Service: Golf 2004

Service
Workshop Manual
Golf 2004 ➤
General body repairs, exterior
Edition 04.2008
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Service Department. Technical Information
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
50 - Body - front
55 - Bonnet, rear lid
57 - Front doors, door components, central locking
58 - Rear doors, door components wage
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64 - Glazing
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66 - Exterior equipment
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg K0058991620

Golf 2004 ➤
General body repairs, exterior - Edition 04.2008
Contents
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Assembly overview - lock carrier, service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Removing and installing lock carrier with add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Assembly overview - front wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Removing and installing wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Removing and installing wing strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Assembly overview - noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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5 sPlenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5.2 Assembly overview - plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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1 Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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1.2 Assembly overview - bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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1.3 Removing and installing bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.4 Removing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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1.5 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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1.6 Removing and installing flap hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.7 Removing and installing insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.8 Assembly overview - bonnet latch and release components . . . . . . . . . . . . . . . . . . . . . . . . 24
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1.9 Removing and installing bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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1.10 Separating Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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1.11 Adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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1.12 Removing and installing release lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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2 Rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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2.2 Assembly overview - rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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2.3 Removing and installing rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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2.4 Removing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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2.5 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.6 Removing and installing rear lid hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.7 Removing and installing striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.8 Adjusting lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.9 Assembly overview - rear lid latch and release components . . . . . . . . . . . . . . . . . . . . . . . . 37
2.10 Removing and installing release element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.11 Removing and installing lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.12 Rear lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.13 Removing and installing rear lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3 Tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.2 Assembly overview - tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Contents i
Golf 2004 ➤ agen
AG. Volkswagen AG d
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General body repairs, exterior - Edition 04.2008 by
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57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 45 ss c
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1 Front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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1.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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1.3 Assembly overview - door assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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1.4 Assembly overview - door hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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1.5 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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1.6 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.7 Removing and installing door outer panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.8 Installing new outer panel for door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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1.9 Removing and installing retaining rail on door outer panel . . . . . . . . . . . . . . . . . . . . . . . .
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1.10 Installation instructions for bonding in new door outer panel . . . . . . . . . . . . . . . . . . . . . . . . 63
1.11 Minimum curing period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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1.12 Cleaning off excess adhesive sealing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

1.13 Assembly overview - door inner part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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1.14 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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1.15 Removing and installing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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1.16 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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1.17 Removing and installing mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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1.18 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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1.19 Assembly overview - side impact protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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1.20 Door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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1.21 Removing and installing door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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1.22 Removing and installing door outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2 Central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.1 Location overview - central locking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.2 Adapting keys with remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.3 Assembly overview - battery for folding key with remote control . . . . . . . . . . . . . . . . . . . . 82
2.4 Removing and installing battery for folding key with remote control . . . . . . . . . . . . . . . . . . 83
58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

1 Rear door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.3 Assembly overview - door assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.4 Assembly overview - door hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.5 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.6 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.7 Removing and installing door outer panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.8 Installing new outer panel for door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.9 Removing and installing retaining rail on door outer panel . . . . . . . . . . . . . . . . . . . . . . . . 101
1.10 Installation instructions for bonding in new door outer panel . . . . . . . . . . . . . . . . . . . . . . . . 102
1.13 Assembly overview - door inner part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.14 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.15 Removing and installing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.16 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.17 Removing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.18 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.19 Assembly overview - side impact protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.20 Door inner seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.21 Removing and installing door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.22 Removing and installing door outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
ii Contents
Golf 2004 ➤
60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1 Sliding/tilting sunroof with glass panel (Meritor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.3 Assembly overview - sliding/tilting sunroof with glass panel . . . . . . . . . . . . . . . . . . . . . . . . 120
1.4 Removing and installing bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.5 Removing glass panel of sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.6 Installing glass panel of sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.7 Adjusting height of glass panel of sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.8 Adjusting panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.9 Renewing panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.10 Removing and installing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.11 Removing and installing sliding headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.12 Removing and installing sliding/tilting sunroof glass panel drive . . . . . . . . . . . . . . . . . . . . 128
1.13 Adjusting drive for sliding/tilting sunroof glass panel (0 position) . . . . . . . . . . . . . . . . . . . . 129
1.14 Removing and installing sliding/tilting sunroof glass panel automatic preselection switch
........................................................................ 130
1.15 Checking parallel running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.16 Adjusting parallel running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.17 Assembly overview - carrier unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.18 Removing and installing carrier unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.19 Operating without electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.20 Removing and installing guide plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.21 Removing and installing sliding gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.22 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1 Front bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
AG. Volkswagen AG d
1.1 Tools
lksw . . . . . . . . . . . . . . . . .e.s n. o.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
agen o 139
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yV bumper cover . . . . . .g.ua. r.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.3 ris Assembly overview - bumper cover n. te.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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ss 1.4 Removing and installing front bumper cover .................................... 140
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1.5 Front bumper attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
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1.6 Front bumper substructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

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1.7 Assembly overview - bumper carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

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1.8 Assembly overview - number plate carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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2 Front bumper for GTI, GTI special models, GT, R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
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2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

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2.2 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

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2.3 Assembly overview - bumper cover for GTI, GT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

2.4 Removing and installing front bumper cover for GT, GTI . . . . . . . . . . . . . . . . . . . . . . . . . . 147
rrectness of i
2.5 Front bumper attachments for GT, GTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

2.6 Assembly overview - bumper cover for R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
l purpos
2.7 Removing and installing front bumper cover for R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.8 Front bumper attachments for R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
nf
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2.9 Assembly overview - front bumper cover for GTI special models . . . . . . . . . . . . . . . . . . . . 154
rm
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2.10 Removing and installing front bumper cover for GTI special models . . . . . . . . . . . . . . . . . . 154
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2.11 Front bumper attachments for GTI special models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

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2.12 Front bumper substructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

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3 Rear bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

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3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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3.2 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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3.3
Prote
cted Assembly overview - bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AG.
agen
160
3.4 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Contents iii
Golf 2004 ➤
3.5 Rear bumper attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

3.6 Rear bumper substructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.8 Assembly overview e-ntowing AG. Volkbracket
swagen AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
swag does
4 Rear bumper y V for R32 and GTI special models
olk not
gu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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4.1 Tools or.ise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d
166
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t bumper cover . . . . . . . . . . . . . . . . . . . . .or.ac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
ss
4.3 Assembly overview - bumper cover for R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
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4.4 Removing and installing bumper cover for R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
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4.5 Rear bumper attachments for R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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4.6 Assembly overview - rear bumper cover for GTI special models . . . . . . . . . . . . . . . . . . . . 170
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4.7 Removing and installing rear bumper cover for GTI special models . . . . . . . . . . . . . . . . . . 170
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4.8 Rear bumper attachments for GTI special models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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4.9 Rear bumper substructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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t to the co
64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
rrectness of i
1 Flush bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
l purpos
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

1.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
nform
ercia
1.3 Repairing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

1.4 Assembly overview - windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
m
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i
1.5 Assembly overview - plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on 179
c
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1.6 Removing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

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1.7 Installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

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1.8 Assembly overview - rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

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for
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1.9 Removing undamaged rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

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1.10 Removing broken rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
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1.11 Installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
p by
co Vo
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1.12 Assembly overview - rear side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
cted agen
Prote AG.
1.13 Removing undamaged rear side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.14 Removing damaged rear side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.15 Installing rear side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.16 Preparing old undamaged window for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.17 Preparing new window without precoating for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.18 Preparing new window with precoating for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.19 Preparing body flange for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.20 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
1.22 Touching up paint damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2 Front door windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.2 Assembly overview - front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.3 Removing and installing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
2.4 Adjusting door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.5 Assembly overview - window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.6 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.7 Assembly overview - window guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.8 Removing and installing window guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.9 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.10 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3 Rear door windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.2 Assembly overview - rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
iv Contents
Golf 2004 ➤
3.3 Removing and installing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

3.4 Assembly overview - fixed door window with window guide . . . . . . . . . . . . . . . . . . . . . . . . 209
3.5 Removing and installing fixed door window with window guide . . . . . . . . . . . . . . . . . . . . . . 209
3.6 Assembly overview - window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.7 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.8 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.9 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

1 Wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1.2 Assembly overview - front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1.3 Removing and installing front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1.4 Assembly overview - rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
1.5 Removing and installing rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
2 Exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
2.2 Assembly overview - exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2.3 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2.4 Removing and installing mirror housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.5 Removing and installing trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
2.6 Removing and installing side turn signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
2.7 Removing and installing exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3 Radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3.2 Assembly overview - radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3.3 Removing and installing radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3.4 Assembly overview - radiator grille for AGTI,
G. VolkGTI
swagspecial
en AG models and GT . . . . . . . . . . . . . . 231
agen does
3.5 Removing and installing radiator Vol grille for GT, GTI special models
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and GT . . . . . . . . . . . . 233
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3.6 Radiator grille for GTI, GTI ise d b
special models, GT and R32 - number
ara plate carrier . . . . . . . .
nte
235
or
3.7 Assembly overviewau-thradiator grille for R32 . . . . . . . . . . . . . . . . .e.or.a . . . . . . . . . . . . . . . . . 236
3.8 Removing and installing
ss radiator grille for R32 . . . . . . . . . . . . . . . . .c. . . . . . . . . . . . . . . . . 237
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3.9 R32 radiator grille - company emblem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

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4 Mouldings and trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

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4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

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4.2 Assembly overview - water deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

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4.3 Removing and installing water deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

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spec
4.4 Assembly overview - protective side strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

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4.5 Renewing side protective mouldings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

4.6 Removing and installing stone-chip protection trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
4.7 Assembly overview - side member extension for GTI, GTI special models and R32 . . . . . . 250
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4.8 Removing and installing side member extension for GTI, GTI special models and R32 . . 251
4.9 Retaining strip for side member extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
ss o
5 Roof edge spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

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5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

form
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5.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

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5.3 Assembly overview - roof spoiler for GTI, GTI special models and R32 . . . . . . . . . . . . . . 258
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5.4 Removing and installing roof spoiler for GTI, GTI special models and R32 . . . . . . . . . . . . 259
thi
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5.5 Retaining strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

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5.6 Preparing body kit component for bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

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5.7 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
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5.9 Touching up paint damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
cop Vo
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5.10 Cleaning off excess adhesive sealing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote AG.
265
6 Protective backing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Contents v
AG. Volkswagen AG d
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Golf 2004 ➤ed b y gu
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General body
thor repairs, exterior - Edition 04.2008 eo
au ra
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6.1 Attachment notes for protective backing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
ce
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nl
pt
du
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6.2 Renewing scuff protection film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
itte
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erm
ab
7 Lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
ility
ot p
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
wit
, is n
7.2 Installation instructions for lettering and emblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
h re
hole
spec
7.3 Rear lettering dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
es, in part or in w
7.4 Rear lettering dimensions for GTI and R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
t to the co
7.5 Rear lettering dimensions - USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
7.6 Side lettering dimensions - Individual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
rrectness of i
8 Vermin repellent system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
l purpos
8.1 Assembly overview - vermin repellent system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
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vi Contents
Golf 2004 ➤
50 – Body - front
1 Lock carrier
1.1 Tools
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1.1.1 Required special tools, workshop equip‐
ment, test and measuring devices and
auxiliary items
♦ Guide pins -T 10093-
♦ Torque wrench 5...50 Nm -V.A.G 1331-
1. Lock carrier 1
Golf 2004 ➤
1.2 Assembly overview - lock carrier, service position
1 - Lock carrier with add-on

parts
❑ Removing and installing
⇒ page 4
❑ Service position
⇒ page 3
2 - Bolt
❑ Qty. 4
❑ 8 Nm
3 - Bolt
❑ Qty. 8
❑ 60 Nm
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Rep. Gr.50 - Body - front
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Golf 2004 ➤
General
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AG exterior - Edition 04.2008
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– Remove front bumper ⇒ page 140 , GTI ⇒ page 147 , R32

⇒ page 151 .
– Unhook Bowden cable at coupling ⇒ page 26 .
– If vehicle has charge air cooler, disconnect pressure hoses
⇒ page 4
– Unscrew horn -4- with bracket on right side of longitudinal
member.⇒ Electrical system; Rep. Gr. 96 ; Interior lights,
lamps, switches; Removing and installing horn .
– Remove bolts -3- from left and right longitudinal members.
– Attach special tool guide pins -T 10093- to left and right lon‐
gitudinal members.
– Remove bolts -2- on left and right from upper part of lock car‐
rier -1-.
– The lock carrier -1- can be pulled forwards about 10 cm on the
special tool guide pins -T 10093- .
1. Lock carrier 3
Golf 2004 ➤
1.3.2 Moving from service position

Install in reverse order of removal.
– Align lock carrier to longitudinal members and between wings
⇒ Body Repairs; Rep. Gr. 00 ; Technical data; Body gap di‐
mensions .
Note
♦ Ensure that the charge air cooler pressure hoses are properly
engaged again.
♦ Hoses and lines must not be pinched.
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– Release push-on couplings a-1- and pull pressure hose -2- in
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– During installation of pressure hoses, ensure that push-on
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1.4 Removing and installing lock carrier with
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♦ If damaged, the lock carrier must be renewed.
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4 Rep. Gr.50 - Body - front

Golf 2004 ➤
AG. Volkswagen AG d General body repairs, exterior - Edition 04.2008
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– Set lock carrier with add-on parts -1- to service position

⇒ page 3
– Disconnect all electrical connectors.
– Drain coolant and disconnect coolant lines ⇒ Engine cooling
system; Rep. Gr. 19 ; Parts of cooling system; Draining and
filling coolant .
– Disconnect wiring for condenser ⇒ Heating and air condition‐
ing system; Rep. Gr. 87 ; Air conditioning system; Removing
and installing condenser .
– Together with a second mechanic, unscrew guide pins -T
10093- from left and right longitudinal member and lift lock
carrier out.
WARNING
Do not start the engine if the air conditioning system and/or the
coolant system lines are disconnected.
1. Lock carrier 5
Golf 2004 ➤
Note
♦ Do not hang condenser and hydraulic oil cooler from lines.

♦ Do not kink condenser and hydraulic lines.
1.4.2 Installing
• During assembly, ensure that all connectors and hose con‐
nections are properly installed.
– Align lock carrier to longitudinal members and between wings
⇒ Body Repairs; Rep. Gr. 00 ; Technical data; Body gap di‐
mensions .
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Golf 2004 ➤
2 Wing
2.1 Tools
Special tools and workshop equipment required
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♦ Hot air blower -V.A.G 1416- s
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2. Wing 7
Golf 2004 ➤
2.2 Assembly overview - front wing
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1 - Wing
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⇒ page 8
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2 - Bolt
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❑ Qty. 2, side member
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❑ Qty. 2, wheel housing
❑ Qty. 2, wing strut
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❑ Qty. 3, wing connection
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3 - Intermediate piece (zinc)

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4 - Foam piece
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6 - Moulded foamed plastic
part
❑ Inserted on top of longi‐
tudinal member
❑ Bonds to wing
7 - Hexagon nut
❑ One, on wing connec‐
tion piece
❑ 6 Nm
2.3 Removing and installing wing
Note
The removal and installation sequence is only described for the

left wing. The removal and installation of the right wing is similar.

Golf 2004 ➤
2.3.1 Removing
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– Remove front bumper ⇒ page 140 .

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– Remove wheel housing liners ⇒ page 218 . Cop py
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– Remove guide ⇒ Item 10 (page 143) . py by
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– Loosen hexagon nut -6- and remove bolts -2-. Prote AG.
– Pull out moulded plastic part -3- between wing and longitudinal
member.
– Lightly heat outside of wing -1- in area of moulded foam part
-arrow- using hot air blower -V.A.G 1416- .
– The bonding on moulded foamed plastic part -5- releases and
the wing -1- can be removed.
2. Wing 9
AG. Volkswagen AG d
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Golf 2004 or➤
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General
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2.3.2 Installing
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– Always insert “zinc intermediate piece AKL 381 035 50” be‐
tween wing and side member.
– Specified torque for bolts -2- and hexagon nuts -5-: 6 Nm.
– Ensure that gaps are parallel and specified dimensions are
maintained ⇒ Body Repairs; Rep. Gr. 00 ; Technical data;
Body panel gaps/shut lines .
2.4 Removing and installing wing strut
Note
The removal and installation sequence is described for the left

wing strut. The removal and installation of the right wing strut is
similar.
2.4.1 Removing
• The wing has been removed.

Golf 2004 ➤
– Remove bolts -2- and remove wing strut -1-.
2.4.2 Installing
– Install wing strut -1-.
– Specified torque for bolts -2-: 6 Nm
– Wing and wing strut are adjusted together to bonnet and
bumper ⇒ Body Repairs; Rep. Gr. 00 ; Technical data; Body
gap dimensions .
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2. Wing 11
Golf 2004 ➤
3 Noise insulation
3.1 Tools
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Prote AG.

Golf 2004 ➤
3.2 Assembly overview - noise insulation
Note
The removal and installation procedures may have to be modified slightly depending on engine fitted.
1 - Noise insulation
❑ Arrow points forwards
❑ Removing:
– Remove bolts -2- and
-3-.
2 - Bolt
❑ Qty. 8
❑ 2 Nm
3 - Bolt
❑ Qty. 3
❑ 6 Nm
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3. Noise insulation 13
Golf 2004 ➤
4 Underbody cladding
4.1 Tools
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Golf 2004 ➤
4.2 Assembly overview - underbody cladding
Note
Only the left side is shown. The right side is similar.
1 - Underbody cladding
❑ Arrow points forwards
❑ Removing:
– Remove hexagon nuts
-2-
2 - Hexagon nut
❑ Qty. 8
❑ 1.5 Nm
3 - Rear underbody cladding
❑ Installed only on left-
hand side.
❑ Removing:
– Remove hexagon nut
-4- and bolts -5-.
4 - Hexagon nut AG. Volkswagen AG d

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spec
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7 - Bolt
❑ Qty. 2
❑ 2 Nm
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4. Underbody cladding 15
AG. Volkswagen AG d
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Golf 2004 ➤ orise nte
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General body repairs,
s aut
exterior - Edition 04.2008 ra
c
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5 Plenum chamber bulkhead
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5.1 Tools
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5.2 Assembly overview - plenum chamber bulkhead
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1 - Plenum chamber bulkhead
2 - Hexagon nut
❑ 8 Nm
seal
❑ When fitting bulkhead
ensure seal is correctly
fitted.
4 - Bolt
❑ 8 Nm

Golf 2004 ➤
AG. Volkswagen AG d
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55 – Bonnet, rear lid
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1. Bonnet 17
Golf 2004 ➤
1.2 Assembly overview - bonnet
1 - Bonnet
⇒ page 19
❑ Adjusting ⇒ page 26
2 - Adjustment buffer
❑ Qty. 2
3 - Stop buffer
❑ Qty. 2 agen
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6 - Hinge
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⇒ page 20
spec
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7 - Gas strut
❑ Removing ⇒ page 20
rrectness of i
❑ Releasing gas
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⇒ page 20
8 - Seal
nf
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❑ Secured with 17 clips to
orm
inside of bonnet
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18 Rep. Gr.55 - Bonnet, rear lid

Golf 2004 ➤
AG. Volkswagen AG d
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olksw not
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1.3 Removing and installing bonnet r nte
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au ra
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pt
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– Remove left and right washer jets -6- ⇒ Electrical system;

Rep. Gr. 92 ; Window wiper/washer system; Windscreen
washer system; Removing and installing windscreen washer
system jets .
– Unclip line -2- from hinge -3- and bonnet -5-.
– Pull line -2- out through aperture in bonnet -5-.
– Loosen hexagon nuts -1- on left and right (do not remove).
Further dismantling requires the help of a second mechanic.
– Disconnect gas strut -4- at bonnet -5- ⇒ page 20 .
– Now remove hexagon nuts -1- and lift lid -5- out of hinges
-3-.
1.3.2 Installing
1. Bonnet 19
Golf 2004 ➤
– Specified torque for bonnet hexagon nut: 22 Nm.

– Adjusting bonnet -1- ⇒ page 26 . . Volkswagen AG
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– Open rear lid and support it.
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– Pull gas struts -1- from ball-head pins -3- and -4-.
t to the co
After removing gas strut -1-, slide spring clip -2- back immediately.
WARNING
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Proceed with care if gas strut is reused. Spring clip must not
ss
be levered completely out of ball socket, as it will otherwise be
o
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damaged. Gas strut will spring out of mounting, causing dam‐
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age or injury to operator.
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– Specified torque for ball-head pins -3- and -4-: 22 Nm.
thi
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– Releasing gas from gas strut ⇒ page 20
pr
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1.5 Releasing gas from gas strut Cop py
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– Clamp gas strut in vice in area x = 50 mm. co Vo
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Prote AG.
WARNING
Clamp gas strut only within area -x-; otherwise danger of ac‐
cident!
– Saw through cylinder of gas strut within first third of cylinder's

overall length using piston rod end of cylinder as reference
point.
Note
♦ Wear eye protection when sawing.

