protector: → Chapter
– Remove the screw -3- from the bushing-2-.
– Remove the wing cover -1- from the front side.
Body > General body repairs, exterior > Body front > Wing > Cover - remove and install > Remove
Body > General body repairs, exterior > Body front > Wing > Wing dimensions (? 2006) - vehicles

Wing dimensions (► 2006) - vehicles

Distance between the wings.
Distance between the wings on the upper section of the vertical and horizontal support.
a = 0…2 mm
Body > General body repairs, exterior > Body front > Wing > Wing dimensions (? 2006) - vehicles
Body > General body repairs, exterior > Body front > Wing > Wing dimensions (2007 ?) - vehicles

Wing dimensions (2007 ►) - vehicles

Distance between the wings.
Horizontal and vertical difference between wings on the upper backrest section.
a = 0…2 mm
Body > General body repairs, exterior > Body front > Wing > Wing dimensions (2007 ?) - vehicles
Body > General body repairs, exterior > Body front > Lower noise insulation in the engine compartment > Lower noise insulation in the engine compartment (petrol / Totalflex engine) - assembly overview

Lower noise insulation in the engine compartment (petrol / Totalflex engine) - assembly overview

1 - Lower noise insulation in the enginecompartment
 for petrol engines
 Fastened and fitted to the front section of the front panel.
2 - Screw
 6 units
 2.5 Nm

Body > General body repairs, exterior > Body front > Lower noise insulation in the engine compartment > Lower noise insulation in the engine compartment (petrol / Totalflex engine) - assembly overview
Body > General body repairs, exterior > Body front > Lower noise insulation in the engine compartment > Lower noise insulation in the engine compartment (diesel engine) - assembly overview

Lower noise insulation in the engine compartment (diesel engine) - Assembly overview

1 - Lower noise insulation in the enginecompartment
 for diesel engines
 Fastened and fitted to the front section of the front panel.
2 - Screw
 9 units
 2.5 Nm

Body > General body repairs, exterior > Body front > Lower noise insulation in the engine compartment > Lower noise insulation in the engine compartment (diesel engine) - assembly overview
Body > General body repairs, exterior > Body front > Engine compartment partition panel > Tools

Tools
Special tools and workshop equipment required
 Torque wrench - 5 to 50Nm (fit. 1/2") -VAG 1331 -

 Cartridge heater -VAG 1939A-
 Manual pressure gun -V.A.G 1628-

Body > General body repairs, exterior > Body front > Engine compartment partition panel > Tools
Body > General body repairs, exterior > Body front > Engine compartment partition panel > Auxiliary materials for the Brazilian market

Auxiliary materials for the Brazilian market
 Glass adhesion kit
See → Chemicals Manual
 Cleaning solution
-D 009 401 04 -
 Adhesive remover
-D 002 000 10-
1)

Observe the minimum drying time.
Body > General body repairs, exterior > Body front > Engine compartment partition panel > Auxiliary materials for the Brazilian market
Body > General body repairs, exterior > Body front > Engine compartment partition panel > Auxiliary materials for the export market

Auxiliary materials for the export market
 1 K - adhesive glass
-DH 009 100- or -DH 009 100 A2-
 Body primer
-D 009 600-
 Primer applicator
-D 009 500 25-
-D 002 000 10-
-D 009 401 04 -
 Cutting wire
-357 853 999.A-
1)

Observe the minimum drying time. → Chapter
Body > General body repairs, exterior > Body front > Engine compartment partition panel > Auxiliary materials for the export market
Body > General body repairs, exterior > Body front > Engine compartment partition panel > Matching table

Matching table
Note
To help understanding, please find below a comparison table for materials used in the Brazilian and
export markets
Product Brazilian Market Export Market
PU Adhesive U-400 or PU-501 - DH 009 100- or -DH 009 100 A2-
Body primer U-413 or PU-530 Primer -D 009 600-

Body > General body repairs, exterior > Body front > Engine compartment partition panel > Matching table
Body > General body repairs, exterior > Body front > Engine compartment partition panel > Engine compartment partition panel - assembly overview

Engine compartment partition panel - assembly overview

Note
The engine compartment partition panel -1- is fastened also with polyurethane adhesive (PU) -3-.
1 - Engine compartment partition panel

 remove:
– After the screws are removed -2-, cut the adhesive cord.
2 - Screw
 8 units
 25 Nm
3 - Polyurethane adhesive - PUR

 cord profile: -a- = 11 mm, -b- = 8.5 mm and -c- = 7
mm
 minimum drying time → Chapter

Body > General body repairs, exterior > Body front > Engine compartment partition panel > Engine compartment partition panel - assembly overview
Body > General body repairs, exterior > Body front > Engine compartment partition panel > Minimum drying time

Minimum drying time
Note
 For the Brazilian market, if the side glass is glued with the Essex or Nucleus glass gluing kit U-
400, the vehicle can be returned to the customer 3 hours after the repair. If the Nucleus kit has
been used for PU-501 glass gluing, the vehicle can be returned to the customer 1 hour after the
repair.
 For the export market, with adhesive 1K- DH 009 100- or -DH 009 100 A2-, the minimum curing
time is of 3 hours for all glasses.
The minimum curing time is the time from window gluing to vehicle usage. During this time, the
vehicle must remain on a flat surface and at room temperature (at least 15°C).
DANGER!
The vehicle can only be released to the customer after the minimum curing time
haselapsed.
Repair Manual
Manuals
Engine
Workshop Manuals
Minimum
Free car repair manuals
Amigo
Adhesives
Body
Body > General body repairs, exterior > Body front > Engine compartment partition panel > Minimum drying time
Corpo > reparos do corpo Gerais, exterior > Bonnet, flaps, de táxi, fecho central > Bonnet > Ferramentas

Ferramentas
ferramentas especiais e equipamentos de oficina necessários

 chave de torque - 5 a 50Nm (ajuste 1/2 "). -VAG 1331 -
 Ejetor alavanca -80 - 200-
Corpo > reparos do corpo Gerais, exterior > Bonnet, flaps, de táxi, fecho central > Bonnet > Ferramentas
Corpo > reparos do corpo Gerais, exterior > Bonnet, flaps, de táxi, fecho central > Bonnet > capot dianteiro - Resumo de montagem

capot dianteiro - Resumo de montagem
Nota
A ala de "veículos a partir de 2007" tem apenas linhas diferentes. Os pontos de fixação e os
torques de aperto para a instalação permanecerá o mesmo.
1 - Gorro
 remover e instalar → Capítulo
 ajustar → Capítulo
2 - absorvedor de choque com cobertura

 tornar inútil para descartar (mesmo procedimento da porta traseira)→ Capítulo
 Lubrificar os ilhós com graxa lubrificante → Manual de Produtos Químicos ou -G 052 745 A3
3 - Plugue
4 - Amortecedor
 Não existente em veículos 07.06►.
5 - guia de tampa
 Não existente em veículos 07.06►.
6 - tampa do painel deflector de água
7 - Parafuso
 4 unidades
 23 Nm
8 - Complemento
9 - Dobradiça
10 - embalagem Bonnet
 montado no flange
11 - Embalagem
12 - tampão de ajuste
 Desapertando ou apertando esta paragem, é possível ajustar a altura da tampa da frente em relação à asa
13 - Grampo
 para fixar a embalagem → item -11-.

Corpo > reparos do corpo Gerais, exterior > Bonnet, flaps, de táxi, fecho central > Bonnet > capot dianteiro - Resumo de montagem
Corpo > reparos do corpo Gerais, exterior > Bonnet, flaps, de táxi, fecho central > Bonnet > Bonnet - remover e instalar > Remover

Remover
- Desligue os tubos do lava pára-brisas → Sistema elétrico; Rep. Gr.92 e remover os ejetores → Sistema elétrico; Rep. Gr.92
- With the help of a second mechanic, remove the screws -7- from the front bonnet hinges and remove the front bonnet.

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Bonnet - remove and install > Remove
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Bonnet - remove and install > Install

Install
– Installation is performed in the reverse sequence to the removal.
 Screw tightening torque -7-: 23 Nm.
– After the assembly, adjust the screws.

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Bonnet - remove and install > Install
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Front bonnet shock absorber (? 2006) - remove and install

Front bonnet shock absorber (► 2006) - remove and install

– Open the front bonnet and support it.
– Place a small screwdriver underneath the spring clip -3-.
– Raise the spring clip -3- enough to allow it to move over the ball

jointhousing to the -direction of arrow-.
– Pull the shock absorber -1- from the ball plugs -2- and the support

bracket with the ball plugs -4-.
– After removing the shock absorber -1-, immediately move the spring

clip -3- backwards.
WARNING
In case of reusing the shock absorber, please proceed carefully.
The spring clamp cannot be entirely risen outward the ball
jointhousing; otherwise, it will be damaged. The shock absorber
jumps from the fastening, causing damage or injuries.
 Tightening torque: screws -2- 21 Nm.
Note
The ball plug, -4- is an integral part of the support stand.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Front bonnet shock absorber (? 2006) - remove and install
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Bonnet - adjust

Bonnet - adjust
– The front bonnet can be centralized between the wings, moving the front bonnet hinges on the elongated holes, after untightening the screws -7-.
– With the adjustment buffers -12-, it is possible to adjust the front bonnet height in relation to the wing.
– Clearance dimensions → Rep. Gr.00
– After the adjustment, repaint the screws.

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Bonnet - adjust
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Front bonnet latch operating cable - remove and install > Assembly overview

Assembly overview
1 - Front bonnet latch operating cable

2 - Bellows
 from the engine compartment to the water deflector panel
3 - Front bonnet latch cable operating cable clip
4 - Bellows
 from water deflector panel to the cabin
5 - Operating lever

6 - Screw
 2 units
 1.5 Nm
7 - Support stand

 cable geared
8 - Bushing
 2 units
9 - Front bonnet latch operating cable support

 3 units
10 - Bonnet latch
 assembly overview → Chapter
 remove and install the front bonnet latch → Chapter

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Front bonnet latch operating cable - remove and install > Assembly overview
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Front bonnet latch operating cable - remove and install > Remove

Remove

– Remove the operating lever → Chapter.
– Remove the lower pillar A covering on the left side → Body - Internal assembly works; Rep.
Gr.70
– Disengage the on-board network command and keep it under the pedals → Electrical

system; Rep. Gr.97
– Disengage the fuse holder and the relay holder and move them inside the instrument
panel→ Electrical system; Rep. Gr.97.
– Remove the windscreen washer system → Electrical equipment; Rep. Gr.92
– Disengage the bonnet latch operating cable -1- from the support bracket -7- and from the

frontbonnet latch -10-.
– Disengage the bellows -2- and the bellows -4- from the engine compartment partition panel, as

well as the front bonnet latch operating cable -1- from the clip -3- and the supports -9-.
– Remove the front bonnet latch operating cable -1- from inside the engine compartment.
– Place the bellows -2- and -4- on the new front bonnet latch operating cable.
Note
Make sure that the bellows is properly seated, to avoid leaks.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Front bonnet latch operating cable - remove and install > Remove
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Operating lever - remove and install > Remove

Remove

– Pull the handle -seta-, unblock the retaining clip -2- with a screwdriver and remove the handle-
1-.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Operating lever - remove and install > Remove
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Operating lever - remove and install > Install

Install

– Press the retaining clip -2- against the handle -1- and press against the fastening in the support
stand.
– Before closing the front bonnet, check the operation of the operating cable and the
front bonnetlatch operating cable.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Operating lever - remove and install > Install
Front bonnet latch - Assembly overview
1 - Bonnet latch
 adjust: inside the elongated holes
 Clearance dimensions → Rep. Gr.00
 To remove, the front grille must be removed
2 - Switch
 remove and install, remove and install the front bonnet latch.
3 - Screw
 3 units
 10 Nm
4 - Unblocking lever

 with retaining hook and latch eyelet
 Adjust: through elongated holes.
 To remove, remove the screws.

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Front bonnet latch - Assembly overview
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Front bonnet latch - remove and install > Remove

Remove
– Remove the 3 screws -1-.

– To facilitate the removal of the latch operating cable, disengage the front bonnet latch operating
cable from the fastenings in the engine compartment
– Pull the front bonnet latch -3- from upside, to remove it from the latch support cross member.
Remove the bonnet latch operating cable -2- from the front bonnet latch with a screwdriver.
– Disengage the switch connector -1- and remove the switch -1- from the front bonnet latch -3-.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet > Front bonnet latch - remove and install > Remove

Special tools, workshop equipment, test and measurement devices and
auxiliary devices necessary

 Adjustment gauge -3371-
 Torque wrench - 5 to 50Nm (fit. 1/2") -VAG 1331-
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Tools > Special tools, workshop equipment, test and measurement devices and auxiliary devices necessary
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Assembly overview

Assembly overview
1 - Rear door

 adjust → Chapter
2 - Rear door lining

 remove and install → General body repairs, interior; Rep. Gr.70
3 - Lock
4 - Adjustment stop

 mentioned in the operation “Door - adjust” : → Chapter
5 - Cover shock absorber

 make useless for discarding → Chapter
 Lubricate the eyelets with lubricating grease → Chemicals Manual or -G 052 745 A3-
6 - Screw
 2 units
 22 Nm
7 - Latch plate

 adjust - through elongated holes.
8 - Cover packing
 when partially removed, it is necessary to compress the packing sides before assembly.
 splice positioned in the area near the left tail light
9 - Cap
10 - Riveted nut

 To install, use the riveted nut applicator POP NUT -VAG 1765B- or riveted nut applicator POP NUT -EQ 7422-
11 - Hexagonal nut

 2 units
 24 Nm
12 - Screw
 4 units
 10 Nm
13 - Hinge

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Assembly overview
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door shock absorber - remove and install

Rear door shock absorber - remove and install

– Open the rear door and support it.
– Place a small screwdriver underneath the spring clip -2-.
– Raise the spring clip -2- enough to allow it to move over the ball

jointhousing to the -direction of arrow-.
– Pull the rear door shock absorber -1- from the ball pins -3- and -4-.
After removing the shock absorber -1-, immediately move the spring clip-
2- backwards.
WARNING
You must install the shock absorber carefully. The spring clip must
not be completely disengaged from the ball joint housing;
otherwise, it will be damaged. The shock absorber may disengage
from pins -3-or -4- and cause a serious accident.
 Tightening torque of screws -3- and -4-: 21 Nm.
– Support the door.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door shock absorber - remove and install
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door shock absorber - make useless for discarding

Rear door shock absorber - make useless for discarding

– Fasten the shock absorber to the area x = 50 mm in the vise.
WARNING
Tightening can only be performed in this area; otherwise, there is
risk of accident!
– Cut the shock absorber cylinder on the first third of the full cylinder
length, from the reference edge on the plunger rod side.
Note
 Wear protective goggles for sawing.
 Cover the cutting area with a cloth.
 The oil and the cloth must be eliminated as residues.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door shock absorber - make useless for discarding
ody > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door - adjust

Rear door - adjust
Note
 The door is correctly adjusted if, when closed, there is an even clearance dimension throughout
its extension, not too much inwards nor too much outwards, and the contours arealigned.
 In order to perform the adjustment, the vehicle must be on the floor.

– Turn the adjustment buffer 90° with a box wrench (24) and remove it.

– Remove the rubber stop -1- from the adjustment buffer and untighten the screw
(internalhexagonal screw with 3 mm), until it is possible to pull the rod outwards.
– Pull the rod outside the box and adjust it to the dimension a = 12.5 mm.
Note
When it is new, the adjustment buffer already comes adjusted to the distance of 12.5 mm.

– Install the adjustment buffer and assemble it in the hole, turning it 90°.

– Remove the -1- from the rivet -2- on the left and right sides (above the tail lights).
– Close the rear door, putting a little pressure on the centre.
– With the adjustment gauge -3371-, adjust a clearance of 4.5 mm between the door and the
sidepanel.
– Open the rear door again.
– The door is now adjusted with previous tension of approx. 3 mm.

– Thread the pins to the rivets (on the right and left sides).
– Thread the tightening screw -1- until the dimension “a” = 25 mm.
– Check the adjustment.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door - adjust
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door lock - remove and install > Vehicles without central locking

Vehicles without central locking
1 - Handle support

 remove:
 Remove the door lining → Body - Internal assembly works; Rep. Gr.70
 Remove the control rod → Item -6-.
 Remove the safety clip and the cylinder housing from the handle support.
 Remove the internal multi-teeth screw and the handle support.
2 - Safety clip
3 - Handle
 remove
4 - Internal multi-teeth screw

 T 30
 4 units
 8 Nm
 When installing, first fasten the central screws.
5 - Cylinder housing
 remove:
 Remove the rear door lining → General body repairs, interior; Rep. Gr.70
 Disengage the control rod → Item -6- from the operating lever → Item-9-.
 Disengage the safety clip → Item and remove the housing.
 install:
 Position the cylinder housing in the handle support.
 Press the safety clip → Item -2- and lock the housing.
 Fit the control rod to the operating lever.
 Install the rear door lining.
6 - Shifting rod
7 - Lock
 remove:
 Disconnect the connector from the boot lighting switch -F5- in the latch.
 Disengage the control rod → Item -6-, remove the screws → Item -8- and remove the door
lock.
 install - only with the retaining pin coupled
8 - Screw
 23 Nm
 use the multi-teeth socket M8 (enc. 1/2") - VW 007CV-
9 - Operating lever

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door lock - remove and install > Vehicles without central locking
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door lock - remove and install > Vehicles with central locking

Vehicles with central locking
1 - Engine for unblocking the rear door -V139-

 remove:
 Disconnect the motor connector.
 Remove the support → Item.
 Remove the motor for unblocking the rear door.
2 - Safety clip
3 - Support
 remove:
 Disconnect the electric connectors in the cylinder housing → Item-11- and the locking mechanism motor → Item -1- and disengage thecontrol rod → Item-7-.
 Raise the safety clip → Item -2- and remove the cylinder housing→ Item -6- from the support. → Item -2-.
 Remove the internal multi-teeth screw → Item -5- and the door support.
4 - Handle
 remove:
 Remove the support → Item and the door handle.

 T 30
 4 units
 8 Nm
 When assembling, first screw both central screws.
6 - Lock cylinder housing

 remove:
 Disconnect the electric connectors in the lock cylinder housing → Item -11- and disengage the control rod → Item -
7-.
 Raise the safety clip → Item -2- and remove the cylinder housing from the lock with the help of the the lock barrel → Item -2- from the support → Item -2-.
 install:
 Fit the retaining clip → Item -2-.
 Apply the lock barrel crankcase with the help of the lock barrel and fit audibly to the handle with a snap.
7 - Operating lever
8 - Lock
 remove:
 Disconnect the electric connectors from the lock.
 Disengage the control rod, remove the screws and remove the door lock.
 install - only with the retaining pin coupled
9 - Screw
 2 units
 23 Nm
 use the multi-teeth socket M8 (enc. 1/2") - VW 007CV-
10 - Inverter lever
11 - Lock barrel support cross member

 remove:
 Remove the lock barrel crankcase and the support from the lock crankcase.