♦ Cover area of saw cut with a cloth.
♦ Dispose of oil and cloth via existing disposal channels.
1.6 Removing and installing flap hinge
Note
The removal and installation sequence is only described for the

left hinge. The removal and installation of the right hinge is similar.

Golf 2004 ➤
1.6.1 Removing
– Remove bonnet ⇒ page 19 .
– Remove bolts -2- and remove bonnet hinge -1-.
1.6.2 Installing
– Install flap hinge -1-.
– Specified torque for bolts -2-: 22 Nm.
– Install flap ⇒ page 19 .
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1. Bonnet 21
Golf 2004 ➤
1.7 Removing and installing insulation
1.7.1 Removing
AG. Volkswagen AG d
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– Lever retaining clips -1- (Qty. 10) out of insulation -2- using
removal lever -80-200- .
– Pull insulation -2- out of elongated holes.

Golf 2004 ➤
1.7.2 Installing
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– Push insulation -2- underneath gas strut and place assembly

tongues in elongated holes.
– Engage all retaining clips -1- (Qty. 10) in insulation -2-.
• When installing insulation -2- ensure that retaining clips -1- are
fitted with wider side outwards.
1. Bonnet 23
Golf 2004 ➤
AG. Volkswagen AG d
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1.8 Assembly overview - bonnet latch and release components Vo gu
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1 - Arrester s
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❑ Removing:
du
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– Remove bolts -2- and
ab
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remove latch hook.
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❑ Adjusting:
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spec
– Adjustment is carried
es, in part or in w
out by moving arrester
t to the co
to left or right in elonga‐
ted holes.
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2 - Bolt
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❑ Qty. 3
❑ 10 Nm
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3 - Expanding nut
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❑ Qty. 2
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4 - Bearing bracket
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❑ 1.5 Nm
7 - Release lever
⇒ page 28
8 - Bowden cable
❑ Clipped onto wheel
housing and lock carri‐
er.
9 - Bowden cable coupling
❑ Separating ⇒ page 26
10 - Bonnet lock
❑ Removing and installing ⇒ page 25

AG. Volkswagen AG d
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d ara
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nte 04.2008
eo
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1.9 Removing and installing bonnet lock
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1.9.1 Removing
ility
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– Open bonnet.
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spec
Depending on model
t to the co
– Remove radiator grille ⇒ page 230 ,
– Remove GTI radiator grille ⇒ page 233 ,
rrectne
– Remove R32 radiator grille ⇒ page 237 .
s
All models
s o
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f in
– Separating Bowden cable ⇒ page 26
form
mer
– Separate connector -5- for bonnet contact switch -F 266- .
atio
om
n
c
The connector is secured over the right headlight.
i
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– Remove bolts -4- (Qty. 3) on lock carrier -3- and remove bon‐
iv
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pr
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net lock -1- upwards.
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– To unclip Bowden cable -2-, press tab and Bowden cable to‐
Co
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– The fastening is released and the Bowden cable -2- can be
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removed from the bonnet lock -1-.
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Prote AG.
1.9.2 Installing
– Clip Bowden cable -2- into bonnet lock -1-.
– Install bonnet lock -1- in lock carrier -3-.
– Connect connector -5- for bonnet contact switch -F 266- .
– Install Bowden cable -2- ⇒ page 26 .
– Adjust bonnet lock ⇒ page 27 .
• Before closing the bonnet, check the function of the release
lever and Bowden cable.
1. Bonnet 25
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Golf 2004 ➤ olks
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General body repairs,isexterior
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1.10 Separating Bowden cable
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– Open bonnet.
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– Unclip Bowden coupling -1- above headlight on driver side of
ility
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lock carrier -2-.
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– Open Bowden cable coupling -1- upwards and remove Bow‐
hole
den cable -3- in -direction of arrow- out of Bowden cable
spec
es, in part or in w
coupling.
t to the co
Note
rrectness of i
When installing, ensure that the Bowden cable sleeve is inserted
l purpos
correctly and the coupling engages.
nform
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1.11 Adjusting bonnet
his
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– For initial adjustment of bonnet, -1-, the vehicle must be stand‐

ing on the ground and the latch hook be removed.

Golf 2004 ➤
– Remove arrester -9- ⇒ Item 1 (page 24) .

– Disconnect gas strut -2- at bonnet -1- ⇒ page 20 .
– By loosening hexagon nuts -5- and bolt -3- on both bonnet
hinges -4- (do not remove) the bonnet -1- can be aligned be‐
tween wings.
– The rear part of the bonnet -1- can be adjusted both sides to
the wing height by using the adjustment screws -6-.
– The stop buffers -7- (Qty. 2) are not used for adjustment. They
have the function of stabilising and damping the bonnet -1-.
– The front part of the bonnet -1- can be adjusted to wing height
by using the adjustment buffers -8- (Qty. 2).
– Ensure that gaps are uniform ⇒ Body Repairs; Rep. Gr. 00 ;
Technical data; Body gaps/shut lines .
– Carry out corrosion protection measures on hinge -4-, hexa‐
gon nuts -5- and bolts -3- following assembly or adjustment
procedures.
– After adjusting bonnet -1-, install and adjust arrester
⇒ Item 1 (page 24) .
1.11.1 Adjusting bonnet lock

– If gaps change when the bonnet is closed, a minor correction
can be made via bonnet lock and arrester.
– Removing radiator grille ⇒ page 230
– If bolts -1- are now loosened, bonnet gap dimensions can be . Volkswage
AG
corrected or adjusted ⇒ Body Repairs; Rep. Gr. 00 ; Technical
agen
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data; Body gaps/shut lines . by
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– Specified torque for bolts -1-: 12 Nm. tho
tee
or
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– Adjusting arrester ⇒ Item 1 (page 24) ss
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nl
pt
du
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1. Bonnet 27
Golf 2004 ➤
1.12 Removing and installing release lever
1.12.1 Removing
– Pull release lever -1- and release bonnet.
– Insert a small screwdriver in gap between release lever -1- and
clip -2-.
– Lever clip -2- out of release lever -1- and pull off release lever.
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1.12.2 Installing
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– Slide clip -2- completely
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– Then press release lever -1- onto mounting in mounting brack‐
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et and fasten release lever.

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Golf 2004 ➤
2 Rear lid
2.1 Tools
2.2 Assembly overview - rear lid ksw

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1 - Lid utho eo
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❑ Removing and installing ss
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⇒ page 30
un
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2 - Rear lid lock
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⇒ page 39
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spec
3 - Adjustment buffer
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❑ Left and right
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4 - Gas strut
❑ Removing ⇒ page 31 ss o
❑ Releasing gas
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⇒ page 31
form
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5 - Hinge
atio
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c
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⇒ page 31
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6 - Striker pin
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⇒ page 34 Cop py
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7 - Cap
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❑ Left and right

❑ Stop for adjustment buf‐
fer
2. Rear lid 29
Golf 2004 ➤
General body repairs, exterior - Edition 04.2008 AG. Volkswagen AG d
agen oes
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2.3 Removing and installing rear lid d b ara
rise nte
tho eo
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2.3.1 Removing
nl
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– Open rear lid -1-.

– Remove rear lid trim ⇒ General body repairs, interior; Rep.
Gr. 70 ; Trims and insulation; Rear lid trim .
– Separate connectors for all electrical components and pull
hose off rear window wash and wipe system.
– Guide hose and lines out through opening.
– Loosen bolts -3- for hinges -4- on left and right (do not remove).
Further dismantling is possible only with the help of a second
mechanic.
– Detach gas struts -2- on left and right of lid -1- ⇒ page 31 .
– Now remove bolts -3- and remove rear lid -1-.
2.3.2 Installing
Installation is carried out in reverse order of removal.

Golf 2004 ➤
AG. Volkswagen AG d
agen oes General body repairs, exterior - Edition 04.2008
olksw not
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by ara
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– Specified
ho
ris torque for rear lid bolts: 10 Nm. nte
eo
t
au ra
– sAdjusting
s lid ⇒ page 34 . c
ce
e
nl
pt
• Before closing rear lid, check function of lid release compo‐
du
an
itte
nents.
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ab
ility
2.4 Removing gas strut
ot p
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– Open rear lid and support it.
hole
spec
– Position a small screwdriver beneath spring clip -2-.
es, in part or in w
t to the co
– Raise spring clip -2- until spring clip can be moved over ball
socket in -direction of arrow-.
rrectness of i
– Pull gas struts -1- from ball-head pins -3- and -4-.
l purpos
After removing gas strut -1-, slide spring clip -2- back immediately.
nform
ercia
WARNING
m
at
om
io
Proceed with care if gas strut is reused. Spring clip must not
n
c
in t
r
be levered completely out of ball socket, as it will otherwise be

o
his
e
damaged. Gas strut springs out of mounting and causes dam‐

at
do
riv
age or injury to operator.

p
cum
for
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ng
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– Specified torque for ball-head pins -3- and -4-: 21 Nm.
t. C rig
gh ht
pyri by
Vo
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– Releasing gas from gas strut ⇒ page 31
c by lksw
cted agen
Prote AG.
2.5 Releasing gas from gas strut

– Clamp gas strut in vice in area x = 50 mm.
WARNING
Clamp gas strut only within area -x-; otherwise danger of ac‐
cident!
– Saw through cylinder of gas strut within first third of cylinder's

overall length using piston rod end of cylinder as reference
point.
Note
♦ Wear eye protection when sawing.

♦ Cover area of saw cut with a cloth.
♦ Dispose of oil and cloth via existing disposal channels.
2.6 Removing and installing rear lid hinges
Note
Removal and installation is described for the right rear lid hinge.
Follow same instructions for the left rear lid hinge as appropriate.
2. Rear lid 31
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Golf 2004 ➤ olks
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2.6.1 Removing
a c
ss
ce
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nl
pt
du
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ab
ility
ot p
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hole
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es, in part or in w
t to the co
rrectness of i
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nf
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Prote AG.
– Remove rear lid -1- ⇒ page 30 .

– Lower rear of moulded headlining ⇒ General body repairs,
interior; Rep. Gr. 70 ; Trims, insulation; Roof trims; Removing
and installing moulded headlining .
– Remove hexagon nut -3- and remove rear lid hinge -2- from
roof bracing.

Golf 2004 ➤
2.6.2 Installing
Note
After installing rear lid -1- tighten hexagon nut -3- for rear lid hinge -2- again to 24 Nm.
AG. Volkswagen AG d
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hole
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es, in part or in w
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– Install rear lid hinge -2- and tighten hexagon nut -3- to 24 Nm.
rrectness of i
– Install rear lid -1- ⇒ page 30 .

l purpos
– Retighten hexagon nuts -3- to 24 Nm after completing assem‐

bly procedure.
nform
ercia
– Install moulded headlining ⇒ General body repairs, interior;

Rep. Gr. 70 ; Trims, insulation; Roof trims; Removing and in‐
m
at
om
stalling moulded headlining .

on
c
in t
or
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do
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2. Rear lid 33
Golf 2004 ➤
2.7 Removing and installing striker pin
AG. Volkswagen AG d
2.7.1 Removing olksw
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– Remove lock carrier cover ⇒ General body repairs,ointerior;
ris
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Rep. Gr. 70 ; Luggage and load area compartmentaut trim; Re‐
h eo
ra
moving and installing lock carrier cover . ss c
ce
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un
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– Remove bolts -1- and remove striker pin.
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2.7.2 Installing
ss
– Install striker pin -2-.
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form
mer
atio
– Adjust striker pin ⇒ page 35
om
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Further installation is performed in the reverse order of removal.
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2.8 Adjusting lid
Note
♦ Vehicle must be standing on the ground to perform the basic

adjustment of the rear lid.
♦ The rear lid lock is bolted directly to the rear lid. It does not
have elongated holes, so it cannot be adjusted.
♦ Adjusting buffers cannot be used to adjust rear lid as they are
in some other vehicles. They have the function of stabilising
and damping the rear lid.
In conclusion, the rear lid adjustment is described in several

steps.
Use the setting gauge -3371- ⇒ Body Repairs; Rep. Gr. 00 ;
Technical data; Body gap dimensions to check or adjust the gap
dimensions.
– Remove gas strut ⇒ page 31 .
– Adjust rear lid at striker pin ⇒ page 35 .
– Adjust rear lid on rear lid hinges by loosening bolts -3-
⇒ page 30 .
– Adjust rear lid on rear lid hinges by loosening hexagon nut
-3- ⇒ page 32 .

Golf 2004 ➤
– Adjust adjustment buffer ⇒ page 35 .
Note
The lid is adjusted correctly if the gaps/shut lines are even all
around, the lid is not too deep or too high and all contours align
when the lid closed.
2.8.1 Adjusting striker pin

– Remove lock carrier cover ⇒ General body repairs, interior;
Rep. Gr. 70 ; Luggage and load area compartment trim; Re‐
moving and installing lock carrier cover .
– Loosen striker pin -2-.
– Move striker pin -2- to rearmost position -arrow- and tighten
bolts -1-.
– Close rear lid and check adjustment.
– By loosening bolts -1- it is possible to slide striker pin -2- within
over-sized holes.
2.8.2 Adjusting adjustment buffer
Note
Only the adjustment for the right adjustment buffer is described.

The adjustment for the left adjustment buffer is similar.
– Loosen clamping bolt -2- until it is visible in rubber buffer.

olkswagen AG
en AG. V
– Now pull detent slide -1- out of adjustment buffer.
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2. Rear lid 35
Golf 2004 ➤
– Adjust detent slide to dimension -a = 12.5 mm-.

– Close rear lid to detent position with light pressure at centre of
lid.
AG. Volkswagen AG d
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– Open rear lid again.
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rm
– Screw in adjustment buffer clamping screw -1- to a depth of
ab
pe
ility
dimension -a = 25 mm-.
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– Check setting.
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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tion in
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Golf 2004 ➤
2.9 Assembly overview - rear lid latch and release components
1 - Release element with but‐

ton E234
⇒ page 37
2 - Bolt
❑ Qty. 5
❑ 4 Nm
3 - Emergency release
❑ Emergency release can
be found through an
aperture in the rear lid
trim
4 - Lid lock
⇒ page 39
5 - Lid lock connector
6 - Retaining bracket
7 - Release element connector
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2.10 Removing and installing release ele‐ h re

hole
spec
ment
es, in part or in w
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Note
rrectness of i
If rear lid will not open, it can be opened by hand using the emer‐
l purpos
gency release -3- on rear lid lock -4-. Emergency release can be
found through an aperture in the rear lid trim
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2. Rear lid 37
Golf 2004 ➤
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2.10.1 Removing ed
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Gr. 70; ; Trims and insulation; Rear lid trim .
– Remove rear window wiper motor ⇒ Electrical system; Rep.
Gr. 92 ; Window wiper and washer system; Rear window wiper
system .
– Separate connector -7- from release element -1-.
– Loosen release element contrary to the -arrow- from the re‐
taining brackets -6-
– Then remove release element -1-.
2.10.2 Installing
– Specified torque for release element bolts: 4 Nm.
nents.

Golf 2004 ➤
2.11 Removing and installing lid lock
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If rear lid will not open, it can be opened by hand usingthothe emer‐
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gency release -1- on rear lid lock -2-. Emergency release
s au can be ra
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2.11.1 Removing
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Gr. 70; ; Trims and insulation; Rear lid trim .
h re
hole
spec
– Disconnect connector -4- from lid lock -2-. es, in part or in w
t to the co
– Remove bolts -3- and guide lid lock -2- downwards and out of
lid.
rrectness of i
l purpos
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2.11.2 Installing cted agen
Prote AG.
– Guide rear lid lock -2- into rear lid and tighten bolts -3-.
– Attach connector -4- for rear lid lock -2-.
nents.
2.12 Rear lid seal

During production, a sealant is applied to the rear lid seals, the
seal is then placed on the rear lid flange and rolled on.
2. Rear lid 39
olksw
agen AG
Golf 2004 ➤ wage
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General body
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♦ When seals are removed, the sealant will spread to the inside
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of the seal and the flanks will be bent out slightly. If the seal is
pe
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then refitted, a leak-free tight seal is not guaranteed.
ot
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♦ Therefore each seal which is removed completely should be
hole
spec
replaced by a so-called “tap-on” seal.
es, in part or in w
t to the co
♦ If a seal has been partially removed, squeeze sides of seal
together before installing.
rrectness of i
2.13 Removing and installing rear lid seal
l purpos
2.13.1 Removing
nform
mercia
a
– Pull rear lid seal -1- off body flange.
com
tion in
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2.13.2 Installing
– Align rear lid seal -1- so that the vulcanised point -arrow- is
located to the middle of the rear left light cluster.

Golf 2004 ➤
3 Tank flap unit
3.1 Tools
♦ Socket -T 10010-
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Assembly overview - tank flap unit ra
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1 - Tank flap unit
itte
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❑ Removing ⇒ page 42 ility
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2 - Bolt
h re
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❑ 1.5 Nm
spec
es, in part or in w
3 - Drain hose
t to the co
4 - Assembly piece
5 - Release rod
rrectness of i
6 - Securing bolt for actuator

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❑ Qty. 2
nform
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❑ 1.5 Nm
m
7 - Fuel tank filler flap actuator

at
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(F219)
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3. Tank flap unit 41

Golf 2004 ➤
3.2.1 Removing tank flap unit
Note
If the fuel tank filler flap does not open, open by hand using the release rod -5-. The side trim must be removed
to do this.
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– Open fuel tank flap.

– Remove fuel filler cap.
nform
ercia
– Remove bolt -2-.

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– Pull rubber part off fuel tank filler neck.

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– Pull fuel tank flap unit -1- with drain hose -3- to rear and swing
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fuel tank flap unit out of side panel.

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– Unclip assembly part -4- out of side panel and pull assembly
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Golf 2004 ➤
3.2.2 Installing tank flap unit
AG. Volkswagen AG d
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• The mounting part -4- has been pushed in.

– Pass drain hose -3- through the opening in tank flap unit and t to the co
pull hose through as far as possible.
rrectness of i
– Guide drain hose into side panel.

l purpos
– With hinge side leading guide tank flap unit -1- into side panel.
nform
– Then swivel tank flap unit completely into side panel, ensure
ercia
that the locating hooks at top and bottom properly locate in

m
side panel.
com
tion in
– Pull rubber part over filler neck and tighten bolt -2-.
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Specified torque for bolt -2-: 1.5 Nm.