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door lock - remove and install > Vehicles with central locking
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door latch cylinder - assembly overview

Rear door latch cylinder - assembly overview

1 - Handle
2 - Operating rod
4 - Gorge
5 - Spring
6 - Cylinder
 Disassemble and assemble → Chapter
 Lubricate with multipurpose grease → Chemicals Manual; Rep. Gr.00 or -G 052 745 A3-
7 - Sealing ring
8 - Wrench
9 - Operating ring
10 - Clip
11 - Spring
12 - Latch

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door latch cylinder - assembly overview
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door latch cylinder - disassemble and assemble > Disassemble

Disassemble
– Remove the rear door lock cylinder housing.
– Insert the key in the cylinder.

– Remove the lock -arrow-.
– Remove the spring.
– Release the operating rod and remove the operating ring.
– Remove the cylinder along with the key, from the housing.
– Remove the sealing ring.
– Clean the cylinder, removing all the dirt and grease remains.

– Manually press the gorges in the cylinder and, then, carefully remove the key.
– Slowly loosen the cylinder, releasing the pressure from the gorge springs.

– Remove the gorges and the springs, marking their position in relation to the cylinder.
Note
The gorges are identified by numbers from 1 to 4 (it is also possible to identify the gorges
throughcolours). Write down the sequence, in the example - 2 3 1 4 3 2 3 or then, 2 1, on the lower
section, and 3 4 3 2 3, on the upper section.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door latch cylinder - disassemble and assemble > Disassemble
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door latch cylinder - disassemble and assemble > Assemble

Assemble
– Place the sealing ring on the cylinder.
– Place the springs and gorges in the correct position (sequence).
Note
During this operation, lubricate the gorges and the cylinder with multipurpose grease.→ Chemicals
Manual; Rep. Gr.00 or -G 052 745 A3-.
– When assembling, it is possible to combine gorges depending on the vehicle key, in case of

cylinder replacement. To do so, follow the steps below:
– Beginning with the last gorge position on the cylinder, place the spring and gorge number 1.
Insert the key and observe the gorge position in relation to the cylinder.

– If the upper gorge section is aligned with the cylinder housing -arrow-, then gorge number 1 is
the correct one for this position. Otherwise, place the gorge number 2, and so forth, until finding
the one that is aligned with cylinder when the key is inserted in the cylinder.
Note
Repeat the operation for all other gorge positions in the cylinder. Mark the position (sequence) of
the gorges in relation to the cylinder.
– Insert the cylinder in the housing.
– Install the operating rod and ring.
– Position the spring.
– Install the lock.
– Install the rear door lock cylinder.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door latch cylinder - disassemble and assemble > Assemble
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door lock cylinder (central locking) - assembly overview

Rear door lock cylinder (central locking) - assembly overview
1 - Handle
2 - Latch
3 - Ring
4 - Spring
5 - Operating ring
7 - Gorge
8 - Spring
9 - Cylinder
 Disassemble and assemble → Chapter.
 Lubricate with multipurpose grease → Chemicals Manual - Products Authorised
10 - Wrench
11 - Sealing ring
12 - Microswitch
13 - Clip

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Hatch > Rear door lock cylinder (central locking) - assembly overview
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan

Rear door - Sedan


Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door - Assembly overview

Rear door - assembly overview
1 - Lid
 Adjust → Chapter
 Dimensions of lid clearances in the body → Rep. Gr.00
2 - Lining
 Remove and install → Body- Internal assembly works; Rep. Gr.70
3 - Lock
 Adjust → Chapter
4 - Latch
 Remove and install → Chapter
5 - Rear door shock absorber

 Make useless for discarding → Chapter
 Lubricate the eyelets with multipurpose grease → Chemicals Manual; Rep. Gr.00 or -G 052 745 A3-
6 - Screw
 24 Nm
7 - Hinge
8 - Rubber stop
9 - Nut
 24 Nm
10 - Multi-tooth screw

 22 Nm
11 - Door buffer

 Adjust: through elongated holes
12 - Cover packing
 If the packing was partially removed, press the edges to increase the interference.

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door - Assembly overview
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door shock absorber - remove

Rear door shock absorber - remove

– Raise the safety clip -2- with a screwdriver and remove the shock absorber -3- from the ball
support -1-.
Note
In case of reusing the rear door shock absorber, do not remove completely the safety clip -2- from
the ball joint housing. Otherwise, the safety clip may be damaged.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door shock absorber - remove
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door - adjust

Rear door - adjust
Note
 The door is adjusted correctly and, when closed, the clearance around it is uniform. The door
must not be too protruded nor too receded, and the contours must be aligned.
 For this adjustment, the vehicle must be supported on the wheels.
– Remove the rear door lining → Body - Internal assembly works; Rep. Gr.70.

– Turn the adjustable buffer 90° with a wrench (24) and remove the buffer.
– Remove the rubber buffer -1- from the adjustment buffer and release the fastening screw
(internal hex screw with 3 mm) until it is possible to pull the lock tab out.

– Pull the lock tab out of the housing and adjust it to the dimension a = approx. 14 mm.
Note
When the buffer is new, it is adjusted to a distance of 12.5 mm.

– Place the adjustment buffer, turning it 90°.
– Lower the rear door slowly until the adjustment buffers are seated on the latch support.

– Continue to press the door downward carefully, until there is a movement upward of a = 4.5 mm
(see illustration) between the lower corners of the split tail lights.
– Open the rear door again.

– Thread the screw -1- until the dimension a = 25 mm.
– Check the adjustment of the second adjustment stop and, if necessary, correct it.
– Open the door and thread the tightening screw from the second adjustment buffer evenly, until
reaching the dimension a = 25 mm.
– Then, the door is adjusted with previous tension of approx. 3 mm.
– Install the rear door lining → Body - Internal assembly works; Rep. Gr.70.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door - adjust
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Cylinder housing of the lock with symbol (without central locking) - remove and install

Cylinder housing of the lock with symbol (without central locking) -
remove and install
Remove
– Remove the door lining → Body - Internal assembly works; Rep. Gr.70

– Disengage the operating rod -4-.
– Release the screws -5- until the support -6- can be dislocated.
– Move the support inside elongated holes. Meanwhile, hold the lock cylinder housing.
– Remove the lock cylinder housing.
Install

– Position the lock cylinder housing, place a support -6- and slide up to the installation position
– Tighten the screws -5- with 4 Nm and connect the operating rod -4-.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Cylinder housing of the lock with symbol (without central locking) - remove and install
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door lock (without central locking) - remove and install

Rear door lock (without central locking) - remove and install

1 - Cylinder housing of lock with symbol
2 - Lock
 Remove:
 Disengage the operating rod - → Item-, remove the nuts - → Item- and remove the door lock.
3 - Nut
 7 Nm
4 - Operating rod
5 - Screw
 Nm
6 - Support

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door lock (without central locking) - remove and install
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door lock (with central locking) - remove and install

Rear door lock (with central locking) - remove and install
1 - Cylinder housing of lock with symbol

2 - Lock
 remove:
 Disconnect the harness from the boot lighting switch -F5-
 Disengage the operating rod - → Item- in the lock, remove the nuts -→ Item- and remove the door lock.
3 - Nut
 7 Nm
4 - Engine for unblocking the rear door -V139-

 remove:
 Disconnect the electric connectors in the motor for unblocking.
 Disconnect the operating rod - → Item-.
 Unthread the nuts - → Item-.
 Remove the fastening screws from the motor for unblocking
5 - Nut
 7 Nm
6 - Operating rod
7 - Screw
 4 Nm
8 - Support

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door lock (with central locking) - remove and install
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Cylinder housing of the lock with symbol (with central locking) - remove and install

Cylinder housing of the lock with symbol (with central locking) -
remove and install
Remove
– Remove the door lining → Body - Internal assembly works; Rep. Gr.70

– Disconnect the electric connector from the alarm/central locking system contact switch in the
rear door lock cylinder -F124- in the lock cylinder housing.
– Disengage the operating rod -6- in the lock cylinder housing.
– Release the screws -7- until the support -8- can slide.
– Slide the support inside elongated holes. Meanwhile, hold the lock cylinder housing.
Install

– Position the lock cylinder, place the support -8- and slide up to the installation position
– Tighten the screws -7- with 4 Nm and connect the operating rod -6-.
– Fit the contact switch connector to the alarm/central locking system rear door lock cylinder
-F124-
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Cylinder housing of the lock with symbol (with central locking) - remove and install
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door latch activation handle - assembly overview

Rear door latch activation handle - assembly overview

1 - Fastening frame
 The frame halves are pre-assembled
2 - Spring
3 - Screw
 4 Nm
4 - Handle
 for mechanical activation
 lined with a rubber cover
5 - Handle with switch

 for electric activation
 lined with a rubber cover

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door latch activation handle - assembly overview
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door latch activation handle (without central locking) - remove and install

Rear door latch activation handle (without central locking) - remove
and install
Remove
Remove the door lining → Body - Internal assembly works; Rep. Gr.70

Untighten the screws -3- (not completely), until the fastening frame -1- can be removed.
Remove the frame, holding the handle.
Remove the door handle
Install

Place the handle in the door (attention to the locking “ear”) and hold it.
Position the fastening frame -1- in the handle housing.
Lock the handle with the fastening frame and tighten the screws -3- with 4 Nm.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door latch activation handle (without central locking) - remove and install
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door latch cylinder - assembly overview

Rear door latch cylinder - assembly overview
1 - Wrench
2 - Logotype
 self-adhesive
 also fastened by screw ► 08.04
3 - Sealing ring

5 - Support
6 - Cylinder
 Disassemble and assemble → Chapter
 Lubricate with multipurpose grease. → Chemicals Manual; Rep. Gr.00 or -G 052 745 A3-
7 - Support of the contact switch in the alarm/central locking system rear door lock cylinder -F124-
8 - Cylinder guide
9 - Operating ring
10 - Ring
11 - Spring
12 - Clip
13 - Contact switch in the alarm/central locking system rear door lockcylinder -F124-

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door latch cylinder - assembly overview
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door latch cylinder - disassemble and assemble > Disassemble

Disassemble
– Remove the rear door lock cylinder housing.
– Remove the VW symbol.
– Insert the key in the cylinder.

– Remove the lock -arrow-.
– Remove the spring.
– Release the operating rod and remove the operating ring.
– Remove the cylinder along with the housing key.
– Remove the sealing ring.
– Clean the cylinder, removing all the dirt and grease remains.

– Manually press the gorges in the cylinder and, then, carefully remove the key.
– Slowly loosen the cylinder, releasing the pressure from the gorge springs.

– Remove the gorges and the springs, marking their position in relation to the cylinder.
Note
The gorges are identified by numbers from 1 to 4 (it is also possible to identify the gorges
throughcolours). Write down the sequence, in the example - 2 3 1 4 3 2 3 or then, 2 1, on the lower
section, and 3 4 3 2 3, on the upper section.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door latch cylinder - disassemble and assemble > Disassemble
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door latch cylinder - disassemble and assemble > Assemble

Assemble
– Place the sealing ring on the cylinder.
– Place the springs and gorges in the correct position (sequence).
Note
During this operation, lubricate the gorges and the cylinder with multipurpose grease.→ Chemicals
Manual; Rep. Gr.00 or -G 052 745 A3-.
– When assembling, it is possible to combine gorges depending on the vehicle key, in case of

cylinder replacement. To do so, follow the steps below:
– Beginning with the last gorge position on the cylinder, place the spring and gorge number 1.
Insert the key and observe the gorge position in relation to the cylinder.

– If the upper gorge section is aligned with the cylinder housing -arrow-, then gorge number 1 is
the correct one for this position. Otherwise, place gorge number 2 and so forth until finding the
one that is aligned with cylinder when the key is inserted.
Note
Repeat the operation for all other gorge positions in the cylinder. Mark the position (sequence) of
the gorges in relation to the cylinder.
– Insert the cylinder in the housing.
– Install the operating rod and ring.
– Position the spring.
– Install the lock.
– Install the rear door lock cylinder.
– Install the VW symbol.
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door - Sedan > Rear door latch cylinder - disassemble and assemble > Assemble
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Fuel reservoir nozzle compartment and lid set > Fuel reservoir nozzle compartment and lid set (hatch) - remove and install

Fuel reservoir nozzle compartment and lid set (hatch) - remove and install
1 - Fuel reservoir nozzle compartment and lid set

 composed by the set comprised of lid → Item and fuel nozzle small door compartment → Item.
 remove:
 Remove the fuel reservoir nozzle lid.
 Disengage the opening mechanism → Item and remove the opening mechanism.
 Remove the screws → Item.
 Remove the rubber part of the reservoir filling nozzle and remove the fuel reservoir nozzle compartment and lid set from the side panel.
 install:
The assembly part and the adjustment element are assembled
 First, assemble the fuel reservoir nozzle compartment and lid set from the hinge side.
 Fasten the fuel reservoir nozzle compartment and lid set and the assembly part.
2 - Fuel reservoir lid

 can only be removed with the fuel reservoir nozzle compartment and lid set → Item.
 to remove fuel reservoir lid, press the fuel reservoir nozzlecompartment fastening pin outwards.
3 - Opening mechanism
4 - Screw
5 - Fuel nozzle small door compartment
 can only be removed with the fuel reservoir nozzle compartment and lid set → Item
 To remove fuel reservoir lid, it is necessary to remove the fuel reservoir nozzle compartment fastening pin.
6 - Flow pipe
7 - Side panel
8 - Unblocking pin
9 - Reservoir lid locking motor

 Assembly location: Pillar C
 Remove: with the hexagonal wrench 3 mm -T 10010-
10 - Sealing packing
11 - Unblocking pin guide

 It is inserted on the lateral part.

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Fuel reservoir nozzle compartment and lid set > Fuel reservoir nozzle compartment and lid set (hatch) - remove and install
Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Fuel reservoir nozzle compartment and lid set > Fuel reservoir nozzle compartment and lid set (sedan) - remove and install

Fuel reservoir nozzle compartment and lid set (sedan) - remove and install
1 - Fuel reservoir lid positioning element
2 - Eyelet
3 - Unlocking support

 is fitted to the lateral part
4 - Fuel reservoir lid set

 Comprised by reservoir lid -5- and reservoir lid compartment
 Remove:
 Unthread the reservoir lid
 Unlock the pre-locking mechanism tab - → Item- and pull the pre-locking mechanism outward.
 Unthread the screw - → Item-.
 Extract the rubber bellows from the tank filling nozzle and remove the reservoir nozzle case lid from the side panel.
5 - Reservoir lid
 it is only possible to remove it by removing the fuel reservoir lid set -→ Item-
 To remove the reservoir lid, you must remove the reservoir lidfastening pin.
6 - Screw
7 - Unlocking mechanism
8 - Fuel reservoir lid housing

 it is only possible to remove it by removing the fuel reservoir lid set -→ Item-
 to remove the reservoir lid, you must push the reservoir nozzle caselid fastening pin outwards.
9 - Flow hose
10 - Side panel

Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Fuel reservoir nozzle compartment and lid set > Fuel reservoir nozzle compartment and lid set (sedan) - remove and install
Body > General body repairs, exterior > Front door, central locking > Front door > Tools

Tools
Repair Manual
Manuals
Workshop Manuals
Amigo
Body
Door Front
Front Door
Front entry door
Fronts
Repair Manual
Manuals
Workshop Manuals
Amigo
Body

Body > General body repairs, exterior > Front door, central locking > Front door > Tools
Body > General body repairs, exterior > Front door, central locking > Front door > Tools > Special tools, workshop equipment, test and measurement devices, as well as auxiliary means necessary

Special tools, workshop equipment, test and measurement devices, as well as
auxiliary means necessary
 Pincers -T 10072-
 Hook -T 10118-
 Multi-teeth bits -3320/2-for Wrench -3320-
 Multi-teeth bits -3320/3-for Wrench -3320-
 Pressure roll -3356-
Repair Manual
Manuals
Workshop Manuals
Amigo
Body
Device
Door Front
Body > General body repairs, exterior > Front door, central locking > Front door > Tools > Special tools, workshop equipment, test and measurement devices, as well as auxiliary means necessary
Body > General body repairs, exterior > Front door, central locking > Front door > Assembly overview

Assembly overview
Note
 The door hinge screws must always be replaced when removed.
 The instrument panel must be removed to remove or adjust the upper door hinge.
1 - Door
2 - External door handle

3 - Latch cylinder

4 - Plug
5 - Screw
 18 Nm
6 - Lock button

7 - Lock rod
8 - Bellows
9 - Screw
 20 Nm
10 - Buffer
11 - Door latch

 lubricate with -G 000 400 01-
12 - Front door lock operating cable

13 - Internal door handle

 M8 × 28
 20 Nm + 1/4 turn (90°)
 replace if removed.

 M8 × 28
 To remove the door, simply remove this hinge screw.
 20 Nm + 1/4 turn (90°)
16 - Door hinge with door blocker

 The hinge is a two-part set
 lubricate with -G 000 150-

 M8 × 28
 Installed from inside the vehicle
 Remove the lower pillar covering → Body - Internal assembly works; Rep. Gr.70

 M8 × 28
 20 Nm + 1/4 turn (90°)

 M8 × 28
 20 Nm + 1/4 turn (90°)
20 - Nut
 14 Nm
21 - Hinge axle
22 - Door hinge


 M8 × 22
 Installed from inside the vehicle
 To remove or install the screws, remove the instrument panel → Body - Internal assembly works; Rep. Gr.70
 20 Nm + 1/4 turn (90°)

 M8 × 28
 20 Nm + 1/4 turn (90°)

Body > General body repairs, exterior > Front door, central locking > Front door > Assembly overview
Body > General body repairs, exterior > Front door, central locking > Front door > Door - remove and install

Door - remove and install

– Disengage the bellows -3- from pillar A. Disconnect the connectors from pillar A.
– Remove the nut -2- from the upper hinge axle -1-.
Tightening torque: 14 Nm
– Remove the lower screw -4- from the hinge with the wrench -3320- and the multi-teeth bits
-3320/3-3320/3.
Tightening torque: 20 Nm + 1/4 (90°)
– Raise the door, removing it from the hinge.
Note
This screw must always be replaced.
Body > General body repairs, exterior > Front door, central locking > Front door > Door - remove and install
Body > General body repairs, exterior > Front door, central locking > Front door > Front door lock operating cable - remove and install > Remove

Remove
– Remove the front subframe → Chapter

– Remove the clips from the electric harnesses on the back side of the subframe.

– Remove the clips -1- with a punch.
– Remove the bellows -1- from the cable -2- and the bellows -6- from the locking rod-5- with the

help of a screwdriver.
– With the help of a screwdriver -3-, raise the door lock -4- with the support -7- from the subframe.
Note
The support does not belong to the door lock set -4-. The door lock is fitted to the support -7- and
fastened with a rivet.

– Disengage the locking rod -1--arrow-.
– Disengage the cable -2-.
Body > General body repairs, exterior > Front door, central locking > Front door > Front door lock operating cable - remove and install > Remove
Body > General body repairs, exterior > Front door, central locking > Front door > Front door lock operating cable - remove and install > Install

Install

– Fit the cable -2-.
– Install the door lock on the subframe.