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3. Tank flap unit 43

Golf 2004 ➤
3.2.3 Removing actuator
AG. Volkswagen AG d
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– Remove luggage compartment side panel trim ⇒ General

body repairs, interior; Rep. Gr. 70 ; Trims, insulation; Luggage
and load compartment trims .
– Disconnect connector on actuator -7-.
– Release actuator -7- using hexagon socket screwdriver -T
10010- .
– Pull actuator -7- together with release rod -5- out of seal -8-.
3.2.4 Installing actuator


Golf 2004 ➤
General
wa gebody
n AG. Vrepairs,
olkswagenexterior
AG doe - Edition 04.2008
ks s no
Vol t gu
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57 – Front doors, doorss components, central locking au
tho eo
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un
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1 Front door
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1.1 Tools
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spec
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t to the co
Special tools and workshop
equipment required
♦ Socket -T 10072-
rrectness of i
♦ Assembly tool -T 10118-
l purpos
♦ Door alignment tool -3320-
nform
ercia
♦ Universal joint for 3320

-3320/1-
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♦ Bit for 3320 -3320/2-
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♦ Bit for 3320 -3320/3-
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♦ Roller for fitting door insu‐
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lation foil -3356-

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♦ Torque wrench 5...50 Nm -
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♦ Setting gauge -3371-
AG.
1. Front door 45
Golf 2004 ➤
♦ Cartridge gun -V.A.G 1628-

♦ Cartridge heater -V.A.G
1939 A-
♦ Wedge -3409-
♦ Assembly tool set -T
10237-
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1.2 Materials
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♦ 1K window adhesive DH 009 100 012) 3)

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♦ Glass primer/paint primer D 009 200 021)

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♦ Cleaning solution D 009 401 041)

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♦ Primer applicator D 009 500 251)

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♦ Door repair kit D 438 520 A24)

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1) Materials are stored in box D 004 700.
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2) Observe minimum curing period ⇒ page 64 .
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3) Heat, according to manufacturers instructions, using cartridge heater -V.A.G
1939- .
4) Folding cardboard carton with 10 sheets each with 15 adhesive strips.
1.3 Assembly overview - door assembly

A new door concept has been introduced with Golf 2004.
The door consists of a door inner part -6- and door outer panel
-1-.
46 Rep. Gr.57 - Front doors, door components, central locking

Golf 2004 ➤
n AG. Volkswagen A
The parts are joined by the
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wage doesretaining rails.
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The retaining rails
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ed ran
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to the door outer
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The door inner part -6- serves amongst other things as the pre‐
ce
e
nl
viously known assembly carrier. Loudspeaker, window regulator,
pt
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window regulator motor, wiring, window guides, exterior mirror
itte
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and door lock are mounted on the door inner part.
ab
ility
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The door outer panel -1- is additionally bolted to the lower edge
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of the door inner part. The window slot seals, insulation and door
h re
hole
outer handle are mounted on the door outer panel.
spec
es, in part or in w
t to the co
Caution
Bolts of different types are used to secure door outer panel. If
rrectness of i
these are fitted in the wrong positions, the door outer skin will
l purpos
be damaged.
nf
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1 - Door outer panel
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or
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⇒ page 94
t
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2 - Edge protection cu
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❑ Between door outer skin

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3 - Bolt copy Vo
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❑ Feature: bolt with poin‐ Prote AG.
ted end and thin washer.
❑ Qty. 6 on lower edge
❑ Qty. 2 in area of top sec‐
tion of trim
❑ 10 Nm
4 - Rear retaining rail
❑ Adhesive:
DH 009 100 03
5 - Bolt
❑ Feature: bolt without
pointed end but with
thick washer.
❑ Qty. 10 for both retain‐
ing rails on 4 door mod‐
els
❑ Qty. 11 for both retain‐
ing rails on 2 door mod‐
els
❑ 14 Nm
6 - Door inner part
❑ Assembly overview
⇒ page 65
7 - Front retaining rail
❑ Adhesive:
DH 009 100 03
8 - Bolt
❑ Feature: bolt with pointed end and thick washer.
❑ Qty. 1 for front area of top section of trim
1. Front door 47
lkswage es n
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Golf 2004 ➤ ir se
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❑ 10 Nm
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9 - Insulation
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❑ Self-adhesive
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❑ To bond, first heat the insulation and then press on firmly
, is n
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hole
10 - Clip
spec
es, in part or in w
❑ Qty. 6
t to the co
11 - Window slot seal
❑ Must be fitted before assembling door outer panel.
rrectness of i
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1.4 Assembly overview - door hinges
nf
ercia
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m
Caution
atio
om
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Bolt of eccentric pin -10- should not be loosened under any
thi
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sd
a
circumstances on vehicles up to 01.2004. It cannot be tight‐

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ened again using normal workshop tools.
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Prote AG.

Golf 2004 ➤
Note
♦ The right side is shown. The left side is similar.

♦ The hinge bolts must always be renewed if loosened.
♦ Hinges are now one piece.
♦ The specified torque for the hinge bolts to the door (bolts -4, 6 and 14-) has been revised.
1 - Door
⇒ page 50
2 - Guide bolt
AG. Volkswagen AG d
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3 - Door hinge with arrester rise
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4 - Multi-point socket head bolt s au ra
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s
❑ 50 Nm
ce
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nl
pt
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❑ Bolts must always be re‐
itte
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placed by new ones af‐
erm
ab
ter being undone
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5 - Multi-point socket head bolt
h re
hole
❑ Installed from inside the
spec
vehicle
es, in part or in w
t to the co
❑ Remove lower A-pillar
trim ⇒ General body re‐
pairs, interior; Rep. Gr.
rrectness of i
70 ; Trims, insulation;
Pillars and side trims
l purpos
❑ 20 Nm + 1/4 turn further

(90°).
nform
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ion
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❑ 50 Nm
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(90°).
❑ Bolts must always be replaced by new ones after being undone
8 - Guide bolts
❑ 10 Nm
9 - Adjustment ring
❑ Restricts the adjustment range for the eccentric pin
10 - Bolt
❑ For eccentric pin
❑ 28 Nm
1. Front door 49
Golf 2004 ➤
11 - Door hinge
❑ Door hinge no longer comprises of more than one part
❑ 20 Nm + 1/4 turn further (90°).
❑ Bolts must always be renewed after being loosened
❑ 20 Nm + 1/4 turn further (90°).
❑ 50 Nm
15 - Eccentric pin
❑ Eccentric pin is used to adjust gap on vehicles as of 02.2004
1.5 Removing and installing door
Note
The removal and installation sequence is only for the right door.
The removal and installation of the left door is similar.
AG. Volkswagen AG d
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AG. Volkswagen AG d
agen oes
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rise
d b ara
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autho
General
eo
ra body repairs, exterior - Edition 04.2008
ss c
ce
le
1.5.1 un Removing
pt
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d
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es, in part or in w
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l purpos
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Prote AG.
– Release bellows -6- by pressing the catch -arrow a- and pull

bellows off A-pillar.
– Swing release lever -7- downwards -arrow b- and disconnect
electrical connector -8- from coupling station.
– Remove bolts -4, 5 and 11- from hinge using special door
alignment tool -3320- and bit -3320/3- .
– Pull door in -direction of arrow- off guide bolts -2 and 9-.
1.5.2 Installing
– Specified torque, bolts -4, 5 and 11-: 50 Nm.
• Always renew bolts -4, 5 and 11-.
– Note front door gap dimensions ⇒ Body Repairs; Rep. Gr. 00 ;
Technical data; Body gap dimensions .
1. Front door 51
Golf 2004 ➤
lkswage es n
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1.6 Adjusting door ir se
d byV ua
ran
tee
tho
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Note
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nl
pt
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♦ The door is adjusted correctly if the gaps/shut lines are even
erm
ab
all around, the door is not too deep or does not stand proud
ility
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and all contours align when the is door closed.
wit
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♦ Vehicle must be standing on its wheels on flat level ground
hole
spec
when adjustments are performed. es, in part or in w
t to the co
♦ If door outer panel has been removed, door inner part window
frame must be adjusted to roof frame and B-pillar, or rear door.
rrectness of i
1.6.1 Adjusting door gaps
l purpos
nform
ercia
♦ Box spanner 15 mm -T10344-

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WARNING
Vehicles up to 01.2004, the bolt of the eccentric pin -10- must

not be loosened and the eccentric pin -15- must not be used
to adjust the door.

Golf 2004 ➤
AG. Volkswagen AG d
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pt
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ab
ility
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es, in part or in w
t to the co
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nf
ercia
orm
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sd
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Cop py
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– Note front door gap dimensions ⇒ Body Repairs; Rep. Gr. 00 ; py by
co Vo
by lksw
cted agen
Prote AG.
Adjustments are carried out using eccentric pin -7-.
Other measures such as raising the door have no effect. Subse‐
quent pressure from above will cause the door to sack again.
– Loosen bolt for eccentric pin -5-.
– Adjust eccentric pin -7- within adjustment range -6- using 15
mm ring spanner -T10344- .
– Tighten bolt -5- before checking setting.
The door outer panel -2- can be adjusted if the adjustment range
is insufficient.
– Loosen bolts -3- and move door outer panel -2-.
– Retighten bolts -3- ⇒ page 57 .
1. Front door 53
Golf 2004 ➤
1.6.2 Adjusting door fittings for flushness
AG. Volkswagen AG d
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t to the co
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f inform
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or
Use bolts -2, 3, 4, 5 and 6- on hinge to adjust correctly for flush‐

thi
te
ness.
sd
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Use door alignment tool -3320- with bit -3320/3- .

fo
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– Adjusting upper area of door, loosen bolts -5 and 6-. Cop py
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– Specified torque for bolt -5-: 10 Nm. p by
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– Specified torque for bolt -6-: 50 Nm. Prote AG.
– To adjust lower area of door, loosen bolts -5 and 6-.

– Specified torque for bolt -2-: 10 Nm.
– Specified torque for bolts -3 and 4-: 50 Nm.
The bolts -3, 4 and 6- must always be renewed if loosened.
– Guide pin -4- may be ground down if necessary.

AG. Volkswagen AG d
agen oes
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ed
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Golf 2004 ➤
a
ss Generalc body repairs, exterior - Edition 04.2008
ce
le
un
pt
1.7 Removing and installing door outer pan‐
an
d
itte
y li
erm
ab
el
ility
ot p
wit
is n
h re
ole,
1.7.1 Removing
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
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fo
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Cop py
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cted agen
Prote AG.
– Lever out clips-3- from the bottom starting on the door -1- and
remove cover -2-.
1. Front door 55
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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Golf 2004 ➤ rised
nte
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aut - Edition 04.2008
h
ra
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ce
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– Remove lock cylinder ⇒ page 67
un
pt
an
d
itte
y li
– Remove door handle ⇒ page 68 .
erm
ab
ility
ot p
– Remove bolt -1- from mounting bracket -2- which is located
wit
is n
behind door outer panel.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
r
fo
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ng
t.
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.
– Remove all bolts -2, 3 and 4-.

– Carefully remove door outer panel.

Golf 2004 ➤
1.7.2 Installing
Caution

these are fitted in the wrong positions, the door outer panel will
be damaged.
AG. Volkswagen AG d
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ce
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un
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an
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ab
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ot p
wit
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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pr
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fo
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t.
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Cop py
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by c lksw
cted
– Carefully fit door outer panel.
agen
Prote AG.
– Insert all bolts -2, 3 and 4-.

• Observe correct usage for the different types of bolts.
♦ Feature for bolt -2-: bolt with pointed end and thin washer.
♦ Feature for bolt -3-: bolt without pointed end but with thick
washer.
♦ Feature for bolt -4-: bolt with pointed end and thick washer.
– Check whether the securing strut guide pins are located in the
appropriate guide holes in door inner part. Then first tighten
all bolts -2, 3 and 4-.
1. Front door 57
Golf 2004 ➤
• Observe correct specified torque for the different types of

bolts.
Specified torque for bolt -2-: 10 Nm.
1.8 Installing new outer panel for door
Caution

be damaged.
Note
Observe section, installation notes for bonding-in a new door out‐

er panel ⇒ page 63
AG. Volkswagen AG d
agen oes
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V gu
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or eo
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aut ra
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un
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an
d
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erm
ab
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wit
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h re
ole,
spec
t to the co
rrectness o
cial p
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mer
atio
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c
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Prote
58
AG.
Rep. Gr.57 - Front doors, door components, central locking
Golf 2004 ➤
• The old (damaged) door outer panel with retaining rails is re‐
moved ⇒ page 55
– Install front -2- and rear -6- retaining rails to door inner part.
For this use “bolt without point with thick washer”.
Specified torque for bolts -3- and -5-: 10 Nm.
– Fit two guide bolts in lower edge of door inner part.
AG. Volkswagen AG d
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es, in part or in w
t to the co
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nform
ercia
The painted door outer panel is first offered up without bonding

agent.
m
a
com
tion in
Assembly block from assembly tool set -T 10237- is required to

r
te o
thi
offer up the door outer panel. A strip of “Tesa Power Strips large”
s
iva
-6- is applied on the lower side. The pin has the minimum dimen‐
do
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rp
sion for the gap width. The non bonded surface is brought into
um
fo
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position with the adjacent component.

ng
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op py
– Bond assembly block -3- on door outer panel. t. C rig
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– Guide door outer panel -1- over guide bolts in lower edge of
co Vo
by lksw
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door inner part. Prote AG.
– Adjust gap to side member and door outer panel height using
wedges -4- from assembly tool set -T 10237- .
1. Front door 59
Golf 2004 ➤
– Place door outer panel with assembly blocks on surrounding

components -2 and 5-.
– Check gap dimension using setting gauge -3371- ⇒ Bodywage
nRe‐
AG. Volkswagen AG d
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pairs; Rep. Gr. 00 ; Technical data; Body gap dimensions
yV
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– If gap dimension cannot be adjusted further,
ho door inner part
ris nte
e
must be adjusted ⇒ page 52 s aut or
ac
s
– Remove door outer panel again.
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
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t.
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.
– Apply a bead of adhesive material -2- using cartridge gun -

V.A.G 1628- to front -1- and rear -3- retaining rails.

AG. Volkswagen AG d
agen oes
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gu Golf 2004 ➤
ol not
V
d by ara
orise General body repairs, exterior - Edition
nte 04.2008
h eo
aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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for
en
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t.
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Cop py
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Prote AG.
Use fixing block from assembly tool set T10237 to insert door
outer panel. Two strips of “Tesa Power Strips large” -5- are bon‐
ded to the contact surfaces.
door inner part.
– Bring door outer panel with assembly blocks -3- into contact
with surrounding components.
– Adjust the gap to side member and adjust door outer panel
height using wedges -4- from assembly tool set.
– Check gap dimensions using setting gauge -3371- ⇒ Body
Repairs; Rep. Gr. 00 ; Technical data; Body gap dimensions .
– Bond short fixing block -2- evenly on the replacement door and
the adjacent components.
Note
A curing period of 180 minutes must be observed before per‐

forming further work on the door which has been bonded.
– Further installation is performed in the reverse order of re‐

moval ⇒ page 57 .
1. Front door 61
Golf 2004 ➤
1.9 Removing and installing retaining rail on

door outer panel
1.9.1 Removing retaining rail
Caution
AG. Volkswagen AG d
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The following work steps are dtobybeV carried out with great care. ot gu
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As door outer skin is to be orireused,
se
dents and scratches must nte
eo
be avoided. aut
h
ra
c
ss
When cutting through the adhesive bead, always hold the re‐
ce
le
un
pt
taining rail and door outer skin together as shown in the illus‐
an
d
itte
tration. If this is not done, the door outer skin will come away
y li
rm
ab
from the retaining rail, thus rendering it useless.
pe
ility
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, is n
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es, in part or in w
Note
t to the co
The following work steps should be carried out with the aid of an
assistant.
rrectness of i
l purpos
Door outer panel with retaining rail is removed ⇒ page 55

– Place door outer panel -1- on firm surface and protect door
nform
ercia
outer panel against scratches.

m
– Fit reel device -2- in place. a

com
tion in
r
– Secure cord -5- on reel device and counterhold -4-.

te o
thi
s
iva
do
– Hold retaining rail and outer skin together securely when cut‐
r
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ting through adhesive bead.

fo
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– Cut through adhesive bead of retaining rail -3- and door outer Cop py
panel -1- with cord up to just over half way. ht. rig
rig ht
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Prote AG.

Golf 2004 ➤
Generalgebody
n AG. Vrepairs,
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wa oes
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– Once adhesive bead has been cut through to isjust ed over half
b ara
nte
way in step one, turn reel device -2- around thoand insert cord
r eo
-5- in side still bonded. au ra
c
ss
ce
le
– Hold retaining rail -3- and outer skin -1- together securely
un
pt
an
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when cutting through adhesive bead further.
itte
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erm
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– Cut through second half of adhesive bead.
ility
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t to the co
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mer
atio
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1.9.2 Installing retaining rail
thi
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sd
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– Cut away remainder of adhesive bead to a minimum on outer

p
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panel with the greatest of care, ensuring that no damage is
en
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t.
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caused to the paintwork.
Co
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– Remainder of work procedure is described in chapter entitled
ht
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“Installing new door outer panel” ⇒ page 58
co lksw
by
cted agen
Prote AG.
Note
Observe also “instructions for bonding in new door outer panel”

when installing a new retaining rail.
– In place of removed retaining rail, install a new retaining rail

on the door inner panel.
– Apply adhesive to new retaining rail.
– Tighten screws to secure door panel on lower edge and on
retaining rail still in place.
– Secure door outer panel on new retaining rail with fixing
blocks.
1.10 Installation instructions for bonding in

new door outer panel
Note
♦ If both door outer panels on one side have to be renewed, the

sequence must be observed. The rear door outer panel is
aligned and bonded in first, followed immediately by the front
door outer panel. The long fixing blocks must be bonded in
from the rear door outer panel to the front door outer panel.
♦ If door outer panel CDP coating is damaged on inside in bond‐
ing area, or if this area has been painted, this area must be
primed with glass/paint primer D 009 200 02.
♦ The 1K window adhesive DH 009 100 must be heated in car‐
tridge heater -V.A.G 1939 A- for 20 minutes.
1. Front door 63
Golf 2004 ➤
. Volkswage
AG n AG d
agen oes
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– Clean contact surfaces on retainingd brails
y V thoroughly using gu
ara
cleaning solution D 009 401 04. orise nte
eo
th
u ra
– Apply adhesive material to appropriate
ss a
surfaces at right angles c
to retaining rail using cartridge gun -V.A.G 1628- .
ce
e
nl
pt
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WARNING erm
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ility
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Door outer panel must be installed within 10 minutes, or ad‐
h re
hesive properties of adhesive will be impaired.
hole
spec
es, in part or in w
t to the co
♦ With assistance of both assembly blocks, place door outer
panel on retaining rails, align with wedges and setting gauge
-3371- and press contact surfaces of assembly blocks onto
rrectness of i
surrounding components.
l purpos
♦ Secure door with fixing blocks during curing time.

♦ After installation door outer panel must align with other com‐
nf
ercia
o
ponents and gap dimension must be even.
rm
m
atio
m
♦ If adhesive bead is too thick and adhesive exudes between

o
n in
c
retaining rail and door outer panel, excess adhesive must be

or
thi
e
removed.
t
sd
iva
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cu
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1.11 Minimum curing period
f
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t.
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Cop py
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WARNING
p by
co Vo
by lksw
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Prote AG.
Special standards must be adhered to when replacing bonded
door outer panels. One of these standards is, for example, that
a freshly bonded door outer panel must comply with the safety
requirements, even in an accident, following the minimum
specified curing period.
For 1-pack adhesive DH 009 100, the minimum curing time for
the door outer panel is 180 minutes.
Minimum curing time means the time from bonding-in the door
outer panel to the time the vehicle is brought into use or further
work is carried out. During this time, the vehicle must stand on a
level surface at room temperature (at least 15 C).
WARNING
Vehicle is safe to use only after the minimum curing period is

completed.
1.12 Cleaning off excess adhesive sealing

material
– It is recommended to use cleaning solution D 002 000 10 as
a cleaner. Observe the appropriate safety precautions when
performing this work.
Caution
When cleaning vehicle, the door outer panel just bonded-in

must not be moved.

Golf 2004 ➤
– First clean painted surface as much as possible using a dry

cloth. Remove remaining adhesive with adhesive remover
D 002 000 10.
– Cleaning plastic trim: allow adhesive sealant to cure (approx.
one hour) and then peel off.
1.13 Assembly overview - door inner part
Note
The right side is shown. The left side is similar.
1 - Door inner part

2 - Window slot seal wage
es n
olks ot g
3 - Loudspeaker byV ua
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ir se tee
o
4 - Window regulator motor auth or
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ss
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5 - Insulation
an
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❑ Qty. 4
ab
pe
ility
❑ 20 mm x 40 mm com‐
ot
wit
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mercially available tex‐
h re
tile adhesive tape
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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com
tion in
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Cop py
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co lksw
by
cted agen
Prote AG.
1. Front door 65
Golf 2004 ➤
1.14 Assembly overview - door handle and door lock
Note
Only the left side is shown. The procedure for the right side is similar.
1 - Door lock
⇒ page 72
2 - Cable
AG. Volkswagen AG d
❑ To release lock from agen oes
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3 - Bolt utho eo
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❑ To secure lock on door s
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inner part
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❑ 18 Nm
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❑ Qty. 2
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4 - Bearing plate
h re
hole
spec
⇒ page 70
es, in part or in w
t to the co
5 - Bolt
❑ For lock cylinder
rrectness of i
6 - Locking screw
l purpos
❑ Not fitted on all models

❑ This bolt is installed to
nform
ercia
provide additional se‐

curity for the bearing
m
at
plate
om
ion
c
in t
r
7 - Base
o
his
ate
do
riv
8 - Lock cylinder housing

p
cum
or
❑ Only on driver side

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en
ng
t.
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❑ Installed on the passen‐ Cop py
t. rig
ger side is just a housing opyri
gh by
Vo
ht

c by lksw
cted agen
⇒ page 67 Prote AG.
9 - Cover
❑ For lock cylinder housing
❑ Secured to lock cylinder housing with three locking lugs
10 - Key
❑ Changing battery ⇒ page 82
❑ Adapting new or additional key to remote control and immobiliser ⇒ page 81
11 - Door handle with base
12 - Base
❑ Part of door handle
13 - Torx screw
❑ Socket -T 10072-
14 - Spreader rivet
❑ Not installed on Golf

Golf 2004 ➤
16 - Cable
❑ To release lock from inner door handle
17 - Cover
❑ Not supplied as part of door lock
❑ Secured to door lock with three locking lugs
1.15 Removing and installing housing
Note
The removal and installation sequence is only for the right hous‐
ing. The removal and installation of the right lock cylinder is
similar.
1.15.1 Removing
– Lever out caps in front of bolts -1-.
– Pull door handle -2- in -direction of arrow- and unscrew bolt
-1- using socket wrench -T 10072- until housing -3- can be
pulled out.
AG. Volkswagen AG d
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1.15.2 Installing
wit
, is n
h re
hole
– Fit housing -3- in door handle mounting plate at right angles

spec
-arrow-.
es, in part or in w
t to the co
Door handle -2- must rest only lightly against door panel.
– Now tighten bolt -1- in bearing plate using socket -T 10072- .
rrectness of i
The door handle -2- locates in the housing -3- with a well audible
l purpos
click.
nform
ercia
Note
m
at
om
io
During installation, housing must be pressed against door panel.

n
c
in t
r
Door handle rests only lightly against door panel.

o
his
ate
do
priv
cum

for
en
ng
t.
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• Then always check function while door is still open, as an in‐
Co
Cop py
correctly fitted and adjusted Bowden cable cannot open the
t. rig
gh ht
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door.
p by
co Vo
by lksw
cted agen
Prote AG.
1. Front door 67
AG. Volkswagen AG d
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Golf 2004 ➤ rised
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1.16 Removing and installing door handle
nl
pt
du
an
itte
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erm
ab
ility
ot p
Note
wit
, is n
h re
hole
The removal and installation sequence is only for the right door
spec
handle. The removal and installation of the left door handle is
es, in part or in w
t to the co
similar.
1.16.1 Removing
rrectness of i
– Removing housing ⇒ page 67 .
l purpos
– Lever clip -2- out of door handle -1-.
nform
ercia
– Swivel door handle -1- out of door -arrow-.

m
at
om
ion
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ate
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for
en
ng
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

Golf 2004 ➤
1.16.2 Installing
AG. Volkswagen AG d
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ility
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hole
spec
es, in part or in w
t to the co
– Guide assembly tool -T 10118- into door through opening in

door inner panel.
– Use a hand torch to illuminate inside of door for improved vis‐
rrectness of i
ibility.
l purpos
– Hook assembly tool -T 10118- in spring -arrow A-.

– Hook spring into door lock by pulling assembly tool -T 10118-
nform
ercia
-arrow B-.
m
a
com
ti
The release lever is now secured.

on in
r
te o
thi
s
iva
do
Note
r
rp
cum
fo
en
ng
t.
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Hooking the spring into the operating lever secures the lock. This prevents incorrect attachment of the Bowden
Co
op py
cable to the door handle later.
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Prote AG.
1. Front door 69
AG. Volkswagen AG d
agen oes
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byV gu
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Golf 2004 ➤ rised
nte
o eo
General bodyaurepairs,
th exterior - Edition 04.2008 ra
ss c
ce
le
– Swivel door handle -1- into door.
un
pt
an
d
itte
y li
– Pull clip -2- in the panel opening and engage clip in door han‐ erm
ab
dle -1- -arrow-.
ility
ot p
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is n
h re
ole,
Note
spec
t to the co
♦ Door handle -1- must be pressed against door panel when
assembling.
♦ Clip -2- must engage in door handle -1- with a clearly audible
rrectne
click.
ss o
Install housing ⇒ page 67 .
cial p
f inform
mer
atio
m
door.
o
n
c
i
or
n thi
te
sd
a
1.17 Removing and installing mounting plate

iv
o
pr
cum
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fo
en
ng
t.
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op
Note
C py
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rig ht
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co Vo
Removal and installation are described only for the right bearing
by lksw
cted agen
Prote
bracket. The removal and installation of left mounting plate is
AG.
similar.

Golf 2004 ➤
1.17.1 Removing
AG. Volkswagen AG d
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pe
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove lock cylinder housing ⇒ page 67

nform
ercia

m
a
com
tio
– Remove door outer panel ⇒ page 94 .

n in
r
te o
thi
– Pull retaining rubber -4- upwards off guide pins.

s
iva
do
r
rp
– Pull mounting plate -1- in -direction of arrow- with guide pins

um
fo
en
-2- out of mounting -3-.

ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
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Prote AG.
1. Front door 71
Golf 2004 ➤
1.17.2 Installing
AG. Volkswagen AG d
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an
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ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
– Push mounting plate -1- with guide pins -2- in mounting -3-.
mer
atio
m
– Secure retaining rubber -4- to guide pins and securing bolts

o
n
c
on mounting plate support.

or
n thi
te
sd
a

iv
o
pr
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r
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1.18 Removing and installing door lock

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
Note
o
by c lksw
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Prote AG.
lock. The removal and installation of the left door lock is similar.

Golf 2004 ➤
1.18.1 Removing
AG. Volkswagen AG d
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V gu
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h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo

en
ng
t.
yi Co
op
– Remove mounting plate ⇒ page 70 . C py
t. rig
gh ht
yri by
– Disconnect connector -5-. op Vo
by c lksw
cted agen
Prote
AG.
– Release cable -1- from relay lever -8- and remove door lock
-4-.
Cover -3- is not supplied with door lock.
1.18.2 Installing
Specified torque for bolts: 18 Nm.
door.
1. Front door 73
Golf 2004 ➤
1.19 Assembly overview - side impact pro‐

tection
Caution
The nuts and bolts of the side impact protection are also pain‐ G. Volkswagen AG d
ted in the factory. This means that a great deal of force is lkswagen A oes
not
required to remove them, resulting in some circumstancesd bin yV
o gu
ara
the threads shearing. If possible avoid loosening the nutsris and
e nte
bolts. tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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1 - Side impact protection rm
ab
pe
ility
ot
2 - Bolt
wit
, is n
h re
❑ Qty. 4
hole
spec
❑ 20 Nm
es, in part or in w
t to the co
3 - Insulation
4 - Nut
rrectness of i
❑ Qty. 2
l purpos
❑ 20 Nm
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.20 Door inner seal

During production, a sealant is applied to the door inner seals,
which are then placed on the door flange and rolled on.

Golf 2004 ➤
Note
then refitted, a leak-free tight seal is not guaranteed.
1.21 Removing and installing door inner seal
Note
. Volkswagen AG
gen AG
Removal and installation are described for the left door inner olksseal
wa does
not
only. Removal and installation of the right door inner eseal
d by V are gu
ara
similar. tho
ris nte
eo
au ra
c
ss
1.21.1 Removing
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Front door 75
Golf 2004 ➤
– Pull door inner seal off body flange.
1.21.2 Installing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– Align door inner seal with vulcanisation point -arrow b- to

atio
height of lower hinge.

om
n
c
i
or
– Begin installing door inner seal in upper radius -arrow a- of

thi
e
door aperture.
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
1.22 Removing and installing door outer

agen
AGseal
. Volkswagen AG
do
ksw es n
Vol ot g
d by ua
ran
e
ris tee
Note tho or
au ac
ss
♦ Removal and installation are described for the right door outer
ce
le
un
pt
seal only. Removal and installation of the left door outer seal
an
d
itte
are similar.
y li
rm
ab
pe
ility
♦ Remove protective backing immediately before installation.
ot
wit
Working temperature approx. 20 °C. , is n
h re
hole
♦ Adhesive remover D 002 000 10 must be used exclusively.
spec
es, in part or in w
♦ The door outer seal must be bonded in place immediately after
t to the co
cleaning.
♦ After 10 minutes, check to ensure that the seal is firmly seated.
rrectness of i
l purpos
1.22.1 Removing
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Pull door outer seal off door.
1. Front door 77
Golf 2004 ➤
1.22.2 Installing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove existing adhesive residues with adhesive remains re‐

l purpos
mover -VAS 6349- .

– Immediately before bonding the door outer seal, clean bond‐
nform
ercia
ing surface thoroughly with adhesive remover D 002 000 10.

m
at
• Surfaces to be bonded must be free of dust and grease and

om
ion
there should be no adhesive residue.

c
in t
or
his
e
– Align door outer seal with aperture -arrow b- towards door lock
at
do
riv
securing bolt.
p
cum
for
en
g
– Door outer seal vulcanised point -arrow c- should then be in

n
t.
yi Co
op
middle of side member. C py
t. rig
gh ht
yri
– Pull protective backing off in stages and start fitting seal in
p by
o Vo
by c lksw
upper radius -arrow a- of door. Do not pull outer door seal to Prote
cted AG.
agen
avoid stretching seal.

Golf 2004 ➤
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
– Press complete adhesive area of seal -3- on door -1- all around
h re
hole
using roller -3356- .

spec
es, in part or in w
– The seal is pushed aside -arrow a- when doing this so that the
t to the co
roller -3356- runs directly over the contact surface of the seal.
The roller can only apply the necessary force -arrow B- to the
rrectness of i
adhesive surface -2- when procedure described above is followed

correctly.
l purpos
– If the seal is too long: cut seal to required length and press butt
joints on well.
nform
ercia
– If the seal -3- comes loose in small areas again, press seal on
m
at
om
well again using roller -3356- .

ion
c
in t
or
his
ate
do
riv
Note
p
cum
for
en
ng
The door must not be closed for a period of 2 hours to ensure the door outer seal does not move or loosen
t.
yi Co
op
again.
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Front door 79
Golf 2004 ➤
2 Central locking
2.1 Location overview - central locking components
1 - Coupling station
❑ Location: right-hand A-
pillar
❑ To disconnect connec‐
tor, release boot at pillar
⇒ page 51
2 - Convenience system cen‐
tral control unit J393
❑ Location: beneath dash
panel on front passen‐
ger side, behind glove
compartment
❑ Removing ⇒ General
body repairs, interior;
Rep. Gr. 68 ; Interior
equipment; Covers,
compartments and
trims; Removing and in‐
stalling glove compart‐
ment
3 - Front passenger door con‐
trol unit J387
❑ Integrated in window lkswage es n
o ot g
regulator motor d byV ua
ran
ir se
❑ Removing uth ⇒ page 199
o tee
o ra
sa c
4 - Door lock
s
ce
e
nl
pt
❑ Door lock is secured to

du
an
itte
door inner part

y li
erm
ab
❑ Electric central locking

ility
ot p
is integrated in door lock

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
❑ Fitting location: right B-

pillar.
❑ To separate connector, loosen boot at pillar ⇒ page 90
rrectness of i
6 - Rear right door control unit J389

l purpos
❑ Integrated in window regulator motor

nform
mercia
7 - Door lock
at
om
io
❑ Door lock is secured to door inner part

n
c
in t
or
his
e
❑ Electric central locking is integrated in door lock

at
do
riv

p
cum
for
en
g
8 - Coupling station, right side of rear lid

n
t.
yi Co
op py
❑ Fitting location: behind C-pillar trim.
t. C rig
gh ht
yri by
❑ Removing and installing ⇒ General body repairs, interior; Rep. Gr. 70 ; Trim/insulation; Pillar and side
cop Vo
by lksw
panel trim; Removing and installing C-pillar upper trim
cted agen
Prote AG.
9 - Fuel tank filler cap flap release motor V155

❑ Fitting location: behind right trim of load compartment.

Golf 2004 ➤
10 - Rear lid lock
❑ Fitting location: bolted to rear lid.
11 - Release element with button
❑ Fitting location: bolted in rear lid.
12 - Coupling station, left side of rear lid AG. Volkswagen AG d
agen oes
❑ Fitting location: behind C-pillar trim. Vo lksw not
gu
by ara
❑ Removing and installing ⇒ General body repairs,rise
d
interior; Rep. Gr. 70 ; Trim/insulation; nte Pillar and side
panel trim; Removing and installing C-pillar
a ut upper trim
ho eo
ra
ss c
13 - Rear left door lock
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
14 - Rear left door control unit J388
hole
spec
❑ Integrated in window regulator motor
es, in part or in w
t to the co
rrectness of i
❑ Fitting location: left B-pillar.
l purpos
16 - Front left door lock
nform
ercia

m
a
com
tion in
r
te o
thi
17 - Central switch for window regulator
s
iva
do
r
rp
c
❑ Fitting location: installed in door trim.
um
fo
en
ng
❑ Removing and installing centralized switches for window regulators ⇒ Vehicle electrical system; Rep.
t.
yi Co
op
Gr. 96 ; Electrical system; Interior lights, lamps, switches; Lights and switches in doors
C py
t. rig
gh ht
yri by
18 - Front left door control unit J386 cop Vo
by lksw
cted agen
❑ Integrated in window regulator motor Prote AG.
❑ Removing ⇒ page 199 and ⇒ page 73

❑ Fitting location: left A-pillar.
20 - Anti-theft alarm horn
❑ Fitting location: under right wing.
❑ Removing ⇒ Electrical system; Rep. Gr. 96 ; Lights, bulbs, switches - interior; Anti-theft protection; Anti-
theft alarm system (ATA); Alarm horn H12
21 - Bonnet contact switch F266
❑ Anti-theft alarm (ATA) contact switch
❑ Fitting location: on bonnet lock.
❑ Removing ⇒ Electrical systems; Rep. Gr. 96 ; Lights, bulbs, switches - interior; Anti-theft protection;
Lights and switches in engine compartment; Removing and installing bonnet contact switch F266
2.2 Adapting keys with remote control

Keys with remote control can be adapted using the vehicle diag‐
nosis, testing and information system -VAS 5051 A- .
2. Central locking 81
Golf 2004 ➤
– Select “guided fault finding” in diagnostic tester -VAS 5051 A- .

– Using the “GoTo” key, select "Function/component selection"
and the following menu items one after the other:
♦ Body
♦ General body repairs
♦ 01 - Self-diagnosis capable systems
♦ Convenience systems
♦ Functions - convenience system central control unit
♦ Checking/adapting key with remote control J393
2.3 Assembly overview - battery for folding key with remote control
1 - Key with variable code

transponder
2 - Transmitter unit - upper part
3 - LED
❑ When remote control is
operated, this LED must
light up
❑ If LED does not flash
during remote control
operation, the battery is
dead and must be re‐
newed
4 - Battery
❑ Removing battery
⇒ page 83 AG. Volkswagen AG d
agen oes
❑ Installing battery olksw not
y V gu
⇒ page 83 ised b ara
n r tee
ho
5 - Transmitter
sa
uunit
t
- lower part or
ac
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
2.4 Removing and installing battery for fold‐

ing key with remote control
2.4.1 Removing
– Insert a screwdriver in slot between transmitter unit -1- and key
-2-.
– Twist screwdriver in -direction of arrow- to separate transmitter
unit from key.
– Press transmitter unit -1- apart using profile section of key

-2-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
– Unclip battery -1- from retainers -2- with a screwdriver in s
ce
le
-direction of arrow-.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
2.4.2 Installing
o
cial p
f inform
mer
atio
Note
om
n
c
i
or
n thi
e
♦ Before installing battery, always press any key once.

t
sd
iva
o
pr
♦ Thus transmitter unit is reset and can recognize a new battery

um
r
fo
only now.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Central locking 83
lkswage es n
o ot g
byV ua
Golf 2004 ➤ ir se
d ran
tee
o
General body repairs, exterior - Edition 04.2008 auth or
ac
ss
ce
e
Note polarity and correct position when installing battery.
nl
pt
du
an
itte
y li
– Lay battery -1- with positive terminal downwards in sender unit
erm
ab
-2- (positive terminal is marked on housing).
ility
ot p
wit
– Engage battery in transmitter body by pressing down lightly.
, is n
h re
hole
– Fit cover to transmitter body (do not damage seal).
spec
es, in part or in w
– Then clip transmitter unit to key.
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
58 – Rear doors, wage door components

nA n AG d G. Volkswage
oes
Volks not
gu
by ara
ed nte
ris
ho
1 Rear door t e or
au ac
ss
ce
le
un
pt
an
d
itte
1.1 Tools
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
equipment required
spec
♦ Socket -T 10072-
t to the co
♦ Assembly tool -T 10118-
rrectne
♦ Door alignment tool -3320-
♦ Universal joint for 3320
ss
-3320/1-
o
cial p
f in
♦ Bit for 3320 -3320/2-
form
mer
♦ Bit for 3320 -3320/3-
atio
om
n
c
♦ Roller for fitting door insu‐
i
or
n thi
e
lation foil -3356-

t
sd
iva
o
pr
c
♦ Torque wrench 5...50 Nm -
um
r
fo
en
ng
V.A.G 1331- yi
t.
Co
op py
♦ Setting gauge -3371-
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Rear door 85
Golf 2004 ➤
♦ Cartridge gun -V.A.G 1628-

♦ Cartridge heater -V.A.G
1939 A-
♦ Wedge -3409-
♦ Assembly tool set -T
10237-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.2 Materials
♦ Door repair kit D 438 520 A28)
5) Materials are stored in box D 004 700.
6) Observe minimum curing period ⇒ page 103 .

7) Heat, according to manufacturers instructions, using cartridge heater -V.A.G
1939- .
8) Folding cardboard carton with 10 sheets each with 15 adhesive strips.
1.3 Assembly overview - door assembly

A new door concept has been introduced with Golf 2004.
The door consists of a door inner part -6- and door outer panel
-1-.
86 Rep. Gr.58 - Rear doors, door components

Golf 2004 ➤
The parts are joined by the front -7- and rear -4- retaining rails.
The retaining rails are bolted to the door inner part and bonded
to the door outer panel.
Loudspeaker, window regulator, window regulator motor, wiring,
window guide and door lock are mounted on the door inner part.
The door outer panel -1- is additionally bolted to the lower edge
of the door inner part. The window slot seals, insulation and door
outer handle are mounted on the door outer panel.
1 - Door outer panel

door outer panel
⇒ page 94
2 - Edge protection
❑ Between door outer skin
and door inner panel
3 - Bolt
❑ Feature: bolt with poin‐ n AG. Volkswagen AG do
ted end and thin washer. lkswage es n
o ot g
byV ua
❑ Qty. 4 on lower edge ir se
d ran
tee
ho
❑ Qty. 2 in area of top sec‐aut or
ac
tion of trim ss
ce
e
nl
❑ 10 Nm
pt
du
an
itte
y li
4 - Rear retaining rail
erm
ab
ility
ot p
❑ Adhesive:
wit
, is n
DH 009 100 03
h re
hole
5 - Bolt
spec
es, in part or in w
❑ Feature: bolt without

t to the co
pointed end but with
thick washer. rrectness of i
❑ Qty. 11 on both retaining
rails
l purpos
❑ 14 Nm
6 - Door inner part
nf
ercia
or
❑ Assembly overview
m
m
atio
⇒ page 104
om
n in
or c
7 - Front retaining rail

thi
te
sd
a
❑ Adhesive:
iv
o
r
rp
cu
DH 009 100 03
o
m
f
en
ng
t.
yi
8 - Bolt
Co
Cop py
. rig
❑ Feature: bolt with pointed end and thick washer.
t
gh ht
pyri by
Vo
o
❑ Qty. 1 for front area of top section of trim
c by lksw
cted agen
Prote AG.
❑ 10 Nm
9 - Insulation
❑ Self-adhesive
❑ To bond, first heat the insulation and then press on firmly
10 - Clip
❑ Qty. 5
❑ Must be fitted before assembling door outer panel
1. Rear door 87
Golf 2004 ➤
1.4 Assembly overview - door hinges
Caution
Bolt of eccentric pin -10- should not be loosened under any

circumstances on vehicles up to 01.2004. It cannot be tight‐
ened again using normal workshop tools.
Note

♦ The hinge bolts must always be renewed if loosened.
♦ Hinges are now one piece.
♦ The specified torque for the hinge bolts to the door (bolts -4, 6 and 14-) has been revised.
1 - Door
⇒ page 89
2 - Guide bolt
❑ 10 Nm AG. Volkswagen AG d
agen oes
3 - Door hinge with arrester olksw not
V gu
d by ara
e nte
4 - Multi-point socket head bolt horis
eo
ut ra
❑ 50 Nm ss a c
ce
e

nl
pt
du
an
itte
y li
ter being undone
erm
ab
ility
ot p
wit
, is n
h re
❑ Installed from inside the
hole
vehicle
spec
es, in part or in w
❑ Remove B-pillar lower
t to the co
trim ⇒ General body re‐
pairs, interior; Rep. Gr.
70 ; Trim/insulation; Pil‐
lar and side panel trim rrectness of i
l purpos

(90°).
nf
ercia

orm
newed after being loos‐

m
atio
m
ened
o
n in
or c

thi
te
sd
iva
❑ 50 Nm
o
r
rp
cu
o

f
en
ng
t.
newed after being loos‐
yi Co
op py
ened t. C rig
gh ht
pyri by
o Vo
by c lksw
cted agen
Prote
AG.
(90°).