– Pull the operating lever -1- in the direction of the arrow.
– Press, in direction of the arrow, the spring -2- fastened to the door lock, with a screwdriver, and
couple the lock lever to the spring.
Note
When the operating lever is coupled, the lock is locked. Thus, the further “incorrect” coupling of the
operating cable is avoided.
– Install the front subframe → Chapter.
Body > General body repairs, exterior > Front door, central locking > Front door > Front door lock operating cable - remove and install > Install
Body > General body repairs, exterior > Front door, central locking > Front door > Door - adjust

Door - adjust
Note
 The door is adjusted correctly when, once closed, the clearance around it is uniform. The door
must not protrude nor recede, and the contours must be aligned.


Torque wrench - 5 to 50Nm (fit. 1/2") -VAG 1331-
– Remove the instrument panel → Body - Internal assembly works; Rep. Gr.70.
– Remove the lower pillar A covering → Body - Internal assembly works; Rep. Gr.70.

– Untighten the screws -2- from inside the vehicle with a multi-teeth socket M8.
– Untighten the screws -1- with the wrench -3320- and themulti-teeth bits -3320/3 -.
– Position the door and fasten the screws -1- and -2- temporarily. Check the gap in relation to the
door with the adjustment gauge -3371- , → Rep. Gr.00
– Adjust the door buffer → Chapter.
– Install the lower pillar A covering.
– Install the instrument panel.
Note
Lubricate the rollers -3- with grease -G 000 150-.
Body > General body repairs, exterior > Front door, central locking > Front door > Door - adjust
Body > General body repairs, exterior > Front door, central locking > Front door > Door buffer - adjust

Door buffer - adjust
Note
 The description refers only to the right door adjustment. The left door adjustment is identical.
 When closing the front door, it must be completely closed, without additional force, and no
clearance should be verified.
 When adjusting the door buffer, the front door cannot be pressed upwards nor downwards.
With the door buffer, you can adjust:

 If the front door adjustment is not aligned.

– Release the buffer -1- by untightening the screws -2- on pillar B.
– Adjust the front door with the buffer -1- so the front

door closed isaligned with the rear passenger door.
– Tighten the screws -2- on buffer -1-.
Tightening torque: screws -2- 20 Nm.
Body > General body repairs, exterior > Front door, central locking > Front door > Door buffer - adjust
Body > General body repairs, exterior > Front door, central locking > Front door > External door handle and lock - assembly overview

External door handle and lock - assembly overview
1 - Door latch

 The door lock can only be removed along with the support → Item.
2 - Cable
 lock unlocking
3 - Support
 Fitted and riveted to the door lock.
 It is not supplied along with the door lock.
4 - Support
 remove:
 Remove the latch cylinder → Chapter.
 Remove the door handle → Chapter.
 Remove the support.
 Remove the Philips screw → Item, push the support slightly backwards and remove from the door.
5 - Screw
6 - Wrench
 replace batteries → Chapter
 adapt the new or additional keys to the vehicle's remote commandand immobiliser → Chapter
7 - External door handle

 remove and install
8 - Cover cap
9 - Latch cylinder

10 - Base
11 - Torx screw

 The pincers -T 10072- is used to remove.
 When removing the screws, the lock cylinder → Item is unblocked and can be removed from the support → Item
 The screw → Item cannot be threaded without the lock cylinder inserted. The locking ring may fall into the door.

Body > General body repairs, exterior > Front door, central locking > Front door > External door handle and lock - assembly overview
Body > General body repairs, exterior > Front door, central locking > Front door > Latch cylinder - remove and install > Remove

Remove

– Remove the cover cap -1-.
– Pull the handle -1- and hold it. Untighten the screw -3- with the pincers -T 10072- up to the
buffer. The lock cylinder is loosened.
Note
If you release the screw excessively -3-, you may cause the support to fall inside the door.
– Pull the cylinder-2- outside the door handle support.
Repair Manual
Manuals
Workshop Manuals
Amigo
Body
Cabinet Handles
Body > General body repairs, exterior > Front door, central locking > Front door > Latch cylinder - remove and install > Remove
Body > General body repairs, exterior > Front door, central locking > Front door > Latch cylinder - remove and install > Install

Install
'
– Fit the lock cylinder to the support, in the door handle.
– Tighten the screws to the support with the pincers -T 10072-.
The door handle is fitted again to the lock cylinder quite audibly.
Note
During the assembly, the door handle and the lock cylinder must be pressed against the door plate.
 Check the handle operation before closing the door, otherwise, the door will not open.
Repair Manual
Manuals
Workshop Manuals
Amigo
Assemblies
Body
Body > General body repairs, exterior > Front door, central locking > Front door > Latch cylinder - remove and install > Install
Body > General body repairs, exterior > Front door, central locking > Front door > External door handle - remove and install > Remove

Remove
– Remove the door cylinder → Chapter.
– Disengage the clip -1- from the door handle.
– Remove the door handle.
Repair Manual
Manuals
Workshop Manuals
Amigo
Body
Cabinet Handles
Body > General body repairs, exterior > Front door, central locking > Front door > External door handle - remove and install > Remove
Body > General body repairs, exterior > Front door, central locking > Front door > External door handle - remove and install > Install

Install

– Through the opening in the door panel, insert the hook -T 10118- in the door.
– For better vision, illuminate the internal section of the door with a lamp.
– Fasten the hook to the spring -arrow A-.

– Pull the hook-arrow B-, fasten the spring to the door lock.
– Install the hinge in the door.
– Pull the clip -1- through the plate cut and fit to the door handle -2-.
Note
During the assembly, the door handle -2- must be pressed against the door panel.
– Install the latch cylinder → Chapter.
Body > General body repairs, exterior > Front door, central locking > Front door > External door handle - remove and install > Install
Body > General body repairs, exterior > Front door, central locking > Front door > Lock - remove and install

Lock - remove and install
The window drive mechanism, the door lock and the speakers are fastened to the subframe.
The door lock can only be removed along with the subframe.
The subframe can only be removed if the door window is free from the fastening jaws of the window
drive mechanism. For this purpose, the door window must be lowered up to the height of the
assembly holes in the subframe, and the tightening jaws must be released.
If it is not possible to lower the door window with the power window drive mechanism, first you must
determine the exact cause of the damage.
For this purpose, it is necessary to refer to the damage memory of the convenience system
(address code 46) with the diagnosis, measurement and information system -VAS
5051A/52-,→ Body, self-diagnosis; Gr. Rep. 01; convenience system; refer to damage memory.
In case of electric damage, eliminate such damage fist.
In case of electric damage caused by the power window drive mechanism, such mechanism can be
removed from the subframe.
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Body > General body repairs, exterior > Front door, central locking > Front door > Lock - remove and install
Body > General body repairs, exterior > Front door, central locking > Front door > Lock - remove and install > Remove

Remove
– Remove the front door lining → General body repairs, interior; Rep. Gr.70

– Remove the latch cylinder → Chapter.

– Remove the clip -1- from the door handle.
– Remove the plugs -1-.
– Lower the door window until the door window fastening screws -2-are accessible.
Note
If it is not possible to execute this work step due to a damage in the power window drive
mechanism, it is possible to remove the motor fastening screws to move the window downwards.
– Untighten the screws -2- and separate the jaws.

– Move the door window upwards and fasten (for example, with adhesive tape).

– Disconnect the connectors -arrows-.

– Remove the screws -arrows-. Pull the door subframe upwards, raise it and remove it from
thedoor hinge side.
– Move the subframe and disconnect the connectors from the door locking motor.

– Remove the clips from the electric harnesses on the back side of the subframe.

– Remove the clips -1- with a punch.
– Remove the bellows -1- from the cable -2- and the bellows -6- from the locking rod-5- with the

help of a screwdriver.
– With the help of a screwdriver -3-, raise the door lock -4- with the support -7- from the subframe.
Note
The support does not belong to the door lock set -4-. The door lock is fitted to the support -7- and

– Disengage the locking rod -1--arrow-.
Body > General body repairs, exterior > Front door, central locking > Front door > Lock - remove and install > Remove
Body > General body repairs, exterior > Front door, central locking > Front door > Lock - remove and install > Install

Install


Note
– Install the subframe to the door.

– Place all screws. Fasten the screws -1- and -2- following the sequence indicated (tightening
torque: 8 Nm).
– The other screws can be fastened without a determined sequence.
– Adjust the door window → Chapter.
Body > General body repairs, exterior > Front door, central locking > Front door > Lock - remove and install > Install
Body > General body repairs, exterior > Front door, central locking > Front door > Lock button (locking rod) - remove and install > Remove

Remove

– With the lock button completely raised, fit the extractor and fitter -VW 035- with the button
shoulder facing the positioning pin. Turn the tool 180° counterclockwise.
– Remove the tool with the button
Body > General body repairs, exterior > Front door, central locking > Front door > Lock button (locking rod) - remove and install > Remove
Body > General body repairs, exterior > Front door, central locking > Front door > Lock button (locking rod) - remove and install > Install

Install

– Insert the button in the extractor and fitter -VW 035- with the shoulder facing the tool positioning
pin.
– Position the tool with the button in the position it was removed and turn the tool 180° clockwise.
Note
The extractor and fitter -VW 035- determines the correct button height. Therefore, when positioning
it, make sure that the tool is supported in the door lining.
Left front door and right rear passenger door
Body > General body repairs, exterior > Front door, central locking > Front door > Lock button (locking rod) - remove and install > Install
Body > General body repairs, exterior > Front door, central locking > Front door > Front door packings - assembly overview

Front door packings - assembly overview
1 - Internal door packing

2 - External door packing

 self-adhesive
3 - Double-sided adhesive tape
4 - Internal door packing fitting flange

Body > General body repairs, exterior > Front door, central locking > Front door > Front door packings - assembly overview
Body > General body repairs, exterior > Front door, central locking > Front door > Internal front door packing - remove and install > Remove

Remove

– Remove the lower door sill → Body - Internal assembly works; Rep. Gr.68.
– Remove the pillar B covering → Body - Internal assembly works; Rep. Gr.70.
– Remove the lower pillar A covering → Body - Internal assembly works; Rep. Gr.70.
Note
In the instrument panel area, depending on the space conditions, it may be necessary to untighten
the instrument panel.
– Disengage the packing from the fitting -4- flanges.
Body > General body repairs, exterior > Front door, central locking > Front door > Internal front door packing - remove and install > Remove
Body > General body repairs, exterior > Front door, central locking > Front door > Internal front door packing - remove and install > Install

Install
Note
The packing sides must be pressed before starting the assembly.
– Position the vulcanised packing joint, which must remain above the lower door hinge.

– Hit the packing sides against the flanges with a rubber hammer -4-.
– Install the lower pillar A covering.
– Install the pillar B coverings.
– Install the lower door sill.
Body > General body repairs, exterior > Front door, central locking > Front door > Internal front door packing - remove and install > Install
Body > General body repairs, exterior > Front door, central locking > Front door > External front door packing - remove and install

External front door packing - remove and install

 Hot air blower -VAG 1416-
Body > General body repairs, exterior > Front door, central locking > Front door > External front door packing - remove and install
Body > General body repairs, exterior > Front door, central locking > Front door > External front door packing - remove and install > Remove

Remove
– Heat the packing with the hot air blower -VAG 1416-. Unglue the packing -2-.

Body > General body repairs, exterior > Front door, central locking > Front door > External front door packing - remove and install > Remove
Body > General body repairs, exterior > Front door, central locking > Front door > External front door packing - remove and install > Install

Install
– Clean the adhesion area with cleaning solution -D 009 401 04-, and then, apply the silicone
remover -LSE 020 100 A3-.
– Remove the adhesive tape liner, position the packing -2- and glue to the door, and press
strongly by using the pressure roll -3356-. Operating temperature of approx. 20°C.
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Adhesion
Adhesive Tape
Body > General body repairs, exterior > Front door, central locking > Front door > External front door packing - remove and install > Install
Corpo > reparos geral do corpo, exterior > porta da frente, fecho central > bloqueio Central > travamento central - Resumo de montagem

fecho central - Resumo de montagem
1 - elétrica de conexão
 local de montagem: Pillar A
 para desconectar os conectores , desengatar os foles no pilar.
2 - Direito porta da frente comando

 integrado ao motor mecanismo elétrico da janela
 remover:
 Remova o revestimento da porta → corpo repara Geral, interior;Rep. Gr.70 .
 Remova o subframe → capítulo .
 Retire os parafusos de fixação do motor mecanismo elétrico da janela.
 local de montagem: Coluna B
4 - Direito fechadura da porta da frente

 A fechadura da porta é presa ao chassi auxiliar.
 O motor do mecanismo de travamento elétrico é integrado para a fechadura da porta.
 remover:
 Remova o revestimento da porta → corpo repara Geral, interior;Rep. Gr.70 .
 Retire o trinco da porta → capítulo .
5 - Porta traseira direita de comando

 remover:
 Remova o revestimento da porta → corpo repara Geral, interior;Rep. Gr.70
6 - Direito fechadura da porta traseira
 remover:
 Remova o revestimento da porta → corpo repara Geral, interior; Rep. Gr.70
7 - Motor para bloquear a tampa do reservatório de combustível -V155-

 local de montagem: sob a cobertura pilar C
 Para remover, é necessário remover primeiro o bagagem do compartimento de revestimento e o revestimento da roda caso → Body - Montagem interna
funciona; Rep. Gr.70
8 - fechadura da porta traseira

 Fixado à porta traseira
 remover e instalar → item
9 - Motor para desbloquear a porta traseira -V139-

 Presas a um suporte da porta traseira
10 - Esquerda fechadura da porta traseira

 remover:
 local de montagem: na área do telhado cruz membro trás, coberta pelo forro do tejadilho.
12 - Porta traseira esquerda de comando

 remover:
 Remova a parte traseira subframe → capítulo .
13 - sirene de alarme H1
 Local de montagem: na área do lado esquerdo, na parte dianteira da parte traseira do eixo , na parte inferior do soalho.
 local de montagem: Coluna B
15 - Esquerda fechadura da porta da frente

 remover:
16 - controle de unidade
 Montado para o revestimento da porta.
 remover:
17 - Porta dianteira esquerda de comando

 remover:
 Remova o subchassi dianteiro → capítulo .
 local de montagem: Pillar A
19 - Central de comando do sistema de conveniência

 Montadas para o apoio no suporte do painel de instrumentos central.
 Local de montagem: por baixo do painel de instrumentos, do lado do condutor (acima do acelerador de pedal em veículos com volante à esquerda, acima do pedal
da embraiagem em veículos com volante à direita).
20 - Bonnet trava
 Contacto do interruptor de alarme anti-roubo -F 266-
 local de montagem: no painel da direita
 Remova a parte dianteira da tampa trava → Capítulo

Corpo > reparos geral do corpo, exterior > porta da frente, fecho central > bloqueio Central > travamento central - Resumo de montagem
Corpo > reparos geral do corpo, exterior > porta da frente, fecho central > bloqueio Central > fecho central (sedan) - Resumo de montagem

fecho central (sedan) - Resumo de montagem
 Instalação local: Pillar A
 para desligar a ligação , desengatar os foles no pilar
2 - Travamento da porta dianteira direita comando

 Integrado ao motor mecanismo elétrico da janela
 Remover:
 Instalação local: Coluna B
4 - Direito fechadura da porta da frente

 Remover:
 Remover o trinco da porta → capítulo .
5 - Travamento da porta traseira direita de comando

 Remover:
 Remova o subframe de trás.
6 - Direito fechadura da porta de passageiro traseiro

 Remover:
7 - Motor para destravar a tampa V155 reservatório de combustível

 Instalação local: sob a cobertura pilar C
 Para remover, antes de liberar o forro de inicialização até o caso da roda → Body - Montagem interna funciona; Rep. Gr.70
8 - trava da tampa
 Fixado sobre a tampa
 Remover e instalar → Capítulo
9 - Tampa do dispositivo do motor

 Fixado a um suporte no interior da tampa
10 - Esquerda fechadura da porta de passageiro traseiro

 Remover:
 Instalação local: na área painel do lado esquerdo, coberto pelo revestimento lateral da bagagem do compartimento
 Retirar o revestimento do compartimento de bagagem → Body - Montagem interna funciona; Rep. Gr.70 .
12 - Porta do passageiro traseiro esquerdo comando unidade

 Remover:
 Remova o subframe de trás.
13 - Horn e chifre de duas som -H1-

 Instalação local: na área esquerda na frente da parte traseira do eixo no piso inferior
14 - conexão ponto
 Instalação local: Coluna B
15 - Esquerda fechadura da porta da frente

 Remover:
 Remova a porta de bloqueio → capítulo .
16 - controle de unidade
 Instalado no revestimento da porta
 Remover:
17 - Porta dianteira esquerda de bloqueio de comando

 Remover:
 Remova o subframe.
 Instalação local: Pillar A
19 - Central de comando para o sistema de "conveniência"

 montada a um suporte no suporte do painel de instrumentos média
 Instalação local: por baixo do painel de instrumentos (acima do acelerador de pedal, em caso de volante à esquerda, e acima do pedal de embreagem, em caso de
volante à direita)
20 - Bonnet trava
 O interruptor de contato para o motor do compartimento bonnet -F266-
 Instalação local: no painel da direita.
 Remova a porta traseira trava → capítulo .

Corpo > reparos geral do corpo, exterior > porta da frente, fecho central > bloqueio Central > fecho central (sedan) - Resumo de montagem
Corpo > reparos geral do corpo, exterior > porta da frente, fecho central > bloqueio Central > comando do sistema Conveniência - remover e instalar

comando do sistema de conveniência - remover e instalar
- Remova o defletor -1- na área de pés no lado do condutor → Aquecimento - ventilação; Rep.
Gr.80

O comando do sistema conveniência -2- está localizado num suporte de plástico -3- do painel de
instrumentos.montado no suporte central
- Desengatar o dispositivo de comando do sistema de conveniência -1- fora do suporte -2- -

seta- e desligar os conectores.
Corpo > reparos geral do corpo, exterior > porta da frente, fecho central > bloqueio Central > comando do sistema Conveniência - remover e instalar
Corpo > reparos geral do corpo, exterior > porta da frente, fecho central > bloqueio Central > Chaves com comando à distância via rádio - adaptar

Chaves com remoto de comandos via rádio - adaptar
Adaptação teclas com remoto de comandos via rádio é realizada com o diagnóstico, medição e do
veículo informações sistema -VAS 5051-
- Selecione no diagnóstico, medição e do veículo informações -VAS sistema de 5051- a "solução

de problemas assistida".
- Com a tecla "Ir", ir para a seleção das funções e componentes e selecione os seguintes itens no
menu sucessivamente:
 Corpo
 trabalhos de montagem do corpo Geral

 01 - Sistemas com auto-diagnóstico
 sistema de conveniência
 Funções - sistema de conveniência
 Adaptação chaves para o imobilizador electrónico
Nota
É possível adaptar as chaves para o controle remoto de comandos via

rádio automaticamenteatravés de uma adaptação para o imobilizador.
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Corpo > reparos geral do corpo, exterior > porta da frente, fecho central > bloqueio Central > Chaves com comando à distância via rádio - adaptar
Corpo > reparos geral do corpo, exterior > porta da frente, fecho central > bloqueio Central > bateria chave com comando à distância via rádio (articulado) - remover e instalar

pilha da chave com comando à distância via rádio (articulado) - remover e instalar
1 - Chave com transponder código variável
2 - Comando remoto via rádio - seção superior
3 - diodo emissor de luz (LED)

 A lâmpada de díodo deve piscar quando o comando remoto está activada.
 Se a lâmpada de diodo não piscar quando o comando remoto é ativado, a bateria está descarregada e deve ser substituído.
4 - Bateria
 Remover a bateria → Capítulo
 Instale a bateria → Capítulo
5 - Comando remoto via rádio - secção inferior

Corpo > reparos geral do corpo, exterior > porta da frente, fecho central > bloqueio Central > bateria chave com comando à distância via rádio (articulado) - remover e instalar
Corpo > reparos geral do corpo, exterior > porta da frente, fecho central > bloqueio Central > bateria chave com comando à distância via rádio (articulado) - remover e instalar > Remover

Remover
- Fit a screwdriver to the slot between the remote command via radio -1- ea chave -2- .