Golf 2004 ➤
8 - Guide bolt
❑ 10 Nm
9 - Adjustment ring
❑ Restricts the adjustment range for the eccentric pin
10 - Bolt
❑ 28 Nm
❑ For eccentric pin
11 - Door hinge
❑ Door hinge no longer comprises of more than one part
❑ 20 Nm + 1/4 turn further (90°).
❑ Bolts must always be renewed after being loosened
❑ 20 Nm + 1/4 turn further (90°).
❑ 50 Nm
15 - Eccentric pin
❑ Eccentric pin is used to adjust gap on vehicles as of 02.2004
1.5 Removing and installing door
Note
AG. Volkswagen AG d
agen oes
ksw
The removal and installation
by Vol
sequence is only for the
not
guright door.
The removal and riseinstallation of the left door is similar. ante
d ar
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Rear door 89
Golf 2004 ➤
1.5.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Release bellows -6- by pressing catch -arrow a- and pull bel‐

lows off B-pillar.
– Swing release lever -7- downwards -arrow b- and disconnect
electrical connector -8- from coupling station.
– Remove bolts -4, 5 and 11- from hinge using special door
alignment tool -3320- and bit -3320/3- .
– Pull door in -direction of arrow- off guide bolts -3 and 9-.
1.5.2 Installing
– Specified torque for bolts -4, 5 and 11-: 50 Nm.
• Always renew bolts -4, 5 and 11-.
– Note rear door gaps ⇒ Body Repairs; Rep. Gr. 00 ; Technical
data; Body panel gaps/shut lines .

Golf 2004 ➤
1.6 Adjusting door
Note
♦ The door is adjusted correctly if the gaps/shut lines are even

all around, the door is not too deep or does not stand proud. Volkswagen AG
and all contours align when the is door closed. lkswagen AG does
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♦ Vehicle must be standing on its wheels on iflat
se level ground
db ua
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when adjustments are performed. ut
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♦ If door outer panel has been removed,s door inner part window
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frame must be adjusted to roof frame and B-pillar, or rear door.
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1.6.1 Adjusting door gaps
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♦ Box spanner 15 mm -T10344-
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Vehicles up to 01.2004, the bolt of the eccentric pin -4- must
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not be loosened and the eccentric pin -6- must not be used to
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adjust the door. Prote AG.
1. Rear door 91
Golf 2004 ➤ agen
AG. Volkswagen AG d
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– Note front door gap dimensions ⇒ Body Repairs; Rep. Gr. 00 ;

Adjustments are carried out using eccentric pin -7-.
Other measures such as raising the door have no effect. Subse‐
quent pressure from above will cause the door to sack again.
– Loosen bolt for eccentric pin -4-.
– Adjust eccentric pin -6- within adjustment range -5- using 15
mm ring spanner -T10344- .
– Tighten bolt -4- before checking setting.
If the adjustment range is insufficient, the door outer panel -2- can
be adjusted.
– Loosen bolts -3- and move door outer panel -2-.
– Retighten bolts -3- ⇒ page 57 .

Golf 2004 ➤
1.6.2 Adjusting door fittings for flushness
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Use bolts -2, 3, 4, 5 and 6- on hinge to adjust correctly for flush‐
ness.
Use door alignment tool -3320- with bit -3320/3- .
– Adjusting upper area of door, loosen bolts -5 and 6-.
– To adjust lower area of door, loosen bolts -5 and 6-.
– Specified torque for bolts -3 and 4-: 50 Nm.
The bolts -3, 4 and 6- must always be renewed if loosened.
– Guide pin -4- may be ground down if necessary.
1. Rear door 93
Golf 2004 ➤
1.7 Removing and installing door outer pan‐

el
1.7.1 Removing
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– Lever out clips -3- from the bottom starting on the door -1- and
f in
remove rear cover -2-.

form
mer
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– Lever out clips -5- from the bottom starting on the door -1- and
om
remove rear cover -4-.

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Golf 2004 ➤
– Remove lock cylinder housing: ⇒ page 67 .

– Remove bolt -1- from mounting bracket -2- which is located
behind door outer panel.
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– Remove all bolts -2, 3 and 4-.

– Carefully remove door outer panel.
1. Rear door 95
Golf 2004 ➤
1.7.2 Installing
Caution

be damaged.
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– Carefully fit door outer panel.

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– Insert all bolts -2, 3 and 4-.

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• Observe correct usage for the different types of bolts.

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– Check whether the securing strut guide pins are located in the
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appropriate guide holes in door inner part. Then first tighten
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all bolts -2, 3 and 4-.

Golf 2004 ➤
• Observe correct specified torque for the different types of

bolts.
1.8 Installing
swa
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Volkswagpanel
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door
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Note
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Observe section, installation notes for bonding-in a new door out‐
er panel ⇒ page 102
rrectness of i
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1. Rear door 97
Golf 2004 ➤
• The old (damaged) door outer panel with retaining rails is re‐
moved ⇒ page 94
– Install front -2- and rear -6- retaining rails to door inner part.
For this use “bolt without point with thick washer”.
Specified torque for bolts -3- and -5-: 10 Nm.
– Fit two guide bolts in lower edge of door inner part.
AG. Volkswagen AG d
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The painted door outer panel is first offered up without bonding
ht
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To fit door outer panel, assembly block from assembly tool set -
T 10237- is required. A strip of “Tesa Power Strips large” -6- is
applied on the lower side. The pin has the minimum dimension
for the gap width. The non bonded surface is brought into position
with the adjacent component.
– Bond assembly block -3- on door outer panel.
door inner part.
wedges -4- from assembly tool set -T 10237- .

Golf 2004 ➤
– Place door outer panel with assembly blocks on surrounding

components -2 and 5-.
– Check gap dimension using setting gauge -3371- ⇒ Body Re‐
pairs; Rep. Gr. 00 ; Technical data; Body gap dimensions .
– If gap dimension cannot be adjusted, door inner part must be
adjusted ⇒ page 104
– Remove door outer panel again.
AG. Volkswagen AG d
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– Apply a bead of adhesive material -2- using cartridge gun -
rig ht
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V.A.G 1628- to front -1- and rear -3- retaining rails. by c lksw
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1. Rear door 99
Golf 2004 ➤
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To fit door outer panel, assembly block from assembly tool set -
te
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T 10237- is required. Two strips of “Tesa Power Strips large” -5-

iv
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are bonded to the contact surfaces.

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– Place door outer panel with assembly blocks -3- on surround‐
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wedges -4- from assembly tool set.
– Check gap dimensions using setting gauge -3371- ⇒ Body
Repairs; Rep. Gr. 00 ; Technical data; Body gap dimensions .
– Bond short fixing block -2- evenly on the replacement door and
the adjacent components.
Note
A curing period of 180 minutes must be observed before per‐

forming further work on the door which has been bonded.
– Further installation is performed in the reverse order of re‐

moval ⇒ page 96 .

Golf 2004 ➤
1.9 Removing and installing retaining rail on

door outer panel
1.9.1 Removing retaining rail
Caution
The following work steps are to be carried out with great care.
As door outer skin is to be reused, dents and scratches must
be avoided.
When cutting through the adhesive bead, always hold the re‐
taining rail and door outer skin together as shown in the illus‐
tration. If this is not done, the door outer skin will come away
from the retaining rail, thus rendering it useless.
Note
The following work steps should be carried out with the aid of an
assistant.
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Door outer panel with o retaining rail is removed s⇒
lks e n
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t gu 94
byV ara
ed
– Place door ho
r outer panel -1- on firm surface and protect
is ntee door
outer panel
aut against scratches. or
ac
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– Fit reel device -2- in place.
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– Secure cord -5- on reel device and counterhold -4-.

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– Hold retaining rail and outer skin together securely when cut‐
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ting through adhesive bead.

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– Cut through adhesive bead of retaining rail -3- and door outer
spec
panel -1- with cord up to just over half way.

t to the co
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1. Rear door 101

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Golf 2004 ➤ yV
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General body repairs, exterior - Edition 04.2008rised
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– Once adhesive bead has been cut through tos just over half
s c
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way in step one, turn reel device -2- around and insert cord
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-5- in side still bonded.
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– Hold retaining rail -3- and outer skin -1- together securely
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– Cut through second half of adhesive bead.
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1.9.2 Installing retaining rail
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– Cut away remainder of adhesive bead to a minimum on outer C py
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panel with the greatest of care, ensuring that no damage is rig ht
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caused to the paintwork.
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Prote AG.
– Remainder of work procedure is described in chapter entitled
“Installing new door outer panel” ⇒ page 58
Note
Observe also “instructions for bonding in new door outer panel”

when installing a new retaining rail.
– In place of removed retaining rail, install a new retaining rail

on the door inner panel.
– Apply adhesive to new retaining rail.
– Tighten screws to secure door panel on lower edge and on
retaining rail still in place.
– Secure door outer panel on new retaining rail with fixing
blocks.
1.10 Installation instructions for bonding in

new door outer panel
Note
♦ If both door outer panels on one side have to be renewed, the

sequence must be observed. The rear door outer panel is
aligned and bonded in first, followed immediately by the front
door outer panel. The long fixing blocks must be bonded in
from the rear door outer panel to the front door outer panel.
♦ If the door outer panel CDP coating is damaged on inside in
bonding area, or if this area has paint on it, this area must be
primed with glass/paint primer D 009 200 02.
♦ The 1K window adhesive DH 009 100 must be heated in car‐
tridge heater -V.A.G 1939 A- for 20 minutes.

Golf 2004 ➤
– Apply adhesive material to appropriate surfaces at right angles

to retaining rail using cartridge gun -V.A.G 1628- .
WARNING
Door outer panel must be installed within 10 minutes, or ad‐

hesive properties of adhesive will be impaired.
♦ With assistance of both assembly blocks, place door outer

panel on retaining rails, align with wedges and setting gauge
-3371- and press contact surfaces of assembly blocks onto
surrounding components.
♦ Secure door with fixing blocks during curing time.
♦ After installation door outer panel must align with other com‐
ponents and gap dimension must be even.
♦ If adhesive bead is too thick and
agen
AGadhesive
. Volkswageswells
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oes
retaining rail and doorVoouter
lksw panel, excess adhesive notmust be
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WARNING
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door outer panels. One of these standards is, for example, that
hole
a freshly bonded door outer panel must comply with the safety spec
requirements, even in an accident, following the minimum
es, in part or in w
t to the co
specified curing time.
rrectness of i
For 1K adhesive DH 009 100 minimum curing time for door outer
panel is 180 minutes.
l purpos
Minimum curing time means the time from bonding-in the door
outer panel to the time the vehicle is brought into use or further
nform
ercia
work is carried out. During this time, the vehicle must stand on a
m
level surface at room temperature (at least 15 C).

a
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WARNING
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material
– Adhesive remover D 002 000 10 must be used as cleaning
agent. Observe the appropriate safety precautions when per‐
forming this work.
WARNING
When cleaning vehicle, the door outer panel just bonded-in

must not be moved.

D 002 000 10.
1. Rear door 103

Golf 2004 ➤

1.13 Assembly overview - door inner part
Note

2 - Insulation
❑ Qty. 4
❑ 20 mm x 40 mm, com‐
mercially available tex‐
tile adhesive tape.
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Prote AG.

Golf 2004 ➤
1.14 Assembly overview - door handle and door lock
Note
1 - Door lock
❑ Door lock can only be
removed together with
door outer panel
⇒ page 110
3 - Spreader rivet
4 - Cable
❑ To release lock from in‐
ner door handle
5 - Cover
❑ Not supplied as part of
door lock
❑ Secured to door lock
AG. Volkswagen AG d
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6 - Bearing plate ised ara
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❑ Removing ⇒ page 108auth
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7 - Bolt
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8 - Base
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⇒ page 106
es, in part or in w
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10 - Cover
❑ For lock cylinder hous‐
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rrectness of i
lock cylinder
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❑ Secured to lock cylinder housing with three locking lugs

11 - Housing
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12 - Base
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13 - Torx screw
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❑ Loosening this screw releases the lock cylinder housing ⇒ Item 11 (page 105) , which can then be pulled
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14 - Bolt cted agen
Prote AG.
❑ 18 Nm
1. Rear door 105

Golf 2004 ➤
15 - Cable
❑ To release lock from outer door handle
1.15 Removing and installing housing
Note
Removal and installation sequence is only for right housing. Re‐

moval and installation of left housing is similar.
1.15.1 Removing
– Lever out caps in front of bolts -1-.
– Pull door handle -2- in -direction of arrow- and unscrew bolt
-1- using socket wrench -T 10072- until housing -3- can be
pulled out.
– Pull housing -3- out of door handle mounting bracket at right
angles to door.
1.15.2 Installing
– Fit housing -2- into door handle mounting bracket at right an‐
gles.
Door handle -1- must rest only lightly against door panel.
– Now tighten bolt -3- in bearing plate using socket -T 10072- .
o wagen AG lks
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During installation, housing must be pressed against door panel.

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Door handle rests only lightly against door panel.

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– Then perform remaining installation in reverse order of remov‐

, is n
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es, in part or in w
t to the co

door.
rrectness of i
1.16 Removing and installing door handle

l purpos
Note
nform
mercia
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handle. The removal and installation of the left door handle is

n in
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similar.
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106
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Rep. Gr.58 - Rear doors, door components
agen
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Golf
2004 ➤
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s General body repairs, exterior - Edition 04.2008
ce
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1.16.1 Removing
itte
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– Remove housing ⇒ page 106 .
wit
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– Lever clip -2- out of door handle -1-.
hole
spec
– Swivel door handle -1- out of door -arrow-.
es, in part or in w
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1.16.2 Installing
n
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Prote AG.
– Guide assembly tool -T 10118- into door through opening in

door inner panel.
– Use a hand torch to illuminate inside of door for improved vis‐
ibility.
– Hook assembly tool -T 10118- in spring -arrow A-.
1. Rear door 107

Golf 2004 ➤
– Hook spring into door lock by pulling assembly tool -T 10118-

-arrow B-.
The release lever is now secured.
– Swivel door handle -1- into door.
– Pull clip -2- in the panel opening and engage clip in door han‐
dle -1- -arrow-.
Note
♦ Door handle -2- must be pressed against door panel when

assembling.
n AG. Volkswagen A
♦ Clip -2- must engageolkinswdoor
age handle -1- with a eclearly
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Installing housing
ss
⇒ page 106 au ra
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door.
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1.17 Removing bearing bracket

h re
hole
spec
es, in part or in w
Note t to the co
Removal and installation are described only for the right bearing
rrectness of i
bracket. The removal and installation of left mounting plate is

similar.
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Prote AG.

Golf 2004 ➤
1.17.1 Removing
lkswage es n
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ss
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un
pt
an
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ab
pe
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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a
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tion in
r
te o
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s
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Prote AG.
– Remove housing ⇒ page 106

– Remove door handle: ⇒ page 106 .
– Remove door outer panel: ⇒ page 94
– Pull retaining rubber -4- off upwards from guide pins and re‐
taining pins on mounting.
– Pull mounting plate -1- with guide pins -2- out of mounting
-3-.
1. Rear door 109

Golf 2004 ➤
1.17.2 Installing
AG. Volkswagen AG d
agen oes
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pt
du
an
itte
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erm
ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
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Prote AG.
– Push mounting plate -1- with guide pins -2- in mounting -3-.
– Secure retaining rubber -4- to guide pins and securing pins on
mounting.
1.18 Removing and installing door lock
Note
lock. The removal and installation of the left door lock is similar.

Golf 2004 ➤
1.18.1 Removing
– Remove mounting plate ⇒ page 108 .
– Separate connector -4-.
– Release cable -3- from relay lever -5- and remove door lock
-1-.
Cover -2- is not supplied with door lock.
1.18.2 Installing
Specified torque for bolts: 18 Nm. lkswage es n
o ot g
byV ua
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• Then always check function while orise door is still open, as an in‐ tee
correctly fitted and adjustedauBowden cable cannot open the
th or
ac
door. ss
ce
e
nl
pt
du
1.19 Assembly overview - side impact pro‐ an

itte
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tection
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Caution
hole
spec
es, in part or in w
The nuts and bolts of the side impact protection are also pain‐
t to the co
ted in the factory. This means that a great deal of force is

required to remove them, resulting in some circumstances in
the threads shearing. If possible avoid loosening the nuts and
rrectness of i
bolts.
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
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for
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Prote AG.
1. Rear door 111

Golf 2004 ➤
1 - Side impact protection

2 - Bolts
❑ Qty. 2
❑ 20 Nm
3 - Nut
❑ Qty. 2
❑ 20 Nm
4 - Door inner part
AG. Volkswagen AG d
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nf
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atio
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1.20 Door inner seals

o
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or c
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sd
During production, a sealant is applied to the door inner seals,

iva
o
r
which are then placed on the door flange and rolled on.
rp
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Prote AG.
then refitted, a tight seal is not guaranteed.

Golf 2004 ➤
1.21 Removing and installing door inner seal
Note
inner seal. The removal and installation of the left door inner seal
is similar.
1.21.1 Removing
AG. Volkswagen AG d
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spec
t to the co
rrectness o
cial p
f inform
mer
– Pull door inner seal off body flange.

atio
om
n
c
i
or
n thi
te
sd
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pr
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fo
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t.
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.
1. Rear door 113

Golf 2004 ➤
1.21.2 Installing
AG. Volkswagen AG d
agen oes
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nl
pt
du
an
– Align door inner seal with vulcanisation point -arrow b- to

itte
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height of lower hinge.

erm
ab
ility
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– Begin installing door inner seal in upper radius -arrow a- of

wit
, is n
door aperture.
h re
hole
spec
1.22 Removing and installing door outer seal

es, in part or in w
t to the co
Note
rrectness of i
♦ Removal and installation are described for the right door outer
l purpos
seal only. Removal and installation of the left door outer seal
are similar.
nform
ercia
♦ Remove protective backing immediately before installation.

m
Working temperature approx. 20 °C.

at
om
ion
c

in t
or
his
ate
♦ The door outer seal must be bonded in place immediately after

do
priv
cleaning.
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114
c by lksw
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Rep. Gr.58 - Rear doors, door components Prote AG.
Golf 2004 ➤
1.22.1 Removing
AG. Volkswagen AG d
agen oes
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nl
pt
du
an
itte
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erm
ab
ility
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es, in part or in w
t to the co
rrectness of i
l purpos
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at
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ion
c
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or
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ate
do
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for
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t.
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Prote AG.
– Pull door outer seal -1- from door -2-.
1. Rear door 115

Golf 2004 ➤
AG. Volkswagen AG d
lksw
agen - Edition 04.2008
oes
n o ot g
yV ua
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1.22.2 Installing tho
ris tee
or
au ac
ss
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nl
pt
du
an
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erm
ab
ility
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nf
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Prote AG.

mover -VAS 6349- .
– Immediately before bonding the door outer seal, clean bond‐
ing surface thoroughly with adhesive remover D 002 000 10.
• Surfaces to be bonded must be free of dust and grease and
there should be no adhesive residue.
– The vulcanised point -arrow b- of outer door seal -1- must be
located in centre of side member.
– Pull protective backing off in stages and start fitting seal in
upper radius -arrow a- of door. Do not pull outer door seal to
avoid stretching seal.