- Turn the screwdriver in the direction of the -arrow- to separate the remote command via radio
from the key.

– Open the remote command via radio -1- with the key body -2-.
– Disengage the battery -1- from the fastenings -2-, with the help of a screwdriver, in the direction
of the arrow.
Body > General body repairs, exterior > Front door, central locking > Central locking > Key battery with remote command via radio (articulated) - remove and install > Remove
Body > General body repairs, exterior > Front door, central locking > Central locking > Key battery with remote command via radio (articulated) - remove and install > Install

Install
When installing the battery, pay attention to the polarity and the assembly position.
– Place the battery -1- in the remote command via radio -2- with the positive pole facing down (the
positive pole is indicated on the box).
– By slightly pressing the battery, it fits to the remote command via radio.
– Place the lid in the remote command via radio (do not damage the joint).
– Fit the remote command via radio to the key.
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Body > General body repairs, exterior > Front door, central locking > Central locking > Key battery with remote command via radio (articulated) - remove and install > Install
Body > General body repairs, exterior > Front door, central locking > Central locking > Key - synchronize

Key - synchronize
The key synchronisation is required in case of disconnection of the earth strap from the
battery, or when the key emitting button is pressed out of the system coverage range.

– Press the key -1-, close the door and open it after 1 minute.
Body > General body repairs, exterior > Front door, central locking > Central locking > Key - synchronize
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Tools

Tools
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Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Tools
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Tools > Special tools, workshop equipment, test and measurement devices and auxiliary devices necessary

Special tools, workshop equipment, test and measurement devices and
auxiliary devices necessary
 Socket wrench -T 10072-
 Assembly tool -T 10118-
 Bit adapter for 3320 -3320/2-
 Bit adapter for 3320 -3320/3-

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Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Tools > Special tools, workshop equipment, test and measurement devices and auxiliary devices necessary
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Assembly overview

Assembly overview
Note
The door hinge screws must always be replaced after being removed.
1 - Door
2 - External handle


 remove the lock cylinder
4 - Cover cap
5 - Lock button

6 - Lock rod
7 - Lock operating rod
8 - Inversion lever
9 - Bellows
10 - Screw
 20 Nm
11 - Door latch

12 - Rear door lock operating cable

13 - Internal door handle

 M8 × 28
 20 Nm + 1/4 turn (90°)

 M8 × 28
 To remove the door, simply untighten this hinge screw.
 20 Nm + 1/4 turn (90°)
16 - Door hinge with door blocker

 The hinge is a split part

 M8 × 28
 Installed from inside the vehicle.
 Remove the lower pillar A covering → Body - Internal assembly works; Rep. Gr.70
 20 Nm + 1/4 turn (90°)

 M8×28
 20 Nm + 1/4 turn (90°)

 M8×28
 20 Nm + 1/4 turn (90°)
20 - Nut
 14 Nm
21 - Hinge axle
22 - Door hinge

 The hinge is a split part

 M8×22
 Installed from inside the vehicle.
 Remove the lower pillar A covering → Body - Internal assembly works; Rep. Gr.70
 20 Nm + 1/4 turn (90°)

 M8×28
 20 Nm + 1/4 turn (90°)

Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Assembly overview
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Rear passenger door (sedan) - assembly overview

Rear passenger door (sedan) - assembly overview
Note
Always replace the door hinge screws after releasing them.
1 - Door
2 - Door hinge with shim

3 - Housing
 remove the lock cylinder housing
4 - Protection cover
5 - Door lock button

6 - Door lock rod
7 - Door lock rod
8 - Angular lever
9 - Bellows
10 - Screw
 20 Nm
11 - Door latch

12 - Rear door lock operating cable

13 - Internal door activation
14 - Torx screw

 M 8 × 28
 20 Nm + 1/4 turn. (90°)
15 - Torx screw

 M 8 × 28
 to remove the door from the hinge, remove only this screw
 20 Nm + 1/4 turn. (90°)
16 - Door hinge with door fastening mechanism

 The hinge is split
17 - Torx screw
 M 8 × 28
 assembled from inside the vehicle
 Remove the lower pillar B covering → Body - Internal assembly works; Rep. Gr.70
 20 Nm + 1/4 turn. (90°)
18 - Torx screw

 M 8 × 28
 20 Nm + 1/4 turn. (90°)
19 - Torx screw

 M 8 × 28
 20 Nm + 1/4 turn. (90°).
20 - Nut
 14 Nm
21 - Hinge pin
22 - Door hinge

23 - Torx screw

 M 8 × 22
 assembled from inside the vehicle
 Remove the lower pillar B covering → Body - Internal assembly works; Rep. Gr.70
 20 Nm + 1/4 turn. (90°)
24 - Torx screw

 M 8 × 28
 20 Nm + 1/4 turn. (90°)

Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Rear passenger door (sedan) - assembly overview
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Door - remove and install

Door - remove and install
– Remove the lower pillar B covering → Body - Internal assembly works; Rep. Gr.70

– Remove the bellows -3- from pillar B. Disconnect the pillar B connectors from the coupling
station.
– Untighten the nut -1- from the upper hinge axle.
– Untighten the lower screw -2- from the hinge.
Tightening torque: 20 Nm and turn + 1/4 back (90°)
Note
This screw must always be replaced.
– Raise the door, removing it from the hinge angle.
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Door - remove and install
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Rear passenger door lock operating cable - remove and install > Remove

Remove
– Remove the rear subframe → Chapter.
– Remove the bellows cables.
– Turn the subframe and disconnect from the door lock.

– Disengage the clips -1- with a punch.

– Disengage the sleeve -1- from the subframe cable -2- with the help of a screwdriver and remove
the cable from the subframe.
– With a screwdriver -3-, raise the door lock -5- with the support -4- from the subframe.
Note
The support -4- does not belong to the door lock. The door lock -5- is fitted to the support -4- and

– Disengage the lock rod -1-. Turn the door lock in the direction of the arrow.
– Turn the cable nipple 90° and remove it from the eyelet.
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Rear passenger door lock operating cable - remove and install > Remove
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Rear passenger door lock operating cable - remove and install > Install

Install
– Fit the operating cable to the lock and the control rod.

– Tighten, in direction of the arrow, the spring -2- fastened to the door lock with a screwdriver, and
fit the lock lever to the spring.
Note
When the operating lever is coupled, the lock is locked. Thus, the further “incorrect” coupling of
theBowden cable is avoided.
– Install the rear subframe → Chapter.
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Rear passenger door lock operating cable - remove and install > Install
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Door - adjust

Door - adjust
Note
 The door is adjusted correctly when, once closed, the clearance around it is uniform. The door
must not protrude nor recede, and the contours must be aligned.


Torque wrench - 5 to 50Nm (fit. 1/2") -VAG 1331-
– Remove the lower pillar B covering → Body - Internal assembly works; Rep. Gr.70.

– Untighten the screws -2- from inside the vehicle with a multi-teeth socket M8.
– Untighten the screws -1- with the wrench -3320- and themulti-teeth bits -3320/3 -.
– Position the door and fasten the screws -1- and -2- temporarily. Check the gap in relation to the
door with the adjustment gauge -3371- , → Rep. Gr.00
– Adjust the door buffer.
– Install the lower pillar B covering.
Note
Lubricate the rollers -3- with grease -G 000 150-.
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Door - adjust
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > External door handle and lock - assembly overview

External door handle and lock - assembly overview

1 - Door latch
 The door lock can only be removed along with the subframe.
 lubricate with -G 000 400 01-
2 - Cable
 lock activation.
3 - Support
 Fitted and riveted to the door lock.
 It is not supplied along with the door lock.
4 - Support
 remove:
 Remove the door handle.
 Remove the subframe.
 Untighten the screw -10-, move the support slightly backwards and remove from the door.
5 - Screw
6 - External handle

7 - Cover cap
9 - Sealing
10 - Torx screw

 Pincers -T 10072-
 When removing the screws, the lock cylinder is unblocked and can be removed from the support.
 The screw cannot be threaded without the lock cylinder inserted. The locking ring may fall into the door.

Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > External door handle and lock - assembly overview
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > External door handle - remove and install > Remove

Remove

– Pull the door handle -1- in the direction of the arrow and hold it. Untighten the screw -3- with the
pincers -T 10072- up to the buffer. The cylinder housing will be loosened.
Note
If you release the screw excessively -3-, you may cause the support to fall inside the door.
– Pull the cylinder housing -2- to outside the door handle support in the door support.

– Disengage the clip -1- from the door handle.
– Remove the door handle.
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > External door handle - remove and install > Remove
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > External door handle - remove and install > Install

Install

– Through the opening in the internal door panel, insert the hook -T 10118- in the door.
– For better vision, illuminate the internal section of the door with a lamp.
– Fasten the hook -T 10118- to the spring -arrow A-.
– Pulling the hook -T 10118--arrow B-, fasten the spring to the door lock.

– Install the door handle.
– Pull the clip -1- through the plate cut and fit to the door handle -2-.
– Fit the right side support, on the door handle support.
– Tighten the screws to the support.
The door handle is fitted again to the lock cylinder quite audibly.
Note
During the assembly, the door handle -2- must be pressed against the door panel.
 Check the operation, because if the cable adjustment is not correct, the door may not open.
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > External door handle - remove and install > Install
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Door latch - remove and install

Door latch - remove and install
The door lock can only be removed along with the subframe.
The subframe can only be removed if the door window is free from the fastening jaws of the window
drive mechanism. For this purpose, the door window must be lowered up to the height of the
assembly holes in the subframe, and the tightening jaws must be released.
If it is not possible to lower the door window with the power window drive mechanism, first you must
determine the exact cause of the damage.
(address code 46) with the Diagnosis, Measurement and Information System -VAS
5051A/52-,→ Body, self-diagnosis; Gr. Rep. 01; convenience system; refer to damage memory.
In case of electric damage, eliminate such damage fist.
In case of electric damage caused by the power window drive mechanism, such mechanism can be
removed from the subframe.
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Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Door latch - remove and install
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Door latch - remove and install > Remove

Remove
– Remove the rear door lining → Body - Internal assembly works; Rep. Gr.70
– Remove the lock cylinder.

– Remove the cover cap -1-.
– Lower the door window until the expansion pin -2- and the expansion bushing -3- in the window
drive mechanism cut are accessible.
Note
If it is not possible to execute this work step due to a damage in the power window drive
mechanism, it is possible to remove the motor fastening screws to move the window downwards.
– Thread a 5 mm screw (approx. 70 mm of length) to the expansion pin -2- and remove it from the
expansion bushing -3-.
– Now, thread a 8 mm screw (approx. 80 mm of length) to the expansion bushing -3-.
Note
When threading the screw to the expansion bushing, do not press the bushing excessively,
because it may fall inside the door.
– Remove the expansion bushing from the window drive mechanism guide and, consequently,
from the door window.
– Deviate the window drive mechanism cable to the side, with a screwdriver.

– Move the door window -1- upwards -arrow- and fasten it (for example, with adhesive tape).

– Remove the bellows -1- from pillar B.
– Disconnect the connectors -2-.

– Remove the screws -arrows-.
– Remove the screws -1- (from the lock).

– Pull the door subframe upwards, raise and remove from the door hinge side -arrow-.
– Remove the bellows cables.
– Turn the subframe and disconnect from the door lock.

– Disengage the clips -1- with a punch.

– Disengage the sleeve -1- from the subframe cable -2- with the help of a screwdriver and remove
the cable from the subframe.
– With a screwdriver -3-, raise the door lock -5- with the support -4- from the subframe.
Note
The support -4- does not belong to the door lock. The door lock -5- is fitted to the support -4- and

– Disengage the lock rod -1-. Turn the door lock in the direction of the arrow.
– Turn the cable nipple 90° and remove it from the eyelet.
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Door latch - remove and install > Remove
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Door latch - remove and install > Install

Install


– Tighten, in direction of the arrow, the spring -2- fastened to the door lock with a screwdriver, and
fit the lock lever to the spring.
Note
When the operating lever is coupled, the lock is locked. Thus, the further “incorrect” coupling of
theBowden cable is avoided.

– Remove the door window fastening (for example, adhesive tape) and move the door
windowdownwards, until it is possible to assemble the expansion bushing -2- and the expansion
pin-1- in the door.
– Place the expansion bushing -2- and the expansion pin -1- in the window.
– Centralize the expansion bushing in the window.
– Move the door window upward and fasten it.
– Insert the electric harnesses in the door, through the bellows, and fasten the clips to the
internaldoor panel.
– Insert the subframe in the door.

– Place all screws. Tighten the screws marked with -1- and -2- in the sequence indicated,
tightening torque: 8 Nm.
– The other screws can be tightened in any sequence.

– Lower the window lift, until the window lift guide -4- is directly below the assembly opening in the
subframe.
– Insert the door window -3- in the window drive mechanism guide slot -4-.
– Fit the lock - with a slight pressure - from above in the window lift -4-.
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Door latch - remove and install > Install
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Rear door packings - assembly overview

Rear door packings - assembly overview
1 - Internal rear door packing

2 - External door packing

4 - Internal door packing fitting flange

Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Rear door packings - assembly overview
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Internal rear door packing - remove and install > Remove

Remove

– Remove the door sill → Body - Internal assembly works; Rep. Gr.68.
– Remove the pillar C coverings → Body - Internal assembly works; Rep. Gr.70.
– Remove the pillar B covering → Body - Internal assembly works; Rep. Gr.70.
– Disengage the packing from the fitting -4- flanges.
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Internal rear door packing - remove and install > Remove
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Internal rear door packing - remove and install > Install

Install
Note
The packing sides must be pressed before starting the assembly.
– Position the vulcanised packing joint, which must remain above the lower door hinge.

– Hit the packing sides against the flanges with a rubber hammer -4-.
– Install the lower pillar B covering.
– Install the pillar C coverings.
– Install the door sill.
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > Internal rear door packing - remove and install > Install
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > External rear door packing - remove and install

External rear door packing - remove and install

Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > External rear door packing - remove and install
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > External rear door packing - remove and install > Remove

Remove
– Heat the packing with the hot air blower -VAG 1416-. Unglue the packing -2-.
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Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > External rear door packing - remove and install > Remove
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > External rear door packing - remove and install > Install

Install
– Clean the adhesion area with cleaning solution -D 009 401 04-, and then, apply the silicone
remover -LSE 020 100 A3-.

– Remove the adhesive tape liner, position the packing -2- and glue to the door, and press
strongly by using the pressure roll -3356-. Operating temperature of approx. 20°C.
Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking > Rear door > External rear door packing - remove and install > Install
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Operation

Operation
The sliding/tilting sunroof may be opened and closed by using the sunroof sliding adjustment
-E139-, with ignition on.
After turning the ignition off, it is possible to open or close the sliding / tilting sunroof while the
driver's or front passenger's door is not opened.
In the sunroof sliding adjustment -E139-, there are marks corresponding to the opening positions
established. Glass pane opening positions. However, it is possible to open the sunroof in any
intermediate position desired, both in the sliding and tilting modes, by turning the command in the
corresponding direction.

Opening the sliding / tilting sunroof with the control position -1- in the so-called convenience position
reduces considerably the noise caused by the wind with the full opening when using
thecontrol position -2-.
The sliding / tilting sunroof is equipped with a closing force limiter for the sliding area. When finding
any obstacle during closing, the sunroof will automatically reopen.
Additionally, there is an emergency closing function. In case of closing problems, the sliding sunroof
may be forced to close by pressing the control, which shall be in the “sunroof closed” position.
With the emergency closing function, the closing force limiting function is turned off.
The sliding / tilting sunroof drive is protected against excessive warming by an operating time
limiter. The protection mechanism is activated after after an uninterrupted activation of
approximately two minutes. The sunroof may only be activated again after a cooling phase.
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Operation
Polo Mk4

Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sliding / tilting roof with glass pane - assembly overview
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Sliding / tilting roof with glass pane - assembly overview
1 - Glass pane for sliding/tilting sunroof (single laminate safety glass)
 Remove the glass pane for the sliding/tilting sunroof → Chapter
 Install the glass pane for the sliding/tilting sunroof → Chapter
 Adjust the glass pane for the sliding/tilting sunroof → Chapter
2 - Cover packing
 Adjust sunroof packing → Chapter
 The packing ends are turned to the centre, on the rear part.
 Replace the sunroof packing → Chapter
3 - Solar protective coating

4 - Screw
 1.5 Nm
5 - Sliding
6 - Lower frame
7 - Water gutter

 Remove → Chapter, the guide with steel cable
8 - Guide with coupling hook
9 - Tip
 for sealing, use Butyl adhesive cord -AKL 450 005 05-
10 - Guide frame

 Remove and install guide frame → Chapter
 When required, lubricate the guide channels with special grease -G 000 450 02-. Otherwise, the operation is not assured.
11 - Screw
 3,5 Nm
 Must always be replaced upon removal
12 - The hexagonal wrench for emergency actuation

 is fitted on the cover of the sliding sunroof drive motor
13 - Control unit for sliding sunroof displacement -J245-

 Remove → Chapter
 The sunroof sliding adjustment -E139- is fitted in the control unit.
 Remove the sunroof sliding adjustment -E139- → Chapter
14 - Siding sunroof drive motor -V1-

 Adjust the motor (position zero) → Chapter
15 - Spring
16 - Air deflector
17 - Torx screw

 T 25
 4.5 Nm
18 - Guide with steel cable

19 - Slide guide

20 - Spacer
21 - Bellows
 Install → Chapter

Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sliding / tilting roof with glass pane - assembly overview
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sliding / tilting sunroof glass pane - remove and install > Removal

Removal
– Push the solar protective coating backward.
– Open the sliding / tilting sunroof.

– Disengage the bellows-1- from the lower part of the sliding guide -3-.
– Remove the bellows-1- from the fastening pins-4-.
– Disengage the bellows -1- upwards and backwards -2-.
– Remove the bellows-1-.

– Disengage the lower frame -2-.

– Remove fastening screws -1- (T 25 to 4.5 Nm).
– Remove the sliding / tilting sunroof cover from above.
Note
The sliding / tilting sunroof must not be taken to the “open” position while the glass pane is
removed, since the water gutter would not be pressed by the glass pane and may get stuck in the
roof.
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sliding / tilting sunroof glass pane - remove and install > Removal
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sliding / tilting sunroof glass pane - remove and install > Installation

Installation
Note
If, after removing the glass pane, works were performed on the assembly unit (disassembly and
assembly, replacement of unit parts) or the drive was removed and the slide guides were
displaced, check the parallelism → Chapter first, and when required, adjust → Chapter.
The sliding sunroof guides are in the “open” position.

– Introduce the sliding / tilting sunroof cover from upside and tighten the screws (slide/cover).
– Moderately tighten the fastening screws -1- (T 25).
Note
Tighten the fastening screws after adjusting the cover height → Chapter (4.5 Nm).
– Install the bellows after adjusting the cover's height.
Note
Do not change the bellows positions.
– Move the glass pane to the “closed” position.
– Check position “zero”:
Position zero:

The mark -arrow- on the upper part of the rear guide -1- must be, on both sides, between the
markers -Measure a- in the slide guide -2-.
The slide guide -2- must fit into the guide rail (it does not slide manually when the drive is removed).
If this is not the case, adjust the cover parallelism → Chapter.
– Adjust the glass pane (height adjustment) → Chapter.
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sliding / tilting sunroof glass pane - remove and install > Installation
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Glass pane for sliding / tilting sunroof - height adjustment

Glass pane for sliding / tilting sunroof - height adjustment
Sliding / tilting sunroof zero position OK.

– Lower frame -2- in front region, disconnect towards the centre of the vehicle and disengage from
backwards.
– Disengage the bellows-1- from the lower part of the sliding guide -3-.
– Disengage the bellows -1- upwards and backwards -2-.
– Remove the bellows-1-.

Cover adjustment on the front section:
– Loosen fastening screws -3- (T 25; 4.5 Nm).
– Move the glass pane to the “open” position.
– Move the glass pane to the “closed” position.
– Adjust the glass pane height in the front and back parts on both sides, as follows:
a = 0... 1 mm lower than the vehicle's roof level.
Arrow = indicating forward

Cover adjustment, rear part:
b = 0... 1 mm higher than the vehicle's roof level.
Arrow = indicating forward
– Tighten the glass cover screws (4.5 Nm).
Always symmetrically adjust the right and left sides of the glass cover.
Note
The bellows and packings should not be inverted. Otherwise, the free displacement of components
will not be assured.

– Disengage the bellows-1- from guides-2-.
– Remove the bellows-1- from the lower part of the slide guides -3-.
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Glass pane for sliding / tilting sunroof - height adjustment
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Cover packing - adjust

Cover packing - adjust
– Control the pre-tension evenly around the whole perimeter between the cover packing -2- and
the body, by using a cardboard strip with approx. 0.3-mm thickness. The cardboard strip must
pass forced between the cover sealing and the body.
 To adjust the cover packing, remove the glass pane -3-.

– The cover packing may be removed with a slight tension, by pressing withwedge -3409--1-.

– The cover packing -1- may be removed with a slight tension, by using a pressure roller -3356- all
around.
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Cover packing - adjust
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Cover packing - replace

Cover packing - replace

– Remove the sliding / tilting sunroof glass pane → Chapter.
– Pull the packing -1- from the glass pane -2- towards the arrow on the rear edge of the glass
pane, by starting in the middle.
– Remove all the adhesive residues from the glass pane edge.

– Apply the primer that is supplied with the sealing kit -6N0 898 209-, by using the applicator -D
009 500 25--1- around the whole contour of the gluing surface.

– Remove the protective plastic by pulling gradually the gluing surface of the new packing, and
glue the packing in the middle of the rear edge of the glass pane.

– The new packing on cover -1- must align perfectly with the glass pane upper edge -arrow-.
– The cover packing must be cut so to adjust it to the cover perimeter.
– Then, press firmly the new packing with the pressure roller -3356-.
– Adjust cover packing → Chapter.
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Cover packing - replace
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Air deflector - remove

Air deflector - remove
– Open fully the sliding / tilting sunroof.

– With a screwdriver, leverage carefully the air deflector bearing -1- out of the guide rail (left /
right).
– Remove the air deflector upwards.
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Air deflector - remove
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sun protective coating - remove and install > Removal

Removal
Sliding / tilting sunroof glass pane removed and sliding/tilting unit in “closed position”.
– Push the solar protective coating forward.

– Press the solar protective coating to the side. Move the slider -1- (front to back) with a
screwdriver, out of the guide channels.
– Remove the solar protective coating upwards.
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sun protective coating - remove and install > Removal
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sun protective coating - remove and install > Installation

Installation

– Place the solar protective coating in the roof profile and fit the solar protective coating slider -1-.
Now, the sliders are connected to the solar protective coating in the guide channels. Only after
this, place the slider in the opposite side of the guide channels.
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Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sun protective coating - remove and install > Installation
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sliding sunroof movement control unit J245 - remove

Sliding sunroof movement control unit -J245- - remove
Note
 Before disconnecting the battery, read the instructions related to coding in the radio
user'smanual.
 After disconnecting the battery, the vehicle accessories (radio, clock, power windows) must be
checked according to the repair and/or operation instruction manuals.
– Disconnect earth strap from Battery -A- .

– Disconnect cover -1- from drive, by using the screwdriver -2-.
– If applicable, disengage the connectors of the INTERNAL ELECTRONIC ALARM

– Disconnect the Sliding sunroof movement control unit -J245--1- (with selector switch and internal
light), and remove the moulded roof downwards, and frontwards -arrow-.
– Remove the fitting connections.
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sliding sunroof movement control unit J245 - remove
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sunroof sliding adjustment E139 - remove

Sunroof sliding adjustment -E139- - remove
– Remove the Sliding sunroof movement control unit -J245- → Chapter.

– At the rear section of the control unit, release the locking tabs -arrows- and remove the sliding
adjustment -1- from the control unit -2-.
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sunroof sliding adjustment E139 - remove
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sliding sunroof drive motor V1 - remove

Sliding sunroof drive motor -V1- - remove
Note
 Remove and install the sliding sunroof drive motor only with the sunroof closed (zero position ).
 Engine and ignition shall be off to do that.
– Remove the Sliding sunroof movement control unit -J245- → Chapter.

– Remove the screws -arrows- and remove the sunroof drive motor.
– Disengage connections and cables
The drive screws are provided with micro-shielded and must always be replaced (3.5 Nm).
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sliding sunroof drive motor V1 - remove
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sliding sunroof drive motor V1 (zero position) - adjust

Sliding sunroof drive motor -V1- (zero position) - adjust
The zero position adjustment may be necessary when the drive has not been removed while on
zero position, or when the sliding / tilting sunroof has been closed or opened by emergency
operation.
Drive removed, but power cables are connected.
– By using the sunroof sliding adjustment, select “roof opened”.
– By using the sunroof sliding adjustment, select “roof closed”
– By using the sunroof sliding adjustment, select “roof opened”
– By using the sunroof sliding adjustment, select “roof closed”.
– In this position (zero position), install the sliding sunroof drive motor.
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Sliding sunroof drive motor -V1- (zero position) - adjust
The zero position adjustment may be necessary when the drive has not been removed while on
zero position, or when the sliding / tilting sunroof has been closed or opened by emergency
operation.
Drive removed, but power cables are connected.
– By using the sunroof sliding adjustment, select “roof opened”.
– By using the sunroof sliding adjustment, select “roof closed”
– By using the sunroof sliding adjustment, select “roof opened”
– By using the sunroof sliding adjustment, select “roof closed”.
– In this position (zero position), install the sliding sunroof drive motor.
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Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Parallelism - adjust

Parallelism - adjust
Note
The parallelism adjustment must only be performed with the drive and glass pane removed (at
zero position).
– Remove the sliding sunroof drive motor -V1- → Chapter.
Position zero:

The mark -arrow- on the upper part of the rear guide -1- must be, on both sides, between
themarkers -measure a- in the slide guide -2-.
The slide guide -2- must be locked on the guide rail (with the sliding sunroof drive motor -V1-; do not
push manually).
– The upper part of the guide -1- must be pushed only front to back, by the middle and between
marks.
– Install the sliding sunroof drive motor -V1- (position zero) in this position.
Then, check the zero position.
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Parallelism - adjust
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sliding guide - remove

Sliding guide - remove

– Disconnect the spacer -2-.
– Push the slide guide -1- towards the arrow, to the stop.
Note
When installing the spacer -2-, pay attention on the installation position (arrow on the spacer).

– Turn the slide guide-1- upwards and remove from guide.
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sliding guide - remove
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Assembly unit - remove and install > Remove

Remove

– Remove the glass pane from the sliding / tilting sunroof for better assembly → Chapter.
– Remove the moulded lining of the roof → Rep. Gr.70.
– Disengage the drive connection -5- on motor -4-.
– Disconnect water drain hose couplings on the assembly unit -1--arrows-.
– Remove screws -3- and the assembly unit from the vehicle with the help from a second
mechanic.
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Assembly unit - remove and install > Remove
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Assembly unit - remove and install > Installation

Installation

– Support the assembly unit -1- on the rear housings and turn upwards.
Note
The fastening pins must be in the assembly holes.
– Align the assembly unit -1- during assembly, by using two cylindrical pins (drill bits turned to the
contrary), in the right side -2- 10 mm and left side -6- 12 mm, in the roof.
– Install screws -3-.
– Check the installation of cables and connectors of the power consumers in the roof, and if
necessary, establish the connection.
– Fasten the assembly unit -1- of the sliding / tilting sunroof drive -4-, starting from the left and
right sides, and moving backwards (8 Nm).
– Insert connector -5-in the motor -4-..
– Install the water draining hoses -arrows-.
– Install the moulded lining of the roof → Rep. Gr.70.
– Install the sliding / tilting sunroof glass pane → Chapter.
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Assembly unit - remove and install > Installation
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Guide with steel cable - remove

Guide with steel cable - remove
– Remove assembly unit → Chapter.

– Remove the sliding / tilting sunroof drive → Chapter
– Disconnect tip -1- on the guide slides -2--arrows-, and then, remove.
Note
When installing, seal the tip -1- with Butyl adhesive cord -AKL 450 005 05- on the opposite side of
the guide rail.

– Release carefully the water gutter -1- by using a screwdriver on both sides of the support, in the
coupling hook guide -2- and remove.

– Move the guide with steel cable -1- towards arrow, on guide rail -4-, until releasing the coupling
hook guide lock -3-.
– Pull the guide with steel cable -1-, coupling hook guide -3- and slide guide -2- outwards, with the
guide rail -4-.
Assembly notes
 Always replace the guides with steel cables in pairs.

 Lubricate the guide channels with special grease -G 000 450 02-
 Install the assembly unit → Chapter.
 Adjust the parallelism → Chapter.
 Install the sliding / tilting sunroof glass pane → Chapter.
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Guide with steel cable - remove
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Draining hoses - clean > Front water draining hoses

Front water draining hoses
The front water draining hoses -3- run along the A pillars and end on the water reservoir. Clean from
the sliding / tilting sunroof profile.
1 - Water draining hose
2 - Water flow valve
Note
To clean, it is recommended the use of an auxiliary tool, a homemade probe from the internal speedometer cable, approx. 2,300
mm long.

Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Draining hoses - clean > Front water draining hoses
Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Draining hoses - clean > Rear water draining hoses

Rear water draining hoses
The rear water draining hoses -1- run and end on the rear roof corner, before the rear lid. Clean
from the rear end of the hose. To do that, remove the cover -3-.
1 - Water draining hose
2 - Water flow valve
3 - Cover
Note
To clean, it is recommended the use of an auxiliary tool, a homemade probe from the internal speedometer cable, approx. 2,300
mm long.

Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Draining hoses - clean > Rear water draining hoses
Body > General body repairs, exterior > Bumper > Front bumper > Tools

Tools

 Torque wrench 2 to 10 Nm -VAG 1783-
 Torque wrench - 5 to 50Nm (fit. 1/2") -VAG 1331-
Body > General body repairs, exterior > Bumper > Front bumper > Tools
Body > General body repairs, exterior > Bumper > Front bumper > Front protector (? 06.06) - assembly overview

Front protector (► 06.06) - assembly overview
1 - Front protector

 PP/EPDM material
2 - Screw
 3 units
 8 Nm
3 - Screw
 3 units
 1.5 Nm
4 - Expansion nut

 3 units
5 - Side support

 To remove and install, move the bumper parallel to the support (on the left and right sides).
6 - Screw
 4 units
 2 Nm
7 - Quick nut

 4 units
8 - Expansion rivet

 4 units
9 - Bumper trim

 fitted to the front protector
10 - Air intake grille

11 - Air intake grille with cut to the fog light

12 - Screw
 2 units
 8 Nm
13 - Headlight washer cover
 The cover is fitted to the cut for the headlight washer ejectors.

Body > General body repairs, exterior > Bumper > Front bumper > Front protector (? 06.06) - assembly overview
Body > General body repairs, exterior > Bumper > Front bumper > Front protector (? 2006) - remove and install

Front protector (► 2006) - remove and install

– Remove the front grille → Chapter.
– Remove and release the packings -13- from the front protector headlight washer.
– Remove the protector -1- from the wheel case area → Chapter.
– Disengage the grille -10-.
– Remove screws -2- and -12-.
The other items are only possible with the help of a second mechanic.
– Remove the cover -1-, with the help from a second mechanic, from both guides (on the left and
right sides) -12- at the same time.
– Disconnect the temperature sensor connector.
Note
The front protector supplied by Parts and accessories already has a base primer coat applied, and
only needs the finish painting. Paint the front protector according to the => Painting Manual.
Body > General body repairs, exterior > Bumper > Front bumper > Front protector (? 2006) - remove and install
Body > General body repairs, exterior > Bumper > Front bumper > Protector support (? 2006) - assembly overview

Protector support (► 2006) - assembly overview
2 - Bushing
 replace if necessary
 3 units
3 - Screw
 3 units
 1.5 Nm
4 - Side support

 To remove and install, move the protector parallel to the support (on the left and right sides).
5 - Screw
 4 units
6 - Hexagonal head screw

 6 units
 30 Nm

Body > General body repairs, exterior > Bumper > Front bumper > Protector support (? 2006) - assembly overview
Body > General body repairs, exterior > Bumper > Front bumper > Front protector (2007 ?) - assembly overview

Front protector (2007 ►) - assembly overview
1 - Front protector

 remove: → Chapter
2 - Expansion rivet

 4 units
3 - Screw
 6 units
 3.5 Nm
4 - Bushing
 1 unit on each side
5 - Screw
 6 units on each side
 1.5 Nm
6 - Screw
 joins the protector to the wing.
 2 Nm

Body > General body repairs, exterior > Bumper > Front bumper > Front protector (2007 ?) - assembly overview
Body > General body repairs, exterior > Bumper > Front bumper > Front protector additional components (2007 ?)

Front protector additional components (2007 ►)
1 - Front protector

2 - Bumper trim, left side

 fitted to the protector
 The bumper trim can be disengaged from the fittings and removed from the outside, by carefully using the wedge -3409-.
3 - Left grille

 Extract from the fitting from the front.
4 - Central grille

5 - Spoiler
 PC/ABS material
 Only disassemble with the bumper disassembled.
6 - Right grille

7 - Bumper trim, right side

 The bumper trim can be released from the fittings and removed from the outside, by carefully using the wedge -3409-.

Body > General body repairs, exterior > Bumper > Front bumper > Front protector additional components (2007 ?)
Body > General body repairs, exterior > Bumper > Front bumper > Front protector support (2007 ?) - assembly overview

Front protector support (2007 ►) - assembly overview
2 - Screw
 30 Nm
3 - Side support

 on the left and right sides
 remove:
– untighten from the wing side with the screws -2-.
4 - Screw
 2 units
 2 Nm
5 - Bushing
 2 units

Body > General body repairs, exterior > Bumper > Front bumper > Front protector support (2007 ?) - assembly overview
Body > General body repairs, exterior > Bumper > Front bumper > Front bumper spoiler - Blue Motion - remove and install

Front bumper spoiler - Blue Motion - remove and install
1 - Front protector

 Material PP/EPDM
2 - Front left protector trim

 Fitted to the front protector
 To remove it, detach carefully, using a plastic wedge.
3 - Left side grille

 Extraer hacia delante, para sacarlo del encastre.
4 - Spoiler
 Material PC/ABS, painted
 To remove it, remove the front protector.
5 - Right side grille

 Extraer hacia delante, para sacarlo del encastre.
6 - Central grille

7 - Front right protector trim


Body > General body repairs, exterior > Bumper > Front bumper > Front bumper spoiler - Blue Motion - remove and install
Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Tools

Tools

 Torque wrench - 40 to 200Nm (enc. 1/2") -VAG 1332-
Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Tools
Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Rear protector - assembly overview

Rear protector - assembly overview
1 - Screw
 4 units
 4 Nm
2 - Rear protector
3 - Screw
 3 units
 4 Nm
4 - Bumper trim

 fitted to the protector → Chapter
5 - Parking aid sensor - G203 / G204 / G205 / G206-

 2007 ►
6 - Sensor support

 2007 ►
7 - Double-sided tape
 2007 ►
8 - Sensor support adhesion area

 2007 ►
9 - Quick nut

 8 units
10 - Screw
 8 units
 1.2 Nm
11 - Side support

 To remove and install, move the protector parallel to the side supports (on the left and right sides).
12 - Fastening support

Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Rear protector - assembly overview
Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Rear protector - remove and install > Remove

Remove

– Remove the lamps → Electrical system; Rep. Gr.94
– Remove the screws -1- and -3-.
– Remove the screws -10-. Remove the cover from the right supports -2- (on the left and right
sides) and remove the fastening support -12-.
– Disconnect the connectors -5- from the rear parking aid sensors -G203 / G204 / G205 / G206-.
Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Rear protector - remove and install > Remove
Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Rear protector - remove and install > Install

Install
Note
The rear protector and the rear parking aid sensors -G203 / G204 / G205 / G206- supplied by Parts
and accessories already has a base primer coat applied and it only needs the finish painting. Paint
the front protector and sensors according to the => Painting Manual.