Golf 2004 ➤
lkswage es n
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– Press complete adhesive area of seal -3- on door -1- all around
, is n
h re
using roller -3356- .

hole
spec
– The seal is pushed aside -arrow a- when doing this so that the
es, in part or in w
t to the co
roller -3356- runs directly over the contact surface of the seal.
The roller can only apply the necessary force -arrow B- to the
adhesive surface -2- when procedure described above is followed
rrectness of i
correctly.
l purpos
– If the seal is too long: cut seal to required length and press butt
joints on well.
nform
ercia
– If the seal -3- comes loose in small areas again, press seal on
m
well again using roller -3356- .

a
com
tion in
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thi
s
Note
iva
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The door must not be closed for a period of 2 hours to ensure the door outer seal does not move or loosen
en
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again. t. Cop py
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Prote AG.
1. Rear door 117

Golf 2004 ➤
60 – Sunroof
1 Sliding/tilting sunroof with glass pan‐
el (Meritor)
1.1 Tools
AG. Volkswagen AG d
agen oes
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un
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t to the co
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cial p
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mer
atio
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Prote AG.
1.1.1 Required special tools, workshop equip‐

ment, test and measuring devices and
auxiliary items
♦ Roller -3356-
♦ Hooks for front end -3370-
♦ Wedge -3409-
118 Rep. Gr.60 - Sunroof

Golf 2004 ➤
1.2 Function
All actions of the sunroof with glass panel can be performed with
the ignition switched on.
After the ignition is switched off, actions can be performed until
either the driver or front passenger door is opened.
The opening of the glass panel in sliding or tilting positions can
be preselected using the rotary switch.
swage es n
On the rotary switch there are marks for preset sliding andytilting Volk ot g
ua
positions of the glass panel. ir se
d b ran
tee
tho
or
Opening sliding/tilting sunroof to the so called comfort
au position, ac
ss
prevents to a large extent wind noise while driving, which can oc‐
ce
le
cur when sunroof is fully open.
un
pt
an
d
itte
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Pre-selector switch erm
ab
ility
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The sliding/tilting sunroof with glass panel is equipped with a force
wit
is n
limitation (roll back) feature while closing. If an obstacle is en‐
h re
ole,
countered during closing or opening from the elevating or sliding
spec
position, the glass panel will be moved in the opposite direction.
t to the co
In addition, there is an emergency closure function. If problems
occur during closure, the sliding/tilting sunroof with glass panel
can be forced to shut by pressing the preselector switch when it
rrectne
is in the “close sunroof” position.
The roll-back function is disabled when the emergency closure
ss
function is active.
o
cial p
f in
The drive for the sliding/tilting sunroof with glass panel is protec‐
form
mer
ted against overheating by a time limit. The protective mechanism
atio
m
activates when the sunroof is operated continuously for approx.

o
n
c
2 minutes. It is functional again after a cooling-off phase.
i
or
n thi
te
sd
a
In the event of power failure, the sliding/tilting sunroof with glass

iv
o
pr
c
panel can be moved using a hexagon key directly on the drive.
um
r
fo
The hexagon drive can be found in a bracket on the rear of the
en
ng
t.
yi
moulded headliner, next to an opening for the rear lighting unit.
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Prote AG.
1. Sliding/tilting sunroof with glass panel (Meritor) 119

Golf 2004 ➤
1.3 Assembly overview - sliding/tilting sunroof with glass panel
1 - Glass panel for sliding/tilting

sunroof (single pane safety
glass)
❑ Removing glass panel
of sliding/tilting sunroof
⇒ page 123 gen AG
. Volkswagen AG
swa does
❑ Installing glass panel of y V olk not
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sliding/tilting sunroof rised b ara
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⇒ page 124 ut
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❑ Adjusting glass panel
ss of c
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sliding/tilting sunroof
un
pt
⇒ page 124
an
d
itte
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2 - Panel seal
ility
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❑ Adjusting panel seal
wit
is n
⇒ page 125
h re
ole,
spec
❑ Seal joint positioned in
middle of rear area
t to the co
❑ Renewing panel seal
⇒ page 126
rrectne
3 - Sliding headliner
ss
sliding headliner
o
cial p
f
⇒ page 127
inform
mer
4 - Bolt
atio
m
❑ Bolts are microencap‐

o
n
c
sulated and must al‐

or
n thi
e
ways be renewed after

t
sd
va
loosening
i
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pr
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❑ Qty. 4
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t.
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❑ 1.8 Nm C py
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5 - Spring slide
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❑ Screwed onto sliding
agen
Prote AG.
headliner
❑ Qty. 4
❑ Can be replaced separately
6 - Bellows
❑ Used to cover guide plate
❑ Installing ⇒ page 123
7 - Water channel
8 - Locking hook guide
❑ Removed together with guide plate
9 - End piece upper part
❑ Clipped securely onto end piece of lower part
10 - End piece lower part
❑ Can be replaced separately

Golf 2004 ➤
❑ To seal use butyl adhesive sealing cord -AKL 450 005 05-
11 - Carrier unit
❑ Removing and installing carrier unit ⇒ page 132
❑ If necessary, guide channels should be lubricated only with special grease G 000 450 02, otherwise
function may be impaired
12 - Bolt n AG. Volkswagen AG do
wage e
❑ Bolts are microencapsulated and must always bey Vrenewed
olks after loosening s not gu
d b ara
❑ Qty. 3 oris
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th eo
❑ 3.5 Nm sa
u ra
c s
ce
e
13 - Hexagon key for emergency operation
nl
pt
du
an
❑ The hexagon key to operate the system in an emergency has been discontinued. Use a commercially
itte
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available hexagon key to operate the system in an emergency erm
ab
ility
ot p
14 - Electric drive
wit
, is n
h re
hole
spec
❑ Adjusting drive (0 position) ⇒ page 129
es, in part or in w
t to the co
15 - Spring
❑ Qty. 2
rrectness of i
❑ Pushes up wind deflector
l purpos
❑ Is clipped onto wind deflector and can be renewed individually

nf
ercia
16 - Wind deflector
orm
m
atio
om
n in
❑ Adjusting on vehicles as of 08.2005 > ⇒ page 127
or c
thi
e
❑ The adjustable wind deflector cannot be retrofitted

t
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cu
17 - Wind deflector bearing
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❑ Qty. 2
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❑ Is clipped onto wind deflector and can be renewed individually
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Prote AG.
18 - Front guide
❑ Can be removed separately from the guide rail
19 - Lower rear guide
❑ Removed together with guide plate
20 - Torx screw
❑ Torx T25
❑ Qty. 3 per side
❑ 5 Nm
21 - Guide plate
22 - Spacer

Golf 2004 ➤
1.4 Removing and installing bellows
1.4.1 Removing
lkswage es n
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un
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rm
ab
pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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op
– Move sliding headliner to rear. C py
t. rig
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– Run sliding/tilting sunroof glass panel to tilted position. cop Vo
by lksw
cted agen
Prote
– Carefully unclip bellows -1- from lower part of guide plate -3-
AG.
using a removal wedge -3409- .

– Pull bellows -1- off securing pins -4-.
– Detach bellows -1- at top rear -2-.
– Remove bellows -1-.

AG. Volkswagen AG d
agen
Volksw
oes
not Golf 2004 ➤
by gu
ised General
ara
nte body repairs, exterior - Edition 04.2008
or eo
th
au ra
1.4.2 ss Installing c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Move sliding headliner to rear.

– Run sliding/tilting sunroof glass panel to tilted position.
– Fit bellows -1- first at top rear -2-.
– Clip bellows -1- with securing pins -4- in guide plate.
– Hook in bellows -1- at bottom rear -3- and clip in bellows,
starting from front, in lower part of guide plate.
1.5 Removing glass panel of sliding/tilting

sunroof
– Remove bellows ⇒ page 122 .

Golf 2004 ➤
– Remove bolts -1- on left and right.

– Remove sliding/tilting sunroof glass panel -2- out upwards.
WARNING
The guide plate must not moved to “Open” position when re‐
moved, because the water channel will not be compressed by
the glass panel and can become wedged together in the roof.
1.6 Installing glass panel of sliding/tilting

sunroof
• Panel must be installed in 0 position (panel closed).
1.6.1 Zero position

The mark -arrow- on the rear of the guide upper section -1- must,
on both sides, lie within the marks dimension -a- on the guide
plate -2-.
The guide plate -2- must be located in the guide rails (cannot be
moved by hand).
If this is not the case, adjust parallel running ⇒ page 130 . n AG. Volkswagen AG
wage doe
ks s no
Vol t gu
d by ara
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ris
tho eo
au ra
c
ss
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nl
pt
du
an
itte
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erm
ab
– Insert sliding/tilting sunroof glass panel -2- from above and fit
ility
ot p
bolts -1-.
wit
, is n
– Lightly tighten bolts -1-. h re

hole
spec
– Adjusting height of glass panel of sliding/tilting sunroof:

es, in part or in w
⇒ page 124
t to the co
rrectness of i
Note
l purpos
♦ After adjusting panel height, tighten securing screws (4.5 Nm).

♦ Install bellows after panel height adjustment.
nf
ercia
orm
m
atio
m
1.7 Adjusting height of glass panel of slid‐

o
n in
or c
thi
ing/tilting sunroof
te
sd
iva
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Note
yi Co
Cop py
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The glass panel height adjustment is performed after the glass p by
o Vo
by c
panel has been closed from slide open position.
lksw
cted agen
Prote AG.
Sliding/tilting sunroof glass panel 0 position OK.

Golf 2004 ➤
– Remove bellows: ⇒ page 122

– Remove sliding/tilting sunroof glass panel -2- securing bolts
-1-.
– Run sliding/tilting sunroof glass panel to “open” position.
– Run sliding/tilting sunroof glass panel to “closed” position.
– Carry out height adjustment of sliding/tilting sunroof glass pan‐
el at front and rear on both sides as follows:
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
ss c
Panel adjustment front:
ce
e
nl
pt
du
an
-a- = 0…1 mm lower than roof
itte
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erm
ab
-Arrow- = Forwards
ility
ot p
wit
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– Tighten front screws (5 Nm).
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Panel adjustment rear:
nf
ercia
o
-b- = 0…1 mm higher than roof
rm
m
atio
m
-Arrow- = Forwards
o
n in
or c
– First tighten middle and then rear screws (5 Nm). thi

te
sd
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f
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ng
Note
t.
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Cop py
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♦ To achieve the best possible optical appearance, ensure that
ht
pyri by
the adjustment on left and right are as far as is possible uniform
co Vo
by lksw
cted agen
(symmetric). Prote AG.
♦ The glass panel should not be higher than the roof at any point
at the front or lower than the roof at any point at the rear.
– Install bellows ⇒ page 123 .
1.8 Adjusting panel seal

– Check that the pre-loading between panel seal -2- and body
is uniform all-round using a 0.3 mm thick strip of paper (a vis‐
iting card for example). It must be possible to pull the paper
strip through tightly between the panel seal and body.
– Remove glass panel of sliding/tilting sunroof ⇒ page 123 .
– The panel seal -2- can be pressed apart with a removal wedge
-3409- -1- if the preload is insufficient

Golf 2004 ➤
– If preload is too great press panel seal -1- together all-round

with roller -3356- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
1.9 Renewing panel seal
ot p
wit
, is n
h re
hole
spec
– Pull seal -1- off sliding/tilting sunroof glass panel -2-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Fit new seal -1- to rear edge of panel, start in middle and push
f
en
ng
t.
onto sliding/tilting sunroof glass panel -2- from bottom to top. Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
o
Note by c lksw
cted agen
Prote AG.
♦ To ease fitting of seal, coat panel edge with a soapy solution.

♦ If the seal is not correctly installed, the surface will be wavy.
♦ The panel seal must be shortened to suit the panel circumfer‐
ence.
– Install glass panel of sliding/tilting sunroof ⇒ page 124 .

– Adjusting panel seal ⇒ page 125
1.10 Removing and installing wind deflector
1.10.1 Removing
– Fully open sliding/tilting sunroof glass panel.

Golf 2004 ➤
– Push wind deflector and height limit stop out at front of roof
aperture and set wind deflector to vertical position.
– Place special tool front-end hook -3370- between edge of roof
and wind deflector bearing -arrow-.
– Pull wind deflector bearings out ofAG detent
. Volkswboth
agen sides in
-direction of arrow- using special
lksw
agen tool front-endAhook
G do -3370- .
es n
o ot g
yV ua
– Remove wind deflector
ris
ed upwards out of guide rails.
b ran
tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
1.10.2 Installing
wit
, is n
h re
– Place wind deflector in guide rail and slide wind deflector with
hole
spec
height limit stop under front of roof aperture on both sides.
es, in part or in w
t to the co
– Using light pressure, press wind deflector bearings into guide
rails.
rrectness of i
Note
l purpos
Wind deflector bearings must audibly engage in the guide rails.
nform
mercia
1.10.3 Adjusting wind deflector on vehicles as
at
om
ion
c
of 08.2005
in t
or
his
ate
do
riv
The wind deflector can be adjusted on vehicles as of 08. 2005.

p
cum
for
– Place special tool front-end hook -3370- between edge of roof

en
ng
t.
yi Co
and wind deflector mounting -2-. t. Cop py
rig
gh ht
– Pull wind deflector mountings -2- out of locking devices of left pyri by
Vo
co
and right guide rails in -direction of arrow- using special tool
by lksw
cted agen
Prote
front-end hook -3370- .
AG.
– Slide wind deflector -1- parallel in guide rails -arrow b- until

measurement -c- of between 0.3 mm and 1.3 mm is set.
– Press wind deflector -2- into guide rails.
Note
Wind deflector bearings must audibly engage in the guide rails.
1.11 Removing and installing sliding headlin‐

er
1.11.1 Removing
– Remove glass panel for sliding/tilting sunroof: ⇒ page 123 .

Golf 2004 ➤
– Slide sliding headlining a little to rear. . Volkswagen AG

gen AG does
swa
– Remove front bolts -arrow- on left and right. Push spring slide y Volk not
gu
forwards past the stop -1-. risedb ara
nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Push sliding headlining forwards and lift it slightly past end of
roof aperture.
rrectne
– Remove rear bolts -arrow- both sides. Push spring slide to rear
and remove sliding headlining -1- out upwards.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
1.11.2 Installing Cop py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.
• Finally carry out a functional check.
1.12 Removing and installing sliding/tilting

sunroof glass panel drive
1.12.1 Removing
– Remove lights and operating unit ⇒ Electrical system; Rep.
Gr. 96 ; Lights, bulbs, switches - interior; Lights and switches
in roof trim; Removing and installing front interior light W1, ve‐
hicles with sunroof
Changing motor - preselection switch recognition:
Note
♦ To interrupt the authorization signal and therefore to activate

the switch recognition, the requirements described below must
be fulfilled.
♦ If this is not the case, it can lead to, that the drive does not
correctly recognise the preselection switch and does not run
to the selected positions. This can be seen if the sunroof stops
approx. 10 cm before the fully closed position when the switch
is in the closed position.

Golf 2004 ➤
WARNING
Remove or install drive for tilting/sliding sunroof glass panel

only when sunroof is closed (0 position ).
The requirements for removing and installing drive are: Engine
not running and ignition off, key not in ignition and door open.
– Switch off engine and ignition, withdraw key and open door.
• This condition must remain until drive has been installed.
– Remove screws -arrows- and pull off sliding/tilting sunroof
drive.
– Separate connector for sliding/tilting sunroof drive.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
1.12.2 Installing ss c
ce
le
un
pt
an
d
• The screws for the sliding/tilting sunroof drive are microen‐

itte
y li
capsulated and must always be renewed (3.5 Nm).
erm
ab
ility
ot p

wit
is n
h re
– After installation is complete the key can be placed in ignition

ole,
spec
and starter switch again.

t to the co
1.13 Adjusting drive for sliding/tilting sunroof

rrectne
glass panel (0 position)

s
There may be a requirement to adjust the 0 position if the drive

s o
was removed when not in 0 position or the sliding/tilting sunroof

cial p
f in
glass panel was opened or closed using the emergency key.

form
mer
atio
Drive removed but still connected electrically.

om
n
c
– Select “open sunroof” using preselection control rotary switch.

or
n thi
te
sd
va
– Select “close sunroof” using preselection control rotary switch.

i
o
pr
cum
r
fo
– Select “tilt sunroof” using preselection control rotary switch.

en
ng
t.
yi Co
op
– Select “close sunroof” using preselection control rotary switch.
C py
t. rig
gh ht
yri by
– Install drive in this position (0 position) with sliding/tilting sun‐
cop Vo
by lksw
cted
roof glass panel closed.
agen
Prote AG.

Golf 2004 ➤
• The sliding/tilting sunroof glass panel drive is in 0 position, if

a white dot can be seen in the drive aperture -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
1.14 Removing and installing sliding/tilting
es, in part or in w
t to the co
sunroof glass panel automatic preselec‐
tion switch
rrectness of i
– Removing sliding/tilting sunroof glass panel automatic prese‐
l purpos
lection switch ⇒ Electrical system; Rep. Gr. 96 ; Lights, bulbs,

switches - interior; Removing and installing sliding sunroof
switch
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
1.15 Checking parallel running
agen
Prote AG.
– Removing glass panel for sunroof ⇒ page 123 .

plate -2-.
moved by hand).
1.16 Adjusting parallel running
Note
The parallel running adjustment can only be made when the drive
and glass panel are removed ("0" position).
– Remove sunroof glass panel drive ⇒ page 128

Golf 2004 ➤
plate -2-.
moved by hand).
– Push guide upper part -1- both sides centrally between the
marks.
– Install drive (zero position) in this position.
AG. Volkswagen AG d
agen oes
• Then check zero position. olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
1.17 Assembly overview - carrier unit
ce
le
un
pt
an
d
itte
y li
erm
ab
1 - Carrier unit
ility
ot p
wit
is n
h re
⇒ page 132
ole,
spec
2 - Bolt
t to the co
❑ Qty. 12
❑ 8 Nm
rrectne
3 - Connector
4 - Connections for water
ss
drainage hoses
o
cial p
f inform
5 - Sliding/tilting sunroof glass
mer
panel drive
atio
om
n
c
i
or
n
⇒ page 128
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2004 ➤
1.18 Removing and installing carrier unit
WARNING
Remove or install drive for tilting/sliding sunroof glass panel

only when sunroof is closed (0 position ).
The requirements for removing and installing drive are: Engine
not running and ignition off, key not in ignition and door open.
1.18.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove moulded headlining ⇒ General body repairs, interior;

nf
ercia

orm
m
atio
m
– Pull off water drainage hoses -4- from carrier unit -1-.
o
n in
or c
– Separate connector -3- on sliding/tilting sunroof glass panel

thi
te
sd
drive -5-.
iva
o
r
rp
cu
o
– Remove screws -2- and remove carrier unit -1- from vehicle
m
f
en
ng
t.
with the help of a second mechanic. Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
o
by c lksw
132
cted agen
Prote
Rep. Gr.60 - Sunroof
AG.
Golf 2004 ➤
1.18.2 Installing
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Fit carrier unit -1- into roof aperture with the help of a second
mechanic.
– During installation, align carrier unit -1- in roof via two cylin‐
drical pins (shank end of drill) 12 mm front right -arrow- and
10 mm rear left -arrow-.
Carrier unit must not contact roof frame.
– Install bolts -2-.
– Check routing of wiring and connectors of electrical consum‐
ers in roof and restore if necessary.
– Tighten screws (8 Nm) for carrier unit -1-, starting at sunroof
drive -5- and moving rearward, alternating between left and
right sides.
– Install water drainage hoses -4-.
– Attach connector -3- on sliding/tilting sunroof glass panel drive
-5-.
– Install moulded headlining ⇒ General body repairs, interior;

Golf 2004 ➤
1.19 Operating without electrics
Note
In the event of power failure, the sliding/tilting sunroof with glass

panel can be moved using a hexagon key directly on the drive.
Hexagon key (crank) is housed in moulded headliner on right next
to opening for rear interior light and reading lamp.
– Removing lights and operating unit ⇒ Electrical system; Rep.

Gr. 96 ; Lights, bulbs, switches - interior; Lights and switches
in moulded headlining .
– Guide hexagon key into bolt on drive.
– Press key upwards -arrow- to release the drive.
The bolt will be pressed a few millimetres inwards -a-. Sliding/
tilting sunroof glass panel can only be moved in this position.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
1.20 Removing and installing guide plate

un
pt
an
d
itte
y li
rm
ab
pe
ility
1.20.1 Removing
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Unclip spacer -2- at front out of guide plate -1- and at rear out
t to the co
of locking hook guide -arrows- using a screwdriver.
– Pull spacer -2- in -direction of arrow- out of guide plate -1- and
rrectness of i
locking hook guide.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
– Lift guide plate up -1- in -direction of arrow-.

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
– Slide front guide -2- forwards and pull guide plate -1- in
-direction of arrow- out of front guide -2-.
1.20.2 Installing olksw

agen
AG. Volkswagen AG d
oes
not
V gu
by ara
rised
nte
ho eo
ut
1.21 Removing and installing sliding gate a ra
ss c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
Always renew guide and cable as a pair.
wit
, is n
h re
hole
spec
1.21.1 Removing
es, in part or in w
t to the co
– Remove carrier unit ⇒ page 132 .
rrectness of i
– Remove sunroof glass panel drive ⇒ page 128
l purpos
– Remove guide plate ⇒ page 134 .
nform
ercia
– Detach water channels -1- carefully using a screwdriver at

both sides on guide locating hook -2- in -direction of arrow-
m
at
om
and remove water channels.
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Using a screwdriver, loosen clips -arrows- on end piece of up‐

per part -1- from end piece lower part -2- and pull off end piece
upper part.

Golf 2004 ➤
– Slide rear guide lower part -1- in -direction of arrow- in guide

rail -3-, until the locating hook guide locking mechanism -2- is
released.
– Pull out rear guide lower part -1- and locking hook guide -2-
together in -direction of arrow- from guide rail -3- and remove.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
1.21.2 Installing
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
1.22 Cleaning water drain hoses
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
For cleaning, a locally manufactured tool made from a speedom‐
eter inner cable, approx. 2300 mm long is recommended.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
1.22.1 Front water drain hoses
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
The front water drain hoses run through the A-pillars and end at
the bulkhead cross member. Cleaning is done from the sunroof
panel aperture.

Golf 2004 ➤
1.22.2 Rear water drain hoses
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
The rear water drain hoses run through the C-pillars and end in
the rear wheel housings. Cleaning is done from the wheel hous‐
ing. The wheel housing liner must be removed.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
63 – Bumpers AG. Volkswagen AG

agen does
olksw not
yV b gu
ara
ed nte
ris
1 Front bumper
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
1.1 Tools
y li
erm
ab
ility
ot p
wit
is n
h re
♦ Torque wrench -V.A.G 1783-
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va

i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.2 Repairing bumper cover
Note
If bumper cover is damaged, determine whether plastic can be

repaired before renewing bumper
Details can be found under: ⇒ General Information; Body Repairs,

General Body Repairs ; Work procedures; Plastic repair proce‐
dures .
1. Front bumper 139

Golf 2004 ➤
1.3 Assembly overview - bumper cover
1 - Cover
❑ Material PP/EPDM
⇒ page 140
2 - Bolt
❑ 1.5 Nm
3 - Bolt
❑ Qty. 4 per side.
❑ 2 Nm
4 - Bolt
❑ Qty. 6
❑ 1.5 Nm
5 - Bolt
❑ Qty. 2 agen
AG. Volkswagen AG d
oes
lksw not
❑ 5 Nm by Vo gu
ara
d
ise nte
6 - Bolt uthor eo
a ra
❑ Qty. 2 ss c
ce
e
nl
❑ 5 Nm
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
1.4 Removing and installing front bumper

o
n in
or c
cover
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
Note Cop
yi Co
py
t. rig
gh ht
The removal and installation procedures may have to be modified pyri by
Vo
co
slightly depending on version.
by lksw
cted agen
Prote AG.
140 Rep. Gr.63 - Bumpers

Golf 2004 ➤
1.4.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Remove radiator grille ⇒ page 230 .

t to the co
– Remove bolts -5- and -6-.

– Remove bolts -4- from below.
rrectne
– Remove bolts -3- and -2- (point upwards) on left and right in
area of wheel housing liner.
ss o
cial p

f in
mechanic.
form
mer
atio
– Press locking devices -5- downwards -arrow- on left and right

om
sides and pull cover -1- parallel out of guide profiles with aid
n
c
i
or
of a second mechanic.
thi
te
sd
iva
– Disconnect all electrical connections from electrical compo‐

pr
cum
r
fo
nents and separate hoses.

en
ng
t.
yi Co
op
1.4.2 Installing C py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
1. Front bumper 141

Golf 2004 ➤

Body gap dimensions .
1.5 Front bumper attachments
Note olkswage es n
ot g
byV ua
d ran
ir se
Minor differences will be
tho encountered on removal and installing, depending
tee
or
on version.
au ac
ss
ce
le
un
pt
1 - Cover
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
⇒ page 140
h re
hole
spec
2 - Side marker light
es, in part or in w
❑ Left and right
t to the co
❑ Not for all countries
❑ Removing ⇒ Electrical
rrectness of i
system; Rep. Gr. 94 ;
Removing side marker
l purpos
lights .
3 - Left bumper moulded strip
nform
ercia
m
a
com
❑ Engaged in cover tion in

r
te o
❑ Bumper strip can be lev‐

thi
s
iva
ered out of fastenings

do
r
rp
carefully from outside

um
fo
using a plastic wedge

en
ng
t.
yi
and removed
Co
Cop py
t. rig
gh
4 - Left air intake grille
ht
pyri by
Vo
co lksw
by
❑ Pull forwards out of de‐ Prote
cted AG.
agen
tents in
-direction of arrow-
5 - Moulded part
❑ Engaged in cover
❑ Can be removed only
when bumper has been
removed
6 - Spoiler bracket
removed
7 - Spoiler
❑ Material PC/ABS
❑ Can be removed only when bumper has been removed
8 - Centre air intake grille
❑ Pull forwards out of detents in -direction of arrow-
9 - Bolt
❑ 1.5 Nm

Golf 2004 ➤
10 - Right air intake grille

❑ Remove bolt -8- and pull forwards out of fastening in -direction of arrow-
11 - Clip
❑ For separate number plate carrier
AG. Volkswagen AG d
❑ Qty. 4 lksw
agen oes
n o ot g
yV ua
12 - Number plate ris
edcarrier
b ran
tee
o
❑ For various
au
th countries or
ac
ss
❑ Installing ⇒ Item 2 (page 235)
ce
e
nl
pt
du
an
13 - Right bumper strip
itte
y li
erm
ab
ility
ot p
❑ Engaged in cover.
wit
, is n
h re
❑ Bumper strip can be levered out of fastenings carefully from outside using a plastic wedge and removed
hole
spec
es, in part or in w
t to the co
1.6 Front bumper substructure
rrectness of i
1 - Left air duct
l purpos
❑ Engages in lock carrier.

2 - Left guide
nform
ercia
❑ Bolted to lock carrier.

m
at
om
3 - Bolt ion
c
in t
or
his
e
❑ Qty. 2 per retainer.

at
do
riv
❑ 2 Nm
p
cum
for
en
g
4 - Transverse member for pe‐

n
t.
yi Co
op
destrian protection C py
ht. rig
rig ht
❑ Not for all countries py by
co Vo
by lksw
cted agen
5 - Bolt Prote AG.
❑ Qty. 6
❑ 8 Nm
6 - Right air duct
7 - Bolt
❑ Qty. 2 per retainer
❑ 2 Nm
8 - Right guide
❑ Bolted to bumper carrier
9 - Spreader nut
❑ Qty. 3
10 - Guide
❑ Left and right
❑ Removing:
– On side of wing remove
with bolts -11-
11 - Bolt
❑ Qty. 3
❑ 2 Nm
1. Front bumper 143

lkswage es n
o ot g
byV ua
Golf 2004 ➤ ir se
d ran
tee
o
General body repairs, exterior - Edition
auth 04.2008 or
ac
ss
ce
le
1.7 Assembly overview - bumper carrier
un
pt
an
d
itte
y li
erm
ab
ility
ot p
1 - Bumper carrier
wit
is n
h re
2 - Bolt
ole,
spec
t to the co
❑ 60 Nm
3 - Bolt
rrectne
❑ Qty. 6
❑ 8 Nm
ss
4 - Foam piece
o
cial p
f in
❑ Self-adhesive
form
mer
❑ Available in various
atio
m
shapes
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
1.8 Assembly overview - number plate carrier
1 - Bumper cover
2 - Number plate carrier
❑ Installing
– Align number plate car‐
rier -3-, mark position of
holes and drill-out
– Insert clips
3 - Centre line
4 - Clip
❑ Qty. 4
lkswage es n
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ility
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ole,
spec
t to the co
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cial p
f inform
mer
atio
om
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c
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or
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te
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Prote AG.
1. Front bumper 145

Golf 2004 ➤
2 Front bumper for GTI, GTI special

models, GT, R32
2.1 Tools
AG. Volkswagen AG d
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pt
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itte
Note
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ility
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spec
es, in part or in w

t to the co

dures .
rrectness of i
2.3 Assembly overview - bumper cover for

GTI, GT
l purpos
nform
ercia
Note
m
at
om
io
The bumper covers of the Golf GT and Golf GTI are identical. Only
n
c
in t
r
the air grilles are different.

o
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ate
do
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cum
for
en
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Cop py
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Prote AG.

Golf 2004 ➤
1 - Cover
⇒ page 147
2 - Bolt
❑ 1.5 Nm
3 - Bolt
❑ 2 Nm
4 - Bolt
❑ Qty. 8
❑ 1.5 Nm
5 - Bolt
❑ Qty. 2
❑ 5 Nm
lkswage es n
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pt
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co

cover for GT, GTI
rrectness
Note
o
cial p
f inform
mer
The removal and installation procedures may have to be modified

atio

om
n
c
i
or
n thi
te
sd
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fo
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t.
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Cop py
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Prote AG.
2. Front bumper for GTI, GTI special models, GT, R32 147
Golf 2004 ➤
2.4.1 Removing
AG. Volkswagen AG d
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ility
ot
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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rp
cum
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en
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t.
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Cop py
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gh ht
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Vo
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Prote AG.

mechanic.
– With help of a second mechanic pull cover -1- parallel out of
guides.
– Disconnect all electrical connections from electrical compo‐
nents and separate hoses.
2.4.2 Installing

Golf 2004 ➤
2.5 Front bumper attachments for GT, GTI
Note
♦ Minor differences will be encountered on removal and instal‐

ling, depending on version.
♦ The bumper covers of the Golf GT and Golf GTI are identical.
Only the air grilles are different.
♦ The air grille for the Golf GTI has a honeycomb pattern, the air
grille for the Golf GT has transverse pieces.
1 - Cover
❑ Material PP/EPDM olkswage es n
ot g
yV
❑ Removing andir se
d installing
b ua
ran
⇒ page 147
tho tee
o
au ra
c
ss moulded strip
2 - Left bumper
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole

spec
es, in part or in w
and removed
t to the co
3 - Side marker light
❑ Left and right
rrectness of i

l purpos
nform
ercia
lights .
m
at
om

ion
c
in t
r
❑ Different appearance
o
his
te
for Golf GT and Golf GTI

a
do
priv
❑ Removing:
um
for
en
ng
t.
yi
– Remove screw -4-
Co
Cop py
t. rig
gh ht
yri
– First remove forwards p by
co Vo
-arrow a- out of latches,
by lksw
cted agen
Prote
then pull out of cover to‐
AG.
wards centre of vehicle

-arrow b-
5 - Bolt
❑ 1.5 Nm
6 - Spoiler upper part
❑ Material PC/ABS
❑ Can be removed only when bumper has been removed and lower part of spoiler has been unbolted.
7 - Lower part of spoiler
❑ Only for Golf GTI
❑ Material PC/ABS
❑ Bolted to spoiler upper part and soundproofing
Golf 2004 ➤
8 - Bolt
❑ Qty. 7
❑ 1.5 Nm
❑ Different appearance for Golf GT and Golf GTI
❑ Can only be removed when the radiator grille is removed
❑ Centre air intake grille can be levered out of latches carefully from outside using a plastic wedge and
removed
❑ Different appearance for Golf GT and Golf GTI
❑ Removing:
– Remove screw -4-
– First remove forwards -arrow a- out of latches, then pull out of cover towards centre of vehicle
-arrow b-
11 - Right bumper moulded strip

❑ Bumper strip can be levered out of fastenings
gen AG
. Volkswagencarefully
AG from outside using a plastic wedge and removed
a does
ksw not
Vol gu
d by ara
e nte
ris
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ss
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
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or c
thi
te
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m
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en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2004 ➤
2.6 Assembly overview - bumper cover for R32
Note
Minor differences may be encountered

en AG. V
olkswagin
enthe
AG assembly overview depending on version.
wag does
olks not
byV gu
ara
ed nte
ris
1 - Cover tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
⇒ page 151
y li
rm
ab
pe
ility
2 - Bolt
ot
wit
, is n
❑ Qty. 2
h re
hole
❑ 1 Nm
spec
es, in part or in w
3 - Bolt
t to the co
❑ 2 Nm
rrectness of i
4 - Bolt
l purpos
❑ Qty. 8
❑ 2 Nm
nform
ercia
5 - Bolt
m
a
com
ti
❑ Qty. 2
on in
r
te o
❑ 3.5 Nm
thi
s
iva
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r
rp
cum
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en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

cover for R32
Note

Golf 2004 ➤
2.7.1 Removing
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove side marker lights (if fitted) ⇒ Electrical system; Rep.
Gr. 94 ; Side marker lights .
mechanic.
guides.
– Separate electrical connections of all electrical components.
– Disconnect hose of headlight washer system (if fitted) ⇒ Elec‐
trical system; Rep. Gr. 92 ; Headlight washer system .
2.7.2 Installing

Golf 2004 ➤

2.8 Front bumper attachments for R32
Note
Minor differences will be encountered on removal and installing, depending on version.
1 - Cover
⇒ page 151
2 - Left side marker light
❑ For various countries
lights .
4 - Bolt
❑ Qty. 6 per side n AG. Volkswagen AG do
lkswage es n
o ot g
❑ 1 Nm byV ua
d ran
ir se tee
o
5 - Cover for headlight washer
auth or
ac
system ss
ce
le
un
pt
6 - Left bumper strip

an
d
itte
y li
erm
ab
ility
❑ Engages in cover.
ot p
wit
is n

h re
ole,

spec


t to the co
and removed
rrectne

s
8 - Right bumper moulded strip

s o
cial p
inform
❑ Engages in cover.
mer
atio
m

o
n
c
ered out of fastenings carefully from outside using a plastic wedge and removed
i
or
n thi
te
sd
a
9 - Cover for headlight washer system

iv
o
pr
cum
r
fo
10 - Right side marker light

en
ng
t.
yi Co
❑ For various countries t. Cop py
rig
❑ Removing ⇒ Electrical system; Rep. Gr. 94 ; Removing side marker lights .
gh ht
pyri by
Vo
co lksw
by
11 - Radiator grille cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
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Golf 2004 ➤ ed b ara
nte
ris
ut
h - Edition 04.2008
o eo
ra
s a c
s
2.9 Assembly overview - front bumper cover for GTI special models
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
Minor differences may be encountered in the assembly overview depending on version.
hole
spec
es, in part or in w
t to the co
1 - Cover
❑ Material: PP/EPDM PU-
rrectness of i
RIM
l purpos

⇒ page 154
nf
ercia
2 - Bolt
orm
m
❑ Points upwards
atio
om
n in
❑ 1.5 Nm
or c
thi
te
3 - Bolt
sd
iva
o
r
rp
cu
o
m
f
en
ng
❑ 2 Nm
t.
yi Co
Cop py
ht. rig
4 - Bolt opy
rig by
Vo
ht
❑ Qty. 8 by c lksw
cted agen
Prote AG.
❑ 1.5 Nm
5 - Bolt
❑ Qty. 2
❑ 5 Nm

cover for GTI special models
Note


Golf 2004 ➤
2.10.1 Removing
AG. Volkswagen AG d
agen oes
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ara
ed
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aut ra
ss c ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia

orm
m
atio
– Remove bolts -5- from above.

om
n in
or c

thi
te
sd
iva
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rp
cu

o
m
f
en
ng
t.
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Further dismantling requires the help of a second mechanic. Cop py
ht. rig
rig ht
– With help of a second mechanic pull cover -1- parallel out of py by
co Vo
guides.
by lksw
cted agen
Prote AG.
– Separate connectors of all installed electrical components and
hoses ⇒ Electrical system; Rep. Gr. 92 ; Windscreen wash/
wipe system; Headlight washer system .
2.10.2 Installing
Body panel gaps/shut lines .
Golf 2004 ➤
2.11 Front bumper attachments for GTI special models
Note
1 - Cover
RIM
⇒ page 154
2 - Left bumper strip
and removed
❑ Removing:
– Unscrew bolt -4-.
– First remove forwards

-arrow a- out of catches,
then pull out of cover to‐
wards centre of vehicle
-arrow b-.
wage es n
4 - Bolt yV
olks ot g
ua
d b
❑ 1.5 Nm o
ir se
ran
tee
th or
u
5 - Spoiler ss
a ac
ce
le
❑ Material: PU-RIM
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
removed and lower part

h re
of spoiler has been un‐

hole
spec
bolted.
es, in part or in w
t to the co

❑ Can only be removed when the radiator grille has been removed.
rrectness of i
❑ Centre air intake grille can be levered out of catches carefully from outside with a plastic wedge and
removed.
l purpos

❑ Removing:
nform
mercia
– Unscrew bolt -4-.

a
com
tion in
– First remove forwards -arrow a- out of catches, then pull out of cover towards centre of vehicle
r
te o
thi
-arrow b-.
s
iva
do
r
rp
cum
8 - Right bumper strip

fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co
❑ Bumper strip can be levered out of fastenings carefully from outside using a plastic wedge and removed
by lksw
cted agen
Prote AG.

Golf 2004 ➤
2.12 Front bumper substructure
1 - Left air duct

2 - Left guide
❑ Bolted to lock carrier.
3 - Bolt
❑ Qty. 2 per retainer.
❑ 2 Nm
4 - Transverse member for pe‐
destrian protection
❑ Not for all countries n AG. Volkswagen AG do
lkswage es n
5 - Bolt d byV
o ot g
ua
ran
❑ Qty. 6 ir se tee
tho
u or
❑ 8 Nm ss
a ac
ce
e
nl
6 - Right air duct
pt
du
an
itte
y li
erm
ab
ility
ot p
7 - Bolt
wit
, is n
❑ Qty. 2 per retainer
h re
hole
❑ 2 Nm
spec
es, in part or in w
t to the co
8 - Right guide
❑ Bolted to bumper carrier
rrectness of i
9 - Spreader nut
❑ Qty. 3
l purpos
10 - Guide
nform
ercia
❑ Left and right

❑ Removing:
m
at
om
ion
– On side of wing, remove

c
in t
or
together with bolts -11-.

his
ate
do
priv
11 - Bolt
um
for
en
ng
❑ Qty. 3
t.
yi Co
Cop py
❑ 2 Nm
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Golf 2004 ➤
1 - Bumper carrier
2 - Bolt
❑ 60 Nm
3 - Bolt
❑ Qty. 6
❑ 8 Nm
4 - Foam piece
❑ Self-adhesive
shapes
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2004 ➤
3 Rear bumper
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
3.1 Tools ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note


dures .
3. Rear bumper 159

Golf 2004 ➤
3.3 Assembly overview - bumper cover
1 - Cover
AG. Volkswagen AG d
❑ Removing and installing agen oes
olksw not
⇒ page 160 d by V gu
ara
rise nte
2 - Bolt utho eo
ra
a c
❑ Qty. 2 ss
ce
e
nl
❑ 5 Nm
pt
du
an
itte
y li
3 - Bolt
erm
ab
ility
ot p
❑ Qty. 4
wit
, is n
❑ 5 Nm
h re
hole
spec
4 - Spreader rivet
es, in part or in w
t to the co
❑ Qty. 2
5 - Bolt
rrectness of i
❑ Qty. 3 per side
❑ 2 Nm
l purpos
6 - Bolt
nform
ercia
❑ Qty. 4
m
❑ 5 Nm
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3.4 Removing and installing bumper cover
Note


Golf 2004 ➤
3.4.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove tail lights ⇒ Electrical system; Rep. Gr. 94 ; Lights,

nform
ercia
bulbs, switches - exterior; Removing and installing tail lights .

m
at
– Remove bolts -5- on left and right in area of wheel housing

om
ion
liner.
c
in t
or
his
e
– Using a screwdriver lever out spreader rivet -4- on left and right
at
do
riv
in area of wheel housing liner.

p
cum
for
en
g
– From below, remove bolts -2- and -3-.