Repair Manual
Manuals
Workshop Manuals
Amigo
Body
Bumper
Coats
Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Rear protector - remove and install > Install
Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Protector support - assembly overview

Protector support - assembly overview
1 - Protector support
2 - Screw
 4 units
 1.5 Nm
3 - Central guide
4 - Side guide

 To remove and install, move the rear protector, parallel to the sideguides (on the left and right sides).
5 - Screw
 4 units
 1.5 Nm
6 - Expansion bushing

 6 units

 2 units
8 - Riveted nut

 4 units
 To install, use the riveted nut applicator POP NUT -VAG 1765B- or riveted nut applicator POP NUT -EQ 7422-
9 - Screw
 1.5 Nm
 4 units
10 - Support
11 - Screw
 2 units
 8 Nm
12 - Hexagonal nut M8
 6 units
 20 Nm

Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Protector support - assembly overview
Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Rear bumper spoiler - Blue Motion - remove and install

Rear bumper spoiler - Blue Motion - remove and install
1 - Rear protector

 Material- PP/EPDM
2 - Side guide

 To disassemble and assemble the bumper, pull it out of the guide parts or push it into them, in parallel (left and right).
3 - Screw
 8 units
 1.2 Nm
4 - Central guide
5 - Screw
 7 units
 4 Nm
6 - Rear spoiler
 Material PC/ABS, painted
 fitted to the rear protector
 To remove it, remove the rear protector.
7 - Quick nut

 8 units

Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Rear bumper spoiler - Blue Motion - remove and install
Body > General body repairs, exterior > Bumper > Rear bumper - sedan > Tools

Tools

 Torque wrench - 40 to 200Nm (enc. 1/2") -VAG 1332-
Body > General body repairs, exterior > Bumper > Rear bumper - sedan > Tools
Body > General body repairs, exterior > Bumper > Rear bumper - sedan > Rear bumper protector (sedan) - assembly overview

Rear bumper protector (sedan) - assembly overview

1 - Sensor support adhesion area
 2007 ►
2 - Double-sided tape
 2007 ►
3 - Sensor support

 2007 ►
4 - Parking aid sensor - G203 / G204 / G205 / G206-

 2007 ►
5 - Support
6 - Rear protector

7 - Screw
 8 parts
 8 Nm
8 - Bumper trim

 Installed on the rear protector
9 - Quick nut

 8 parts
10 - Screw
 8 parts
 8 Nm
11 - Expansion rivet

 2 parts
 to install the rear protector with the side panel
12 - Side support

 To remove and install the bumper, you must pull it out of the side supports in parallel or push it in parallel to inside the side supports.
13 - Nut
 2 parts
 8 Nm

Body > General body repairs, exterior > Bumper > Rear bumper - sedan > Rear bumper protector (sedan) - assembly overview
Body > General body repairs, exterior > Bumper > Rear bumper - sedan > Rear bumper protector (sedan) - remove and install > Remove

Remove

– Move the expansion rivet away -11- (2 parts) (push with pin).
– Remove the nuts -13- (2 parts).
– Remove the screws -7- (8 parts).
– Remove the screws -10- and remove the rear protector from the guide elements -12- (left and
right) and fastening lock -.
Body > General body repairs, exterior > Bumper > Rear bumper - sedan > Rear bumper protector (sedan) - remove and install > Remove
Body > General body repairs, exterior > Bumper > Rear bumper - sedan > Rear bumper (sedan) - assembly overview

Rear bumper (sedan) - assembly overview

 14 parts
2 - Support
3 - Side support

 To remove and install the bumper, you must pull it out of the side supports in parallel (left and right) or push it in parallel to inside the side supports (left and right).
4 - Screw
 2 parts
 1.5 Nm
 First screw to be installed, after it, tighten the others in any sequence.
5 - Screw
 12 parts
 1.5 Nm
6 - Hexagonal nut M 8
 6 parts
 20 Nm
7 - Bumper support

Body > General body repairs, exterior > Bumper > Rear bumper - sedan > Rear bumper (sedan) - assembly overview
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Tools

Tools

 Glued glass removal kit -VAG 1474B-
 Suction pad grippers -VAG 1344-V
 Anchoring tool -VAG 1351-
 Glass removal kit -VAG 1755 -
 Pneumatic Adhesive applicator for glued glasses -VAG 1761/1- or Adhesive applicator for glued
glasses -VAG 1628-
 Cartridge heater -VAG 1939A-
 Electric adhesive cutter - glued glasses -VAG 1561A-

 58 mm blade -VAG 1561//2-
 15 mm blade -VAG 1561/7+8-
 Blade -VAG 1561/10-
 Blade -VAG 1561/19-
 Pneumatic adhesive applicator -VAS 5237-
 Wedge (1 pair) -VW 027-
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Tools
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Auxiliary materials for the Brazilian market

Auxiliary materials for the Brazilian market
 Glass adhesion kit
See Chemicals Manual 1

 Cutting wire
-357 853 999.A-
 Glass adjustment shim
-443 845 631 A-
-D 009 401 04-
1)

Follow the minimum drying time → Chapter.
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Auxiliary materials for the Brazilian market
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Auxiliary materials for the export market

Auxiliary materials for the export market
 Adhesive 2 K for glass
-DA 004 600 A2- → Note → Note
 Adhesive 1K for glass
-DH 009 100 A2-
 Activator
-D 181 801 A1 -
 Primer for glass and body
-D 009 200 02-
-D 009 401 04-
 Primer applicator
-D 009 500 25-
-D 002 000 10-
 Cutting wire
-357 853 999.A-
1)

Follow the minimum period for drying → Chapter
2)
To process these materials, it is necessary to use the pneumatic adhesive applicator -VAS 5237 -.
3)
Heat according to indications from the manufacturer, using the cartridge heater -VAG 1939A-.
4)
Small 110 ml cartridge for sealing works and/or if the 400 ml cartridge is not enough.
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Auxiliary materials for the export market
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Matching table

Matching table
Note
To help understanding, please find below a comparison table for materials used in the Brazilian and
export markets
Product Brazilian Market Export Market
PU Adhesive X-1500 or PU-501 Super Quick High Modulus -DA 004 600 A2- or -DH 009 100 A2-
Activator U-401 or PU-520 Primer -D 181 801 A1-
Body primer U-413 or PU-530 Primer -D 009 200 02-
Glass primer U-401 or PU-520 Primer -D 009 200 02-

Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Matching table
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Windscreen - Assembly overview

Windscreen - assembly overview
1 - Windscreen
 remove the windscreen → Chapter
 install the windscreen → Chapter
2 - Sealing lip
3 - PUR adhesive
 Cord section: width = 7 mm height = 11 mm (adhesive residue, base coat, on the glass and body flange).
4 - Elevation a = 3.5 mm

 on the upper and side sections
5 - Glass adjustment device

 -443 845 631 A-
6 - Starting and ending points for application of PUR adhesive

Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Windscreen - Assembly overview
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Lower windscreen covering - remove and install

Lower windscreen covering - remove and install
1 - Lower windscreen covering

 remove → Chapter
 install → Chapter
2 - Packing
3 - Plastic pads
4 - Windscreen
5 - Covering fitting trim

Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Lower windscreen covering - remove and install
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Lower windscreen covering - remove and install > Remove

Remove

– Remove the windscreen wiper arms → Electrical system; Rep. Gr.92
– Remove the lid packing -2-.
– With the wedge from the glass removal kit -VAG 1755-, press forward the pads -3- of the lower
windscreen covering -1- on the left and right sides, between the hinge and the front bonnet.
– Carefully pull the lower windscreen covering -1- upwards, starting on the right side -arrow A-, to
remove the covering fitting trim -5- from the windscreen -4-.
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Lower windscreen covering - remove and install > Remove
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Lower windscreen covering - remove and install > Install

Install

– In order to facilitate fitting the lower windscreen covering -1- to the trim -5-, apply soap.
– Seat the lower windscreen covering -1- on the trim -5- to the windscreen -4- and, starting from
the centre -arrow B-, fit the lower covering to the trim -5- with a light pressure.
– With the wedge from the glass removal kit -VAG 1755--3-, take the lower windscreen covering-
1- to its assembly position, pressing it on the right and left sides, between the hinge and the
front bonnet.
– Assemble the packing -2- and the windscreen wiper.
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Lower windscreen covering - remove and install > Install
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Windscreen - remove

Windscreen - remove
– Remove the lower pillar A covering → Body - Internal assembly works; Rep. Gr.70
– Remove the sunshades → Body - Internal assembly works; Rep. Gr.70
– Remove the internal rear-view mirror → General body repairs, interior; Rep. Gr.68

– Insert the protective film for panel -VAG 1474/8--1- between the windscreen
and instrumentpanel.
– Using the wedge from the glass removal kit -VAG 1755-, release from the glass flange the
sealing lip on the upper windscreen section and spray with the cleaning solution -D 009 401 04-.
– Insert the cutting wire -2- in the glass flange, with the help of the tube from the glass removal kit
-VAG 1755-.
– If the clearance dimensions are too small, continue to insert the cutting wire from the outside and
pass it below the lip with the wedge from the glass removal kit -VAG 1755-.
– Pull the cutting wire tip to inside the vehicle, with the handle from the glued glass removal kit
-VAG 1474B-, through the adhesive.
Note
Insert the handle in the side section of the glass, near the body glass flange, through the adhesive,
to not damage the sealing lip.

– Fasten a wire tip to the device with ratchet -VAG 1654A-.
– Pass the other wire tip to inside and assemble the pulling grasp from the anchoring tool -VAG
1351- to counter-support it.
– Place the device with ratchet -VAG 1654A- in “position I”.
– Change the device position to “position II”, then to “position III” and so forth, until completely
cutting the adhesive.
– During the cutting operation, press the cutting wire against the glass with the wedge from the
glass removal kit -VAG 1755-, to have access to the glass flange and to the instrument panel.
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Windscreen - remove
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Side glass (hatch) - assembly overview

Side glass (hatch) - assembly overview
1 - Side glass

 remove the side glass → Chapter
 Install the side glass → Chapter
2 - PUR adhesive
 cord section: width = 8 mm height = 12 mm (including the adhesivebase coat on the glass and body flange)
 minimum drying period
3 - Encapsulation (is part of the glass)

Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Side glass (hatch) - assembly overview
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Undamaged side glass (hatch) - remove

Undamaged side glass (hatch) - remove

– Remove the pillar C lining → General body repairs, interior; Rep. Gr.70
– Raise the sealing lip around the entire glass flange and spray with the cleaning solution -D 009
401 04- (replacement for the sliding material).

– Pull the cutting wire to inside the vehicle, with the drilling tool (from the glued glass removal kit
-VAG 1474B-), through the adhesive.
– Insert the cutting wire between the lip and the glass flange, with the help of the tube -1- (if the
cutting wire breaks, the cutting metal wire can also be used).
– If the clearance dimensions are too small, continue to insert the cutting wire from the outside and
pass it below the lip with a plastic wedge.

– Place the cutting wire around the side glass.
– Place the handle -VAG 1351- outside and inside the vehicle.
– Pull the handle, inside the vehicle, until cutting the adhesive.
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Undamaged side glass (hatch) - remove
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Rear door glass - assembly overview

Rear door glass - assembly overview

Note
The rear door glass for “vehicles as of 07.06” has a different shape in the lower glass edge. The removal and installation remain the same.
1 - Rear door glass
2 - Terminals for the glass demister
3 - Sealing packing

 from the rear glass wiper motor axle
4 - Clearance between glass and gap

 equal on the upper and lower sections
 from the sides, the rear door glass can never be protruding in relation to the rear door contour.
5 - PUR adhesive
 cord section: width = 7 mm height = 11 mm (adhesive residue, base coat, on the glass and body flange).
6 - Lining
7 - Glass wiring for TV antenna

 Japan version vehicles
8 - Spacer

Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Rear door glass - assembly overview
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Rear door glass (undamaged) - remove

Rear door glass (undamaged) - remove
– Remove the rear door lining → General body repairs, interior; Rep. Gr.70
– Disconnect the rear door glass demister terminals and press the fittings on the glass.

– Remove the rear window wiper motor → Electrical system; Rep. Gr.92
– Insert the drilling tool (glued glass removal kit -VAG 1474B-) through the adhesive (use the side
area of the rear door glass).
The drilling tool must be inserted as close as possible to the glass.

– Pass a cutting wire tip to the internal side (use pliers and gloves).
– Insert the cutting wire between the door lip and the flange, with the help of the tube -1- (from the
glass removal kit -VAG 1755-).

– If the clearance dimensions are too small, insert the cutting wire from below the lip with the
plastic wedge (from the glass removal kit -VAG 1755-).
– Place the cutting wire around the rear door glass as illustrated in the figure.
Note
Press the cutting wire to a sufficient depth, to avoid damage to the door lip and flange.

– Pass the wire tip to inside and fasten the pulling grasp traction cable -VAG 1351/1- for support.
– Glue the internal glass flange -1- with adhesive tape with screen reinforcement.
– Fasten the wire tip to the device with ratchet.
– Change the position of the device with ratchet to the “position II”, and so forth up to the “position
V”, and remove the glass.
– During the cutting operation, press the cutting metal wire against the glass with a plastic wedge,
to gain access to the glass flange.
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Rear door glass (undamaged) - remove
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Rear door glass (damaged) - remove

Rear door glass (damaged) - remove
– Protect the internal part of the body against glass chips.
– Remove the glass pieces up to the gluing and sealing material.
– Disconnect the glass demister connectors.
– Glue the entire flange -2- with adhesive tape with screen reinforcement.
– Cut the adhesive (with glass remains) in the glass gap with the electric adhesive cutter - glued
glasses - VAG 1561A- and the blade -VAG 1561/10- (with buffer roll).
WARNING
Wearing safety goggles and gloves is mandatory.
Repair Manual
Manuals
Workshop Manuals
Amigo
Adhesive Tape
Adhesives
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Rear door glass (damaged) - remove
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Undamaged rear door glass - remove

Undamaged rear door glass - remove
– Remove the rear door lining → General body repairs, interior; Rep. Gr.70
– Disconnect the rear window demister connectors and press the fittings on the glass.

– Remove the rear wiper motor → Electrical system; Rep. Gr.92
– Slightly round the awl edge, to avoid an excessive effort to the rear glass.
– Insert the drilling tool -VAG 1474/2 - through the glue cord (use the rear window side area).
The drilling tool -VAG 1474/2- must be inserted as close as possible to the glass.

– Pass a cutting metal wire tip inside (use pliers and gloves).
– Insert the cutting metal wire between the lip and the glass flange, with the help of the tube -1-

– If the clearance dimensions are too narrow, continue to insert the cutting metal wire from the
outside and pass it below the lip with a plastic wedge.
– Place the cutting metal wire around the rear glass as illustrated in the figure.
Note
Press the cutting metal wire to a sufficient depth, to avoid damage to the lip and the distancing
shoulder.

– Pass the external wire tip inside and fasten the traction cable -VAG 1351/1- for counter-support.
– Glue the internal glass flange -1- with adhesive tape with screen reinforcement.
– During the cutting operation, press the cutting metal wire against the glass with a plastic wedge,
to gain access to the glass flange.
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Undamaged rear door glass - remove
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the undamaged glass for glass assembly

Prepare the undamaged glass for glass assembly
Note
 In case of reusing a undamaged glass, cut the remaining of the
adhesive shortly before the new gluing in 8 to 9 mm, without damaging
the primer and ceramic painting coat.
 The residual adhesive serves as an adherence base for the new
adhesive and sealing to be applied.
WARNING
Do not apply primer to the gluing surface nor treat with cleaning
solution. Keep the gluing surface free from dirt and consistent
putty.
Exception: if the gluing is not performed immediately after the cut, the
existing residual adhesive must be activated with the activator -D 181 801
A1-.
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the undamaged glass for glass assembly
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the new glass with encapsulation for glass assembly

Prepare the new glass with encapsulation for glass assembly

The new glasses are supplied with PUR encapsulation. The encapsulation
is comprised of items 1, 2 and 3.
1 - Sealing lip

2 - Spacer
3 - Adhesive application area
4 - Glass
Note
Due to the prior cover material of the side glass, the prior cover must be
treated as described below:
– Moisten a cloth with the silicone remover -LSE 020 100 A3-.
– Clean the glue cord application area twice -3- with the cloth moistened.
– After a drying period of at least five minutes, the activator -D 181 801

A1- must be applied, as usual for glasses with prior cover.
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the new glass with encapsulation for glass assembly
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the new glass with encapsulation for glass assembly > Clearance dimensions for the side glass

Clearance dimensions for the side glass
When the side glass is installed, there must be a clearance on the side panel of 5 to 6 mm between
the upper glass edge and the glass flange.
Reason: this distance is necessary for fastening the roof cross member.
The clearance in relation to pillar C in the side panel is of 3.5 mm.
Note
 The activator cannot contact the paint, since it causes damage to it.
 The activator cannot be applied to the glass demister drain channel.
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Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the new glass with encapsulation for glass assembly > Clearance dimensions for the side glass
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the new glass without encapsulation for glass assembly

Prepare the new glass without encapsulation for glass assembly
All glasses (Exceptions: rear window - sedan) are supplied without encapsulation. These glasses
only have the PUR sealing lip -1- and the distancing shoulder -2-.
Follow the different distances from windscreens without sealing lip -1- and without distancing
shoulder -2- in relation to the glass edge:
for the upper edge → Chapter
for the lower edge → Chapter

and for the side edge → Chapter
1 - Sealing lip

2 - Distancing shoulder
3 - Glass
Note
The adhesive cord application area -3- does not have pre-cover nor primer.
– Clean around the glass edge, with a width of 20 mm, with the cleaning solution -D 009 401 04-.
– Then, clean the glass edge with a lint-free cloth in order to dry it.
WARNING
The ceramic paint coat in the glass is not a primer coat! Before applying the gluing and
sealing material, the glass must mandatorily have the primer coat! Use only the primer for
glass and body -D 009 200 02-.

– Then, apply the primer -2- with the primer applicator -D 009 500 25--1- evenly on a cord.
 Drying period, approx. 10 minutes
When installing the side glass, the clearance must be split.
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the new glass without encapsulation for glass assembly
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the new glass without encapsulation for glass assembly > Dimensions for the adhesive cord and primer on the upper glass edge

Dimensions for the adhesive cord and primer on the upper glass edge
A windscreen without sealing lip can be installed from 45/04 Kw. The preparation is described in
“Prepare a new glass without prior cover for glass assembly” → Chapter.
1 - Windscreen
2 - 7 mm
 is the distance from the upper glass edge to the external adhesivecord edge.
3 - Roof structure
4 - Spacer
5 - Primer
 It is applied directly with a spacer in a width of 20 mm.
6 - Polyurethane adhesive PUR

Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the new glass without encapsulation for glass assembly > Dimensions for the adhesive cord and primer on the upper glass edge
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the new glass without encapsulation for glass assembly > Dimensions for the adhesive cord and primer on the lower glass edge

Dimensions for the adhesive cord and primer on the lower glass edge
1 - Windscreen
3 - Primer
 It is applied directly with a spacer in a width of 20 mm.
4 - Baffle
5 - PUR spacer
6 - Covering fitting profile
7 - 23 mm
 It is the distance from the external fitting profile edge to the externaladhesive cord edge.

Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the new glass without encapsulation for glass assembly > Dimensions for the adhesive cord and primer on the lower glass edge
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the new glass without encapsulation for glass assembly > Dimensions for the adhesive cord and primer on the side glass edge

Dimensions for the adhesive cord and primer on the side glass edge

1 - Windscreen
3 - Primer
 It is applied from the side glass edge on a width of 20 mm.
4 - Pillar A
5 - 6 mm
 It is the distance from the side glass edge to the external adhesivecord edge.

Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the new glass without encapsulation for glass assembly > Dimensions for the adhesive cord and primer on the side glass edge
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the body flange for glass assembly

Prepare the body flange for glass assembly
– Remove the residues of material on the glass flange with the 15 mm blade -VAG 1561/8-,
without removing them completely.
Note
The residual adhesive serves as an adherence base for the new adhesive material to be applied.
Keep the gluing surface free from dirt and consistent putty.
WARNING
The activator cannot contact the paint, since it causes damage to it.
Exception: if the gluing is not performed immediately after the cut, the existing residual material
must be activated with the activator -D 181 801 A1-.
 If the body flange is treated or partially replaced before painting, it is necessary to clean and
reapply the primer on the respective area.
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Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Prepare the body flange for glass assembly
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Rear window (sedan) - assembly overview

Rear window (sedan) - assembly overview
1 - Roof
2 - Dimension a = 2.5 + 1 mm

 Connection always even
3 - Dimension b = 2.3 ± 0,8 mm
4 - Rear window

 Install → Chapter
5 - Adhesive
 Cord cross-section: Width = 6 to 7 mm Height = 9 to 11 mm.
 Minimum drying time → Chapter
6 - Buffer
 Self-adhesive
 above and below, respectively 4 units
 Assembly dimensions → Fig.
7 - Demister terminal
8 - Dimension a = 7 + 1 mm
9 - Rear door
10 - Wedge (1 pair) -VW 027-

 for glass assembly
 do not remove before 90 minutes from glass assembly have elapsed
11 - Gap to PUR adhesive
12 - Side panel
13 - Dimension d = 3 ± 1 mm
 Left and right connections equal
14 - Dimension e = 6.3 ± 0.8 mm

fig. 1 Assembly dimensions for the buffer
Dimension -a- = 50 mm
Dimension -b-= 360 mm
Dimension -c-= 60 mm
Dimension -d-= 415 mm
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Rear window (sedan) - assembly overview
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Undamaged rear window (Sedan) - remove

Undamaged rear window (sedan) - remove
– Remove both upper pillar C coverings → Body - Internal assembly works; Rep. Gr.70.
– Remove the package holder lining → Body - Internal assembly works; Rep. Gr.70.
– Remove the roof lining.
– Disconnect the connections for rear window with demister and press the fitting pads against the
glass.

– Using the drilling tool -VAG 1474/2 -, drill the adhesive cord (use the rear window lower side
region).
The drilling tool -VAG 1474/2- must be kept as close as possible to the glass.
– Pull one cutting wire tip inwards (use pliers and gloves).
– If the space is too narrow, lead the cutting wire from outside and press it with the plastic wedge
towards below the glass.

– Place the cutting wire around the rear window as shown in the figure.
– Pull the external wire tip inside and fasten the traction cable -VAG 1351/1- for support.

– Fasten the wire tip to the device with ratchet - VAG 1654A-.
– Apply the corresponding device and cut, releasing the glass (if necessary, use the inverter role
to guide the wire
– During the cut, push the cutting wire against the glass with the plastic wedge to gain space on
the glass flange.
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Undamaged rear window (Sedan) - remove
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Damaged rear window (sedan) - remove

Damaged rear window (sedan) - remove
– Protect the internal part of the body from glass chips.
– Remove the glass pieces up to the adhesive.
– Disconnect the glass demister connectors and the antenna.
– Glue the entire flange -2- with adhesive tape with screen reinforcement.
– Cut the adhesive (with glass remains) in the glass edges with the electric adhesive cutter - glued
glasses -VAG 1561A- and the blade -VAG 1561/10- (with buffer roll).
WARNING
Wearing safety goggles and gloves is mandatory.
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Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > New rear window (sedan) - prepare a new glass for assembly

New rear window (sedan) - prepare a new glass for assembly
1 - Buffers (self-adhesive) -6Y6 845 237 A-
2 - PUR primer coat (Application area for the adhesive cord)
3 - Glass
– Using a cloth with silicone remover - LSE 020 100 A3-, clean thoroughly
the adhesive cordapplication area -1-, passing twice with the cloth soaked with the solution.
– After a minimum drying time of five minutes, it is necessary to apply the activator -D 181 801
A1-, as in the glasses with preliminary coat.
Buffer assembly dimensions → Fig.
Rear window clearances → Fig..

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Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > New rear window (sedan) - prepare a new glass for assembly
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Assembly instructions

Assembly instructions

– Apply the adhesive around the border at a straight angle to the window.
WARNING
The glass must be placed within 10 minutes, otherwise, the glass adhesive adherence will
be impaired
 Place the glass in the glass gap with the help of two suction pad grippers -VAG 1344-, centralize
and press until the distancing shoulder leans on the gap.
 Windscreen clearance dimensions → Chapter.
 During the drying time, fasten the windscreen with the glass adjustment shim -443 845 631 A-.
 Install the lower windscreen covering → Chapter.
 Place eventual existing self-adhesive labels again (for example, from the airbag).
 Insert the rear window wiper motor axle sealing rubber in the rear window.
 Rear window clearance dimensions → Chapter.
 The activator cannot be applied to the glass demister filaments.
 To apply the adhesive coat, marks are placed on the left and right sides of the rear window.
 After the assembly, the rear window sides can never protrude in relation to the rear door contour
 During the drying time, fasten the rear window with adhesive tape.
 If the adhesive cord has been applied with an excessively thick coat, and the adhesive invades
the window demister area, remove the adhesive.
Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses > Assembly instructions
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Tools

Tools
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Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Tools
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Front door window - assembly overview

Front door window - assembly overview
1 - Door
2 - Front door window

3 - Door window groove

 fitted to the flange and the door
4 - Plastic nut

 2 units
5 - Screw
 2 Nm
 2 units
6 - External door lining

 in assembly, first fasten the upper screw and, then, the lower screw→ Item.
7 - External door window packing

 fitted to the flange
8 - Intermediate support
 external side with clearer mark
9 - Window drive mechanism

 assembled to the subframe
 the electric window drive mechanism motor is fastened to the subframe.
 Fasten the electric window drive mechanism motor → Chapter.
10 - Subframe
 the window drive mechanism is fastened to the subframe.
11 - Internal door window packing

 fitted to the flange

Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Front door window - assembly overview
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Front door window - remove and install

Front door window - remove and install
Remove

– Remove the front door lining → Body - Internal assembly works; Rep. Gr.70.
– Remove the rubber plugs -1-.
– Lower the window glass, until the fastening screws -2- from the tightening jaws are accessible.
Note
If the window drive mechanism motor is not operating, preventing the door window from being
lowered, remove the electric motor so the window lowers.

– Loosen the screws -2- and separate the tightening jaws.
– Hold the internal door packing -1- with pliers -2-. Then, move the pliers in the direction of the
arrow and, at the same time, pull the internal door packing -1- upwards, to remove the door
flange packing.

– To facilitate the removal of the internal door packing, the pliers can be supported with the wedge
-3409--3-.
– Raise the rear section of the door window and move it forward, in direction of the arrow, to
remove it from the door.
Install
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Front door window - remove and install
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Front door window - adjust

Front door window - adjust

 The door window tightening jaws must be in the assembly openings.
– Loosen the screws -2- and separate the tightening jaws.
– Press the door window -1- on the window groove -arrow- and tighten the tightening jaws with the
screws -2- (10 Nm).
– Check the operation.
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Front door window - adjust
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Front subframe - remove and install > Remove

Remove

– Remove the front door lining → General body repairs, interior; Rep. Gr.70
– Remove the latch cylinder → Chapter.

– Remove the clip -1- from the door handle.
– Remove the plugs -1-.
Note
– Lower the door window until the door window fastening screws -2- are accessible.
– Remove the screws -2- and separate the tightening jaws.

– Move the door window upwards and fasten (for example, with adhesive tape).

– Disconnect the electric connectors -arrows-.
– Loosen the screws -2-.

– Tightening torque: Screws -2- = 20 Nm
– Loosen the screws -arrows-. Pull the door subframe upwards, raise and remove from the door
hinge side.
– Turn the subframe and disconnect the connector from the door lock.
– Disengage the clips from the electric harnesses on the back side of the subframe.
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Front subframe - remove and install > Remove
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Front subframe - remove and install > Install

Install

Note

– Install the subframe to the door.
– Place all screws. Tighten the screws marked with -1- and -2- on the sequence indicated, with
– The other screws can be tightened in any order.
 Check the operation, because if the operating cable adjustment and the clips are not correct, the
door cannot be opened.
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Front subframe - remove and install > Install
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Front and rear door window drive crank - remove and install > Remove

Remove
– With the window closed, push the spacer -2- of the crank towards the arrow (the fastening clip
releases the crank) and remove the crank from window-1-.
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Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Front and rear door window drive crank - remove and install > Remove
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Front and rear door window drive crank - remove and install > Install

Install
– Place the window crank on the shaft of the window drive mechanism and
fit the spacer ring.
Note
 With the window closed, the assembly position is: a = 45° ± 12°.
 The -arrow- on the figure indicates the movement direction.
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Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Front and rear door window drive crank - remove and install > Install
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Rear door window - assembly overview

Rear door window - assembly overview
1 - Door
2 - Rear door window

 install the door window to the window drive mechanism
3 - Screw
 2 Nm
 2 units
 In assembly, first fasten the upper screw and, then, the lower screw.

 In assembly, first tighten the screws on the right door edge, then the screws on the sequence indicated.
5 - Screw
 2 Nm
 2 units
 In assembly, first fasten the upper screw and, then, the lower screw.

 Fitted to the flange and inserted in the door.
 With Confortline equipment with the upper edge more compressed.
7 - Clip
 5 units
8 - Screw
 2 Nm
 2 units
 in assembly, first tighten the upper screw and, then, the lower screw
9 - Rear packing with the window guide rail
10 - Elastic nut

 4 units
11 - Intermediate support
 External part with clearer marking.
12 - External door window packing
 Fitted to the flange.
13 - Screw
 9 units
 6 Nm
14 - Cover cap
15 - Subframe
 remove and install
 The glass lift is a component of the subframe.

 It is assembled on the back part of the subframe.
 The window drive mechanism motor is fastened to the subframe.
 Remove the window lift motor → Chapter.
17 - Internal door window packing

 Fitted to the flange.

Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Rear door window - assembly overview
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Rear door window - remove

Rear door window - remove

– Remove the plug -1-.
drive mechanism opening are accessible.
Note
– Thread a 8 mm screw (approx. 80 mm of length) to the expansion bushing -3-.
Note

– Here, the operating cable must be pulled away from the window drive mechanism, by pressing it
aside with a screwdriver.
– Fasten the internal door window packing -1- with pliers -2-. Move the pliers in direction of the

arrow and, at the same time, pull the internal door window packing -1- upwards, to remove from
the door flange packing.

– To facilitate the removal of the internal door window packing, the pliers can be supported with
the wedge -3409--3-.
– Lower the door window.
– Remove the window groove -1- from the window shield.

– Remove the fastening screws -arrows- from the external door lining-2-.
– Remove the door groove -1- from the door flange.

– Remove the screws -arrows- and remove the external door lining-2-.
– Move the door window -1- upwards and outside -arrow- the door.
– Install the door window and assemble it to the drive mechanism → Chapter.
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Rear door window - remove
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Rear door window - install

Rear door window - install
– Lower the window drive mechanism, until the guide -4- is directly below the assembly opening in
the subframe.
– Place the expansion bushing -2- and the expansion pin -1- in the window.
– Centralize the expansion bushing in the window.
– Insert the door window in the door.
– Insert the door window -3- in the guide slot -4-.
– Lightly beat the window - upside down - to fit the glass to the window drive mechanism -arrow-.
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Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Rear door window - install
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Rear subframe - remove and install

Rear subframe - remove and install
The window drive mechanism is part of the subframe.
The window drive mechanism is supplied with the subframe and cannot be replaced individually.
The subframe can only be removed if the door window is not fastened to the window drive
mechanism. For this purpose, the door window must be lowered up to the height of the assembly
hole in the subframe, and the expansion pin must be removed.
If it is not possible to lower the door window with the window drive mechanism, first you must
determine the exact cause of the problem.
(address code 46) with the damage reader Diagnosis, Measurement and Information System -VAS
5051A/52--V.A.G 1551 - → Vehicle diagnosis, testing and information system VAS 5051
In case of electric problems, solve them first.
In case of electric problems caused by the electric window drive mechanism motor, such motor can
be removed from the subframe.
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Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Rear subframe - remove and install
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Rear subframe - remove and install > Remove

Remove
– Remove the bellows -1- from pillar B.
– Disconnect the connectors -2-.


– Disengage the clip -1- from the external door handle.
– Remove the plug -1-.
drive mechanism opening are accessible.
Note
– Thread a 8 mm screw (approx. 80 mm of length) to the expansion bushing -3-.
Note

– Here, the operating cable must be pulled away from the window drive mechanism, by pressing it
aside with a screwdriver.
– Remove the screws -1- (from the lock).

– Remove the screws -arrows-.
– Pull the door subframe upwards, raise and remove from the door hinge side -arrow-.
– Remove the harness from the bellows.
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Rear subframe - remove and install > Remove
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Rear subframe - remove and install > Install

Install

Note
– Insert the electric harnesses in the door, through the bellows.

– Insert the subframe in the door.
– Place all screws. Tighten the screws marked with -1- and -2- on the sequence indicated, with
– The other screws can be tightened in any order.
– Install the door window and assemble it to the drive mechanism → Chapter.
 Check the operation, because if the operating cable adjustment and the clips are not correct, the
door will not open.
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Rear subframe - remove and install > Install
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Power window drive mechanism (automatic opening and closing system) with force limiter

Power window drive mechanism (automatic opening and closing
system) with force limiter
With the introduction of power window drive mechanism with convenience function, the front Power
window drive mechanisms started being equipped additionally with the automatic closing and
opening functions.
The front window automatic closing/opening switch is located in the driver's door control unit. The
driver and passenger door switches have a dual-phase function.
If the switch is pressed or pulled up to the first phase, the respective front window is opened
orclosed manually.
If the switch is completely pressed or pulled up to the second phase, the respective front window is
opened or closed automatically.
Additionally, there are additional switches for each window in the front passenger door and rear
passenger doors.
All power window drive mechanisms have a force limiter. When the window is being closed, if there
is an obstacle to the window travel, its movement is automatically interrupted.
However, this is not applicable when the windows are closed from outside the vehicle with the
ignition key. In this case, the force limitation is not activated.
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Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Power window drive mechanism (automatic opening and closing system) with force limiter
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Power window drive mechanism (automatic opening and closing system) with force limiter > Operation of the power window drive mechanism with
the ignition on

Operation of the power window drive mechanism with the ignition on
Open
Switch on the driver's door
 front windows:
– Press the front switch up to the first phase. The window opens while the switch is pressed or
until it reaches its end.
– Press the front switch up to the second phase. The window is automatically opened (automatic
lowering).
– If the switch is activated again, the window stops immediately.
 rear windows:
– Press the front switch. The window opens while the switch is pressed or until it reaches its end.
Switches on the passenger's door and the rear passenger doors
– Press the lower switch surface. The window opens while the switch is pressed or until it reaches
its end.
Close
Switch on the driver's door
 front windows:
– Pull the front switch up to the first phase. The window closes while the switch is pulled or until it
reaches its end.
– Pull the front switch up to the second phase. The window is automatically closed (automatic
raising).
– If the switch is activated again, the window stops immediately.
 rear windows:
– Pull the front switch. The window closes while the switch is pulled or until it reaches its end.
Switches on the passenger's door and the rear passenger doors
– Press the upper switch surface. The window closes while the switch is pulled or until it reaches
its end.
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the ignition on
the ignition off

Operation of the power window drive mechanism with the ignition off
The window lifts can also be operated within approximately 10 minutes after the ignition is turned
off, provided that the driver's or the passenger's door is not opened.
There is no automatic closing function for the front windows closed.
If the driver's or passenger's door window is prevented from closing, due to an obstacle in its travel
(force limiting), the window is reopened immediately.
In this case, the window can only be closed again after the ignition is turned on.
In vehicles with central locking, the windows can also be closed and opened from outside. For this
purpose, keep the key in the closing or opening position.
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the ignition off
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Power window drive mechanism (automatic opening and closing system) with force limiter > Activating the automatic closing and opening

Activating the automatic closing and opening
Note
After the vehicle battery is turned off then turned on again, the automatic driver and passenger
window closing and opening function is deactivated.
To reactivate this function after the battery is turned on, follow the procedure below:
– Lock the vehicle from outside, through the driver's or passenger's door.
Here, it is necessary that all doors and windows are completely closed.
– Unlock the vehicle and lock it again through the driver's or passenger's door. For this purpose,
leave the key for at least one second in the closing position.
The automatic driver's and passenger's window closing and opening function is activated again.
If there is an abnormality in the power window drive mechanism, it will be indicated by the blinking
of the switch lights, on the driver's and passenger's door and on the rear passenger doors.
The lights, located in the door linings, blink for about 15 seconds after the ignition is turned on.
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Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Power window drive mechanism (automatic opening and closing system) with force limiter > Activating the automatic closing and opening
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Re-establish the operation after the force limiting activation

Re-establish the operation after the force limiting activation
 Prior condition: the automatic closing and opening function is OK.
 Ignition turned on.
– Close the door window with the power window drive mechanism (automatic closing).
If a window is prevented from closing, due to an obstacle during its travel, it opens again
immediately (the force limiting has operated).
– After the window opens, it is necessary to close, or press and keep the window switch, on
theinterval of 5 seconds.
If the window is prevented from closing again, due to an obstacle during its travel, it stops
– After the window stops, it is necessary to activate the switch again in the interval of 5 seconds to
close the window.
The window now closes without force limiting, surpassing the obstacle.
 Ignition turned off.
If a window is prevented from closing, due to an obstacle during its travel, it opens again
In this case, the operation of the internal power window drive mechanism switches is blocked.
If, in the interval of 1 minute after the window is opened, the ignition is turned on and the switch is
pressed (close the window), the window is closed without the automatic closing function.
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Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Re-establish the operation after the force limiting activation
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Power window drive mechanism motor - remove and install > Remove

Remove
The figure shows the removal and installation of the power window drive mechanism and the
subframe (SDA) with the power window drive mechanism on the rear doors. The removal
andinstallation on the front doors is identical.

Remove the front or rear subframe → Chapter or → Chapter.
– Insert a proper auxiliary tool (for example: an assembly lever) from behind the subframe,
between the window lift and the subframe, so the auxiliary tool tip presses the subframe gear.
– Remove the screws -1- (from the front section of the subframe) and remove the power window
drive mechanism motor.
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Power window drive mechanism motor - remove and install > Remove
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Power window drive mechanism motor - remove and install > Install

Install
– When the power window drive mechanism is removed, the gear moves and is decentralized.

– When the power window drive mechanism is seated, the gear must be aligned, until the power
window drive mechanism is centralised again.
– Install the screws -1- (from the front section of the subframe) and tighten them; tightening torque:
3.5 Nm.
This tightening torque must be followed, otherwise the plastic shell in the power window drive
mechanism may be damaged.
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Power window drive mechanism motor - remove and install > Install
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Power window drive mechanism motor - remove and install > Assemble the subframe with the power window drive mechanism

Assemble the subframe with the power window drive mechanism

In case of a subframe supplied as replacement part, the gear will be fastened by a clamp -1- to
prevent it from slipping and falling.
– Insert a proper auxiliary tool (for example, an assembly lever) from behind the subframe,
between the window lift and the subframe, so the auxiliary tool tip presses the subframe gear.

– Remove the clamp -1-.
– When the power window drive mechanism is removed, the gear moves and is decentralised.

– When the power window drive mechanism is seated, the gear must be aligned, until the power
window drive mechanism is centralised again.
– Place the screws -1- (from the front section of the subframe) and tighten them: tightening torque:
3.5 Nm.
This tightening torque must be followed, otherwise the plastic shell in the power window
drivemechanism may be damaged.
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Power window drive mechanism motor - remove and install > Assemble the subframe with the power window drive mechanism
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Rear door window (sedan) - assembly overview

Rear door window (sedan) - assembly overview
1 - Door
2 - Screw
 2 Nm
 2 parts
 in assembly, initially tighten the upper screw and, then, the lower screw

 In assembly, first tighten the screws - → Item- on the front section of the door and, then, tighten the screws - → Item- in the sequence established
4 - Screw
 2 Nm
 2 parts
 in assembly, initially tighten the upper screw and, then, the lower screw
5 - Clip
6 - Intermediate segment
7 - Fixed door window

 Firmly connected to the external door lining - → Item-

 Fitted over the flange and fastened inside the door
 for “Confortline” finish, with longer front edge
9 - External window packing

 Fitted to the flange
 Firmly connected to the fixed door window - → Item-
10 - Door window

 Assemble the door window to the window drive mechanism
11 - Screw
 6 Nm
12 - Cover cap
13 - Subframe
 The window drive mechanism is part of the subframe
14 - Internal window packing

 Fitted to the flange

 Is assembled from behind, on the subframe
 The window drive mechanism motor is fastened from the front section to the subframe
 Remove the window drive mechanism motor → Chapter.

Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Rear door window (sedan) - assembly overview
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Fixed rear door window (sedan) - remove

Fixed rear door window (sedan) - remove
– Remove the rear door window glass.

– Remove the window groove, in direction of the arrow.

– Remove the cover cap -1- and the fastening screw -2- from the guide rail.
– Disengage the guide rail -3- from the clip -4-.

– Carefully raise the external door window packing from inside, starting with the door hinges, with
a wedge -arrow A-. Then, release the fastening clamps from the window gap cover -arrows- to
outside the door openings.
– Remove, from the front section, the fixed door window from the door window frame -arrow B-.
Installation is performed in the reverse sequence of the removal.
Note
Tighten the intermediate segment fastening screw with 6 Nm.
– Install the door window glass and install the window drive mechanism.
Body > General body repairs, exterior > Glazing/window mechanism > Door windows > Fixed rear door window (sedan) - remove
Body > General body repairs, exterior > Exterior equipment > Wheel case protector > Front wheel case protector - remove and install

Front wheel case protector - remove and install
1 - Front wheel housing protector

 remove:
 remove the wheel. Tightening torque for wheel screws → Running Gear; Rep. Gr.44
 remove the Torx screws -2- (14 units) and remove the front wheelcase protector.
2 - Torx screw

 17 units
 1.5 Nm
3 - Expansion nut

 8 units

Body > General body repairs, exterior > Exterior equipment > Wheel case protector > Front wheel case protector - remove and install
Body > General body repairs, exterior > Exterior equipment > Wheel case protector > Rear wheel case protector - remove and install

Rear wheel case protector - remove and install
1 - Rear wheel case protector

 remove:
 remove the wheel. Tightening torque for wheel screws → Running Gear; Rep. Gr.44
 remove the Torx screws -3- (11 units) and remove the rear wheel case protector.
2 - Expansion nut

 2 units
3 - Torx screw

 11 units
 1.5 Nm
4 - Expansion nut

 5 units

Body > General body repairs, exterior > Exterior equipment > Wheel case protector > Rear wheel case protector - remove and install
Body > General body repairs, exterior > Exterior equipment > Wheel case protector > Spoiler on the wheel housing front protector - remove and install > Remove

Remove
– Remove screws -1- (2.2 Nm) and remove the spoiler.
Repair Manual
Manuals
Workshop Manuals
Amigo
Body
Equipment
Fronts
Body > General body repairs, exterior > Exterior equipment > Wheel case protector > Spoiler on the wheel housing front protector - remove and install > Remove
Body > General body repairs, exterior > Exterior equipment > External rear-view mirror > Tools

Tools

 Ejector lever -80 - 200-
Body > General body repairs, exterior > Exterior equipment > External rear-view mirror > Tools
Body > General body repairs, exterior > Exterior equipment > External rear-view mirror > External rear-view mirror (with electric command ? 2006) - assembly overview

External rear-view mirror (with electric command ► 2006) - assembly overview

1 - Mirror covering
2 - Finishing
3 - Mirror glass
 Fitted in both versions (with manual and electric command).
 remove - press the mirror glass first downwards, then upwards (ejector lever -80 - 200-), protect the mirror cover from damage.
 Install - insert the mirror glass with the guide claws in the housing and press the glass.
 Pressure only to the glass centre - always wear protective gloves.
4 - Mirror support
 remove:
 Remove the door lining → General body repairs, interior; Rep. Gr.70
 Remove the cover cap.
 Disengage the connector.
 Remove the screws and remove the mirror support.
5 - Connector
6 - Mirror fastening cover
7 - Screw
 2 units
 8 Nm

Body > General body repairs, exterior > Exterior equipment > External rear-view mirror > External rear-view mirror (with electric command ? 2006) - assembly overview
Body > General body repairs, exterior > Exterior equipment > External rear-view mirror > External rear-view mirror (with manual command ? 2006) - assembly overview

External rear-view mirror (with manual command ► 2006) - assembly overview

1 - Mirror glass
 Fitted in both versions (with manual and electric command).
 remove - press the mirror glass first downside up, then upside down (ejector lever -80 - 200-), protect the mirror cover from damage
 Install - insert the mirror glass with the guide claws in the housing and press the glass.
 Pressure only to the glass centre - always wear protective gloves.
2 - Mirror support
 remove:
 Remove the mirror fastening cover → Item.
 Remove the operating button → Item.
 Remove the guide → Item and remove the hexagonal nut.
 Remove the screws → Item and remove the mirror support.
3 - Manual control
4 - Hexagonal nut
5 - Screw
 2 units
 8 Nm
6 - Cover cap
7 - Operating button

 Fitted to the control
8 - Guide
9 - Mirror covering
 ABS material

Body > General body repairs, exterior > Exterior equipment > External rear-view mirror > External rear-view mirror (with manual command ? 2006) - assembly overview
Body > General body repairs, exterior > Exterior equipment > External rear-view mirror > Mirror cover (? 2006) - remove

Mirror cover (► 2006) - remove
– To facilitate the assembly, bend the rear-view mirror forward.
– Remove the mirror glass → Item -1-.

– Disconnect the electric connector from the mirror glass, in case of heated mirrors.
– Fit an “Allen” wrench 3 mm (13 cm of length) -1- or something similar from below, in

the mirrorsupport articulation opening, to unlock the retaining clip -2- in the mirror housing.
Note
The “Allen” wrench is guided by the mirror structure to the retaining clip -2-. Put an adequate
pressure on the retaining clip.

– Unlock the retaining clips -arrows- in the mirror housing.
– Remove the mirror housing -1- from the mirror support -2- from above.
Body > General body repairs, exterior > Exterior equipment > External rear-view mirror > Mirror cover (? 2006) - remove
Body > General body repairs, exterior > Exterior equipment > External rear-view mirror > External rear-view mirror (2007 ?) - assembly overview

External rear-view mirror (2007 ►) - assembly overview

1 - Mirror support
2 - Screw
 2 units
 8 Nm
3 - Guide
 For rear-view mirror guide
4 - Foam part
5 - Harness connector
6 - Cover with lateral direction indication

7 - Screw
 1 units
 1 Nm
8 - Screw
 1 units
 1 Nm

 For the side blinking light

 For mirror heating
11 - Mirror glass
12 - Mirror covering
 ABS material

Body > General body repairs, exterior > Exterior equipment > External rear-view mirror > External rear-view mirror (2007 ?) - assembly overview
Body > General body repairs, exterior > Exterior equipment > Front grille > Front grille (? 2006) - assembly overview

Front grille (► 2006) - assembly overview
1 - Front grille
 ASA material
2 - Retaining hooks

 2 units
3 - Screw
 2 units
4 - Retaining pins

 2 units
5 - Central fastening

 2 units
6 - VW symbol
 fitted to the front grille.

Body > General body repairs, exterior > Exterior equipment > Front grille > Front grille (? 2006) - assembly overview
Body > General body repairs, exterior > Exterior equipment > Front grille > Front grille (2007 ?) - assembly overview

Front grille (2007 ►) - assembly overview

1 - Front grille
 ASA material
2 - Front symbol

 Remove:
– With the front grille removed, disengage the three retaining hooks and remove the front symbol.
 Install:
– Insert the front symbol retaining hooks in the front grille cuts -arrow a-
– Turn the front symbol -arrow b- until the retaining hooks fit audibly.
3 - Front protector
4 - Screw
 4 units
 1.5 Nm
5 - Retaining hooks

 4 units

Body > General body repairs, exterior > Exterior equipment > Front grille > Front grille (2007 ?) - assembly overview
Body > General body repairs, exterior > Exterior equipment > Front grille > Front grille (2007 ?, GT) - assembly overview

Front grille (2007 ►, GT) - assembly overview

1 - Screw
 4 units
 1.5 Nm
2 - Retaining hooks

 4 units
3 - Front grille
 ASA material
4 - Brand symbol

 Remove:
– With the front grille removed, disengage the three retaining hooks and remove the VW symbol.
 Install:
– Insert the VW symbol retaining hooks in the front grille cuts -arrow a-
– Turn the brand symbol -arrow b- until the retaining hooks fit audibly.
5 - GT inscription
6 - Front bumper protector

Body > General body repairs, exterior > Exterior equipment > Front grille > Front grille (2007 ?, GT) - assembly overview
Body > General body repairs, exterior > Exterior equipment > Trims > Door trims - remove and install

Door trims - remove and install

Note
According to the model variation, there are small variations. The figure below shows the Polo. Polo
Sedan is distinguished by a rear area with different format.
1 - Rear door trim

 Material: PP/EPDM
 Before removing, you must heat the trim with the hot air blower -VAG 1416-.
 Clean the area with cleaning solution -D 009 401 04-, and then, apply the silicone remover -LSE 020 100 A3-
 Remove the adhesive tape liner, position the trim and press strongly by using the pressure roll -3356 -. Operating temperature of approx. 20°C.
2 - Location holes
3 - Location pins

 Ensure the alignment and fastening against torsion.
5 - Front door side trim
 Material: PP/EPDM
 Before removing, you must heat the trim with the hot air blower -VAG 1416-.
 Clean the area with cleaning solution -D 009 401 04-, and then, apply the silicone remover -LSE 020 100 A3-
 Remove the adhesive tape liner, position the trim and press strongly by using the pressure roll -3356 -. Operating temperature of approx. 20°C.

Body > General body repairs, exterior > Exterior equipment > Trims > Door trims - remove and install
Body > General body repairs, exterior > Exterior equipment > Trims > Rear lid trim (Hatch, 2010?) - replace

Rear lid trim (Hatch, 2010►) - replace


Pressure roll -3356-
Body > General body repairs, exterior > Exterior equipment > Trims > Rear lid trim (Hatch, 2010?) - replace
Body > General body repairs, exterior > Exterior equipment > Trims > External longitudinal member lining (front door - GT) - replace

External longitudinal member lining (front door - GT) - replace

1 - Covering adhesive area
 Clean the gluing area with the cleaning solution -D 009 401 04-. Scrub the surface with a cloth until it is completely dry.
2 - Rear door front external lining

 self-adhesive
 the internal door packing must be removed.
 Before removing, you must heat the covering with the hot air blower -VAG 1416-.
 Upon installation, heat previously the gluing area for lining -1- with the Hot air blower -VAG 1416-. Remove the covering liner, position the plastic foil (mask) of the
covering in relation to the door crease, press carefully in order not to trap air bubbles into the covering, and then, press strongly by using the pressure roll -3356-.
Operating temperature of approx. 20°C.

Body > General body repairs, exterior > Exterior equipment > Trims > External longitudinal member lining (front door - GT) - replace
Body > General body repairs, exterior > Exterior equipment > Trims > Measures to position the inscriptions on the rear door > Inscriptions on rear door ? 2006

Inscriptions on rear door ► 2006

1 - Dimension a = 25 mm
2 - b = 330 mm

Note
 Before removing, warm up the inscription with the hot air blower -VAG 1416-.
 Use only the adhesive remover -D 002 000 10- to eliminate adhesive residue.
 Scrub the surface with a cloth until it is completely dry.
 Previously heat the gluing area with the Hot air blower -VAG 1416-.
 Only remove the double-sided tape liner when about to install the inscription.
 Operating temperature of approx. 20°C.
Body > General body repairs, exterior > Exterior equipment > Trims > Measures to position the inscriptions on the rear door > Inscriptions on rear door ? 2006
Body > General body repairs, exterior > Exterior equipment > Trims > "CONFORTLINE� and "SPORTLINE� inscriptions - replace

“CONFORTLINE” and “SPORTLINE” inscriptions - replace

Remove
Note
Before the removal, you must heat the inscription with the hot air blower -VAG 1416-.
– Detach the inscription with a plastic spatula.
– Clean the inscription gluing area on the front door, with the cleaning solution -D 009 401 04-.
Scrub the surface with a cloth until it is completely dry.
Install

– Remove the double-sided tape liner and glue the inscription. Use the pressure roll -3356-
a = 85 mm
b = 22 mm
c = 18 mm
Body > General body repairs, exterior > Exterior equipment > Trims > "CONFORTLINE� and "SPORTLINE� inscriptions - replace
Body > General body repairs, exterior > Exterior equipment > Spoiler - Hatch > Rear spoiler (? 07.08)

Rear spoiler (► 07.08)
 Anchoring tool -VAG 1351-

 Climate removal tools -VAG 1474B- or Device with ratchet -VAG 1654A-
 Glass removal kit -VAG 1755 -
 Pneumatic Adhesive applicator -VAS 5237-

Body > General body repairs, exterior > Exterior equipment > Spoiler - Hatch > Rear spoiler (? 07.08)
Body > General body repairs, exterior > Exterior equipment > Spoiler - Hatch > Rear spoiler ( 08.08 ? ) - remove

Rear spoiler ( 08.08 ► ) - remove

 Traction cable -VAG 1351/1-

– Remove the rear door upper lining -7- → Body - Internal assembly works; Rep. Gr.70.
– Apply masking tape around the spoiler in order to protect the paint on the rear door.
– Fasten the cutting wire -357 853 999.A--5- on two traction cables -VAG 1351/1-.
– Position the cutting wire between the spoiler and the lid, and then pull the cutting wire with the
traction cables -VAG 1351/1-.
Note
During removal, ensure that in the area of the auxiliary brake light, the electric harness is
connected.
– Remove the spoiler and disconnect the harness connector for the auxiliary brake light.
– Remove all dirt and oiliness.
– Remove the adhesive residues with the adhesive remover -D 002 000 10- and apply the silicone
remover -LSE 020 100 A3-. Scrub the surface with a cloth until it is completely dry.
Body > General body repairs, exterior > Exterior equipment > Spoiler - Hatch > Rear spoiler ( 08.08 ? ) - remove
Body > General body repairs, interior > Interior equipment > Internal rearview mirror > Internal rear-view mirror with automatic anti-glare

Literatura Técnica VW POLO - CARROCERIA

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Body

Front panel (► 2006) - Assembly overview

3 - Bonnet latch operating cable

4 - Wing fastening hole

5 - Radiator and condenser

6 - Front protector support

9 - Guide Pins -3411-

Front panel (► 2006) - work position

– Remove the front bumper cover → Chapter

– Remove the front grille → Chapter

– Remove the front bonnet latch → Chapter

– Disengage the front bonnet latch operating cable from the latch.

Front panel (2007 ►) - assembly overview

1 - Front panel with assembly components

3 - Bonnet latch operating cable

4 - Wing fastening hole

5 - Radiator and condenser

6 - Front protector support

9 - Guide Pins -3411-

Front panel (2007 ►) - work position

– Remove the front bumper cover → Chapter.

– Remove the front grille → Chapter

– Remove the front bonnet latch → Chapter.

ody > General body repairs, exterior > Body front > Wing > Front wing - assembly overview

Front wing - Assembly overview

Body > General body repairs, exterior > Body front > Wing > Front wing - assembly overview

Body > General body repairs, exterior > Body front > Wing > Wing - remove and install > Remove

– Remove the wheel housing protector → Chapter.

– Remove the cover → Chapter

– Remove the indicator light → Electrical system; Rep. Gr.94

– Remove the screws -2-.

Body > General body repairs, exterior > Body front > Wing > Wing - remove and install > Remove

Body > General body repairs, exterior > Body front > Wing > Wing - remove and install > Install

– Screw tightening torque: 6 Nm.

– Installation is performed in the reverse removal sequence.

Body > General body repairs, exterior > Body front > Wing > Wing - remove and install > Install

Body > General body repairs, exterior > Body front > Wing > Cover - remove and install > Remove

– Remove the screw -3- from the bushing-2-.

– Remove the wing cover -1- from the front side.

Body > General body repairs, exterior > Body front > Wing > Cover - remove and install > Remove

Body > General body repairs, exterior > Body front > Wing > Wing dimensions (? 2006) - vehicles

Wing dimensions (► 2006) - vehicles

Body > General body repairs, exterior > Body front > Wing > Wing dimensions (? 2006) - vehicles

Body > General body repairs, exterior > Body front > Wing > Wing dimensions (2007 ?) - vehicles

Wing dimensions (2007 ►) - vehicles

Horizontal and vertical difference between wings on the upper backrest section.

Body > General body repairs, exterior > Body front > Wing > Wing dimensions (2007 ?) - vehicles

Lower noise insulation in the engine compartment (petrol / Totalflex engine) - assembly overview

Lower noise insulation in the engine compartment (diesel engine) - Assembly overview

Body > General body repairs, exterior > Body front > Engine compartment partition panel > Tools

 Torque wrench - 5 to 50Nm (fit. 1/2") -VAG 1331 -

Body > General body repairs, exterior > Body front > Engine compartment partition panel > Tools

Product Brazilian Market Export Market

PU Adhesive U-400 or PU-501 - DH 009 100- or -DH 009 100 A2-

Body primer U-413 or PU-530 Primer -D 009 600-

Engine compartment partition panel - assembly overview

1 - Engine compartment partition panel

3 - Polyurethane adhesive - PUR

Corpo > reparos do corpo Gerais, exterior > Bonnet, flaps, de táxi, fecho central > Bonnet > Ferramentas

Corpo > reparos do corpo Gerais, exterior > Bonnet, flaps, de táxi, fecho central > Bonnet > Ferramentas

2 - absorvedor de choque com cobertura

6 - tampa do painel deflector de água

 Screw tightening torque -7-: 23 Nm.

– After the assembly, adjust the screws.