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
mechanic.
Prote AG.

guides.
– Disconnect connectors for existing electrical components,
number plate light ⇒ Electrical system; Rep. Gr. 94 ; Lights,
bulbs, exterior switches, number plate light and, if fitted, ⇒
Electrical system; Rep. Gr. 94 ; Lights, bulbs, exterior
switches; Parking aid .
3. Rear bumper 161

Golf 2004 ➤
3.4.2 Installing
3.5 Rear bumper attachments
Note
1 - Cover
⇒ page 160
2 - Number plate lights
AG. Volkswagen AG d
❑ Qty. 2 lksw
agen oes
not
Vo
❑ Removing ⇒ Electrical d by gu
ara
system; Rep. Gr. 94 ; rise nte
tho eo
Lights, bulbs, switches - s au ra
c
exterior; Number plate s
ce
le
illumination
un
pt
an
d
itte
y li
3 - Towing eye cap
rm
ab
pe
ility
ot
wit
, is n
4 - Spoiler
h re
hole
spec
❑ Material PC/ABS
es, in part or in w
t to the co
rrectness of i
removed.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
3.6 Rear bumper substructure
1 - Securing strip
2 - Hexagon nut
❑ Qty. 4
❑ 2 Nm
3 - Guide
❑ Left and right
4 - Hexagon nut
❑ Qty. 3 per side
❑ 2 Nm
❑ Not installed on all mod‐
els
6 - Bolt
❑ Qty. 2
❑ 5 Nm
7 - Foil AG. Volkswagen AG d
agen oes
❑ Left and right olksw not
V gu
d by ara
❑ Self-adhesive orise nte
h eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Rear bumper 163

Golf 2004 ➤
AG. Volkswagen AG d
agen exterior - Edition
General bodyorepairs, 04.2008
oe
lksw s no
t gu
yV
db ara
ise
r nte
tho eo
s au ra
c
s
ce
e
nl
pt
1 - Cross member
du
an
itte
y li
2 - Bolt
erm
ab
ility
ot p
❑ Qty. 6
wit
, is n
❑ 20 Nm
h re
hole
spec
3 - Foam piece
es, in part or in w
t to the co
❑ Only installed in some
countries
❑ Self-adhesive
rrectness of i
l purpos
shapes
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3.8 Assembly overview - towing bracket
DANGER!
The bolts -3- function as plugs and seal the passenger com‐
partment against exhaust fumes, and must without exception
be installed.
Note

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

Golf 2004 ➤
1 - Towing bracket
❑ Towing bracket with re‐
movable ball head is
shown in illustration n AG. Volkswagen AG do
lkswage es n
o ot g
yV
2 - Ball hitch d b ua
ran
ir se tee
❑ The removable ball autho
or
ac
head is located in the left ss
side compartment of the
ce
e
nl
pt
du
luggage compartment
an
itte
y li
erm
ab
3 - Bolt
ility
ot p
❑ Plugs
wit
, is n
h re
❑ Qty. 4
hole
spec
❑ 20 Nm
es, in part or in w
t to the co
4 - Bolt
❑ Qty. 4
rrectness of i
❑ 50 Nm + turn 90° further
l purpos

ter being undone
nf
ercia
o
5 - Cover
rm
m
atio
om
n in
c

or
thi
e
⇒ page 160
t
sd
iva
o
r
rp
cu
6 - Spring clip
o
m
f
en
ng
t.
❑ Qty. 2
yi Co
Cop py
t. rig
7 - Cap - towing bracket
gh ht
pyri by
Vo
co lksw
by
8 - Rotary fastener Prote
cted AG.
agen
❑ Qty. 2
9 - Retaining disc
❑ Qty. 2
3. Rear bumper 165

Golf 2004 ➤
4 Rear bumper for R32 and GTI special

models
4.1 Tools
♦ Torque wrench -V.A.G 1332- AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Note
ss o
cial p
f i
nform
mer
atio
om
n
c

i
or
n thi

te
sd
va
dures .
i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
aut
h
ra Golf 2004 ➤
s c
s General body repairs, exterior - Edition 04.2008
ce
le
un
pt
an
d
4.3 Assembly overview - bumper cover for R32
itte
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
es, in part or in w
t to the co
1 - Cover
rrectness of i
❑ With various forms for
l purpos
number plate
nform
ercia

m
⇒ page 167
a
com
tion in
2 - Bolt
r
te o
thi
❑ Qty. 2
s
iva
do
r
rp
c
❑ 5 Nm
um
fo
en
ng
t.
yi
3 - Bolt
Co
Cop py
.
❑ Qty. 3
ht rig
rig ht
py by
Vo
❑ 5 Nm
co lksw
by
cted agen
Prote AG.
4 - Bolt
❑ 2 Nm
5 - Bolt
❑ Qty. 4
❑ 5 Nm
4.4 Removing and installing bumper cover

for R32
Note

4. Rear bumper for R32 and GTI special models 167

Golf 2004 ➤
4.4.1 Removing
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot

wit
, is n
h re

hole
spec

es, in part or in w
t to the co
liner.
rrectness of i

l purpos

mechanic.
nform
ercia

guides.
m
a
com
tio
– Disconnect connectors for existing electrical components,

n in
r
te o

thi
s
iva
bulbs, exterior switches, number plate light and, if fitted, ⇒

do
r
Electrical system; Rep. Gr. 94 ; Lights, bulbs, exterior

rp
cum
fo
switches; Parking aid .

en
ng
t.
yi Co
op
4.4.2 Installing
C py
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ed
ris
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aut
h
General body repairs, exterior - Edition ra 04.2008
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
4.5 Rear bumper attachments for R32
wit
is n
h re
ole,
spec
Note
t to the co
rrectne
1 - Cover
ss o
cial p
f in
number plate
form
mer
atio
om
n
c
i
or
n
⇒ page 167
thi
te
sd
iva
o
r

p
cum
r
fo
en
ng
❑ Qty. 2
t.
yi Co
op
C py
ht. rig
system; Rep. Gr. 94 ; rig ht
py by
Vo
Lights, bulbs, switches -
co lksw
by
cted agen
exterior; Number plate Prote AG.
illumination
3 - Right fitting bracket
4 - Spoiler
number plate
❑ Material PC/ABS
removed
5 - Rear right reflector
❑ Engaged in spoiler
removed
6 - Trim
❑ Material PC/ABS
removed
7 - Towing eye cap
8 - Rear left reflector
❑ Engaged in spoiler
❑ Can be removed only when bumper has been removed
9 - Left fitting bracket

Golf 2004 ➤
4.6 Assembly overview - rear bumper cover for GTI special models
Note
1 - Cover
RIM
⇒ page 170
2 - Bolt
❑ Qty. 2
❑ 2 Nm
3 - Bolt
❑ Qty. 2
❑ 5 Nm
4 - Bolt
❑ 2 Nm
5 - Bolt
❑ 5 Nm
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
4.7 Removing and installing rear bumper

l purpos
cover for GTI special models

nform
mercia
Note
com
tion in
r
te o
thi

s
iva

do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
4.7.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i

l purpos

liner.
nform
ercia

m
at
om
– Unscrew bolts -5- from above on left and right beneath tail
ion
c
lights.
in t
or
his
ate
Further dismantling requires the help of a second mechanic.

do
priv
cum
or

f
en
ng
t.
guides.
yi Co
Cop py
ht. rig
– Separate connectors for existing electrical components of rig ht
py by
co Vo
by lksw
cted
bulbs, switches - exterior; Number plate lights and, if fitted, ⇒
agen
Prote AG.
Electrical system; Rep. Gr. 94 ; Lights, bulbs, switches - ex‐
terior; Parking aid .
4.7.2 Installing

Golf 2004 ➤

maintained ⇒ Body Repairs; Rep. Gr. 00 ; Technicalagen data;
AG. Volkswagen AG d
oes
Body panel gaps/shut lines . olksw not
yV gu
db ara
ise nte
4.8 Rear bumper attachments
au
tho
r
for GTI special models e or
ac
ss
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
1 - Cover
es, in part or in w
t to the co
RIM
❑ Removing and instal‐
rrectness of i
ling:
l purpos

❑ Qty. 2
nform
ercia
❑ Removing:
m
a
com
t
– ⇒ Electrical system;
ion in
Rep. Gr. 94 ; Lights,
r
te o
thi
bulbs, switches - exteri‐
s
iva
do
or; Number plate lights .
r
rp
cum
fo
en
g
3 - Towing eye cap

n
t.
yi Co
op
C py
t. rig
gh ht
yri by
4 - Spoiler
cop Vo
by lksw
cted agen
❑ Material: PU-RIM
Prote AG.
removed

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by aGolf
ran 2004 ➤
ise
r tee
utho General body repairs, exterior - Edition 04.2008
or
a ac
ss
ce
4.9 Rear bumper substructure
e
nl
pt
du
an
itte
y li
erm
ab
ility
1 - Securing strip
ot p
wit
, is n
2 - Hexagon nut
h re
hole
spec
❑ Qty. 4
es, in part or in w
❑ 2 Nm
t to the co
3 - Guide
❑ Left and right
rrectness of i
4 - Hexagon nut l purpos
❑ Qty. 3 per side
❑ 2 Nm
nf
ercia
orm
m
atio
om
❑ Not installed on all mod‐
n in
or c
els
thi
te
sd
iva
o
6 - Bolt
r
rp
cu
o
m
f
❑ Qty. 2
en
ng
t.
yi Co
op
❑ 5 Nm C py
t. rig
gh ht
yri by
7 - Foil op Vo
by c lksw
cted agen
❑ Left and right Prote AG.
❑ Self-adhesive

Golf 2004 ➤
Note
1 - Cross member
2 - Bolt
AG. Volkswagen AG d
❑ Qty. 6 agen oes
olksw not
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❑ 20 Nm ise
d b ara
nte
or eo
h
3 - Foam piece aut ra
c
ss
❑ Only installed in some
ce
e
nl
pt
countries
du
an
itte
y li
❑ Self-adhesive
erm
ab
ility
ot p
wit
shapes
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
64 – Glazing n AG. Volkswagen AG do

lkswage es n
o ot g
yV
1 Flush bonded windows o
ir se
d b ua
ran
tee
th or
au ac
ss
ce
e
1.1 Tools
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
♦ Removal kit for flush bonded windows -V.A.G 1474 A-
wit
, is n
h re
♦ Suction lifter -V.A.G 1344-
hole
spec
es, in part or in w
♦ Cutting tool -V.A.G 1351-
t to the co
♦ Windscreen removal kit -V.A.G 1755-
♦ Hand-cartridge gun -V.A.G 1628-
rrectness of i
♦ Cartridge heater -V.A.G 1939-
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Electric cutter -V.A.G 1561 A-

♦ Cutting blade -V.A.G 1561/2-
1. Flush bonded windows 175

Golf 2004 ➤
♦ Scraping blade -V.A.G 1561/8-

♦ Double cartridge gun -VAS 5237-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
176 Rep. Gr.64 - Glazing

Golf 2004 ➤
1.2 Materials
♦ 2K window adhesive DA 004 600 A210) 12)
♦ Activator D 181 801 A19)
♦ Adhesive remover D 002 000 109)
♦ Cutting cord 357 853 999
9) Observe instructions for use on the information sheet provided by the manu‐
facturer.
10) Observe minimum curing period: ⇒ page 191

11) Heat, according to manufacturers' instructions, using cartridge heater -V.A.G
1939- .
12) Double cartridge gun -VAS 5237- must be used to apply these materials.
13) Small cartridge 110 ml for sealing and/or when a 400 ml cartridge alone is not
sufficient.
1.3 Repairing windscreen AG. Volkswagen AG d

agen oes
olksw not
y V gu
d b ara
Note orise nte
eo
th
au ra
s c
Before renewing windscreen, explore possibilities of repairing s
ce
e
damage to glass.
nl
pt
du
an
itte
y li
erm
Description can be found under ⇒ General Information; Body Re‐ ab

ility
ot p
pairs, General Body Repairs ; Work procedures; Glass repair . wit

, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
1.4 Assembly overview - windscreen
1 - Windscreen
2 - Windscreen adjuster
❑ 443 845 631 A
3 - Plenum chamber cover
❑ Must be removed from
windscreen seal by
hand only
4 - Windscreen seal
❑ Integral part of wind‐
screen
5 - Spacing lip
screen
6 - PUR adhesive sealant
❑ Cross section of bead:
width = 6.5 mm, height = n AG. Volkswagen AG do
10 mm (including resid‐ olkswage es n
ot g
ual material on window d byV ua
ran
glass and window o
ir se tee
flange) auth or
ac
ss
❑ Minimum curing period
ce
e
nl
⇒ page 191
pt
du
an
itte
y li
7 - Water deflector
erm
ab
ility
ot p
wit
, is n

h re
hole
8 - Sealing lip spec

es, in part or in w
t to the co
❑ If sealing lip is damaged
when it is cut out, a new windscreen must be installed
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
1.5 Assembly overview - plenum chamber cover
1 - Plenum chamber cover

❑ Must be removed from
windscreen seal by
hand only
3 - Windscreen
4 - Plenum chamber seal
5 - Windscreen seal
screen
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
1.5.1 Removing plenum chamber cover
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
– Unbolt wiper arms ⇒ Electrical system; Rep. Gr. 92 ; Wind‐

h re
screen wiper system; Removing and installing windscreen

hole
spec
wiper system; Removing and installing wiper arms .

es, in part or in w
t to the co
WARNING
rrectness of i
The plenum chamber cover must not be levered off with a tool
(wedge). The windscreen will be damaged and can later crack.
l purpos
nform
ercia
– Pull plenum chamber seal -4- off over entire length of plenum
chamber bulkhead -2-.
m
a
com
tion in
– Beginning on right, carefully pull plenum chamber cover -1-

r
te o
thi
upwards out of windscreen seal -5-.

s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
1.5.2 Installing plenum chamber cover
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
WARNING
Striking the plenum chamber cover can cause cracks in the

windscreen.
– Spray windscreen seal -5- with a soapy solution so that ple‐

num chamber cover -1- is easier to press on.
– Place the plenum chamber cover -1- on the windscreen seal
-5- and engage with the windscreen seal -5- starting in the
middle and applying light pressure.
– Install plenum chamber seal -4- and windscreen wiper.
Note
An insert is installed in windscreen seal of new windscreens. Remove this insert before installing plenum
chamber cover.

Golf 2004 ➤
1.6 Removing windscreen

– Remove A-pillar trims ⇒ General body repairs, interior; Rep.
Gr. 70 ; Trims, insulation; Pillars and side trims .
– Remove left and right sun visors ⇒ General body repairs, in‐
terior; Rep. Gr. 68 ; Interior equipment; Compartments, covers
and trims .
– Remove interior mirror ⇒ General body repairs, interior; Rep.
Gr. 68 ; Interior equipment; Interior mirror .
– Remove water deflector strips on left and right ⇒ page 242
– Slide cover -V.A.G 1474/8- between windscreen -1- and dash
panel.
– Thrust awl -V.A.G 1474/2- -2- through adhesive bead.
– Pull cutting cord -3- through adhesivewsealing
agen
AG.material into in‐
Volkswagen AG
does
olks
side of vehicle using awl -V.A.G y1474/2- -2-. not
V gu b ara
ed nte
oris e
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
– Secure inside end of cutting cord against falling out using pull
ole,
handle -V.A.G 1351/1- -3-.
spec
– Loosen sealing lip in upper area of windscreen with a plastic
t to the co
wedge and spray in cleaning solution D 009 401 04 (as sub‐
stitute for lubricant).
– Place cutting cord -2- using small tube -1- in upper area of rrectne
window.
ss
– If gap is too small, guide cutting cord on outside and push un‐
o
cial p
f i
der lip with a plastic wedge.

nform
mer
– Lay cutting cord -2- around window and guide second end of
atio
m
cord inwards into interior.

o
n
c
i
or
n thi
• Ensure that cutting cord -2- lies under window in corners.

te
sd
iva
o
pr
cum
r
fo
– Secure other end of cord to reel device -V.A.G 1654 A- .

en
ng
t.
yi Co
– Position reel device -V.A.G 1654 A- in “position I”. Cop py
t. rig
gh ht
yri
– Reposition reel device -V.A.G 1654 A- as necessary and cut p by
co Vo
by lksw
window free. Prote
cted AG.
agen
– Use wedge -V.A.G 1474/5- to press cutting cord against win‐

dow glass while cutting in order to avoid damaging dash panel
and to create clearance at window flange.
1.7 Installing windscreen

Preparing old undamaged window for glazing ⇒ page 188
Preparing new window for glazing ⇒ page 188
Preparing body flange for glazing ⇒ page 190
Installation instructions ⇒ page 191

Golf 2004 ➤
Minimum curing period ⇒ page 191
1.8 Assembly overview - rear window
1 - Rear window
2 - Seal
❑ For rear window wiper
3 - Rear lid
AG. Volkswagen AG d
4 - PUR adhesive sealant wage
n oes
Volks not
gu
❑ Cross section of bead: ed by ara
nte
width = 6.5 mm, height
tho
ris= eo
10 mm (includings resid‐
au ra
c
ual material on window
s
ce
le
glass and window

un
pt
an
d
flange)
itte
y li
rm
ab
pe
ility
⇒ page 191
ot
wit
, is n
h re
5 - Trim
hole
spec
❑ Remove trim ⇒ General
es, in part or in w
t to the co
Rep. Gr. 70 ; Trim, in‐
sulation; Rear lid trim/in‐
sulation
rrectness of i
6 - Window aerial contact
l purpos
❑ Right and left
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.9 Removing undamaged rear window

Gr. 70 ; Trims, insulation; Luggage/load compartment trims .
– Remove rear window wiper motor ⇒ Electrical system; Rep.
Gr. 92 ; Repairing rear window wipe and wash system .

Golf 2004 ➤
– Pull off connections -1- on left and right for heated rear window
and window aerial.

– Pull cutting cord -2- through adhesive sealing material to in‐
side using awl -V.A.G 1474/2- -1-.
– Secure end of cutting cord -3- against falling out using pull agen
AG. Volkswagen AG d
oes
handle -1-. yV
olksw not
g b ua
ed ran
– Lay cutting cord -3- around window and guide secondho
ris end of tee
cord inwards into interior. s aut or
ac
s
– Secure end of cord to reel device -V.A.G 1654- -2-.
ce
e
nl
pt
du
an
itte
– Position reel device -V.A.G 1654- -2- in “position I”.

y li
erm
ab
ility
– Reposition reel device -V.A.G 1654- -2- as necessary and cut

ot p
window free.
wit
, is n
h re
hole
– Use wedge -V.A.G 1474/5- to press cutting cord -3- against

spec
window glass while cutting in order to have clearance at win‐

es, in part or in w
dow flange.
t to the co
1.10 Removing broken rear window

rrectness of i
– Protect body and interior against damage from glass splinters.

l purpos
– Remove pieces of glass up to adhesive sealing material.

nf
ercia
– Pull off connectors for rear window heating and aerial.

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2004 ➤
– Apply textile reinforced adhesive tape all around flange -1-.

– Cut through adhesive sealing material (with pieces of glass)
in window aperture using electric cutter -V.A.G 1561 A- -3- and
cutting blade -V.A.G 1561/10 - -2-.agen AG. Volkswagen AG do
ksw es n
Vol ot g
d by ua
ran
WARNING horise tee
t or
au ac
ss
Always wear protective goggles and leather gloves.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1.11 Installing rear window
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2004 ➤
1.12 Assembly overview - rear side window
1 - Side window
❑ Removing side window
⇒ page 186
❑ Installing side window
⇒ page 187
2 - PUR adhesive sealant
❑ Cross section of bead:
width = 6.5 mm, height =
10 mm (including resid‐
ual material on window
glass and window
flange)
⇒ page 191
3 - Window flange
4 - Seal with spacing lip
❑ Integral part of side win‐
dow
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
1.13 Removing undamaged rear side window

y li
erm
ab
ility
ot p
– Loosen interior trim in upper area ⇒ General body repairs,

wit
, is n
interior; Rep. Gr. 70 ; Trims, insulation; Load and luggage

h re
compartment trim .
hole
spec
es, in part or in w
– Remove B- and C-pillar trim ⇒ General body repairs, interior;

t to the co
Rep. Gr. 70 ; Trims, insulation; Pillar and side trims .

rrectness of i
– Pull cutting cord -2- through adhesive sealing material into in‐
l purpos
side of vehicle using awl -V.A.G 1474/2- -1-.

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
186
cted agen
Prote AG.
Rep. Gr.64 - Glazing
Golf 2004 ➤
– Secure inside end of cutting cord against falling out using pull
handle -V.A.G 1351/1- -1-.
– Separate sealing lip from window flange all around and spray
in cleaning solution D 009 401 04 (as substitute for lubricant).
– Place cutting cord -2- around side window.
– Using small tube -3- feed cutting cord -2- between lip and win‐
dow flange feed also second cord end into interior.
– Secure other end of cord to reel device -V.A.G 1654 A- and

cut window free, repositioning reel device as necessary.
swa
gen AG
. Volkswagen AG
does
k not
Vol gu
– Use wedge -V.A.G 1474/5- to press cutting cord d b against win‐
y ara
ise nte
dow glass while cutting in order to obtain clearance
ho
r at window eo
flange. ut ra
sa s c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.14 Removing damaged rear side window
A damaged side window is removed in much the same way as a
rrectness of i
damaged rear window.
l purpos
1.15 Installing rear side window
nf
ercia
orm
m
atio
om
n in
c

or
thi
te
sd
a

iv
o
r
rp
cu
o
m
f

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2004 ➤
1.16 Preparing old undamaged window for

glazing
Note
♦ If installing an undamaged window, cut back residual adhesive

seal to 1...2 mm, being careful not to damage primer and ce‐
ramic coating.
♦ Remaining material serves as adhesion base for newly ap‐
plied adhesive sealing compound.
WARNING
Do not prime adhesion surface and do not treat with a cleaning

solution. Keep adhesion surface free of dirt and grease.
Exception: if bonding is not performed immediately after cutting

back, the remaining residual material must be activated with ac‐
tivator D 181 801 A1. en AG. V
olkswagen AG
wag does
olks not
byV gu
1.17 Preparing new window without precoat‐
ara
ed nte
ris
ho eo
ing for glazing
t
au ra
c
ss
ce
le
Only the applied ceramic layer and injection moulded sealing lip
un
pt
an
d
with spacer rib are found on all new windows.

itte
y li
rm
ab
Exception: rear window does not have a sealing lip or spacing lip.
pe
ility
ot
wit
, is n
1 - Sealing lip
h re
hole
spec
2 - Spacing lip
es, in part or in w
t to the co
3 - Window glass
rrectness of i
Note
l purpos
The area on which the adhesive bead is applied is not precoated

or primed.
nform
ercia
– Clean a 20 mm wide strip all around edge of window using

m
a
com
cleaning solution D 009 401 04.

ion in
r
te o
– Then rub edge of window dry using a lint free cloth.

thi
s
iva
do
r
rp
cum
fo
WARNING
en
ng
t.
yi Co
Cop py
Ceramic coating on window is not primer! It must be primed ht. rig
rig ht
before application of adhesive sealing compound! Use only py by
co Vo
lksw
primer D 009 200 02!
by
cted agen
Prote AG.

Golf 2004 ➤
– Apply primer -4- evenly in one motion using applicator

D 009 500 25 -3- to the previously cleaned area -1- of window.
Ensure that glass adhesive is applied to primed area at a distance
of approx. 2 mm from sealing lip -2-.
• Drying time approx. 10 minutes
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
1.18 Preparing new window with precoating
ility
ot p
wit
, is n
for glazing
h re
hole
spec
A replacement part rear window is precoated. A PUR application
es, in part or in w
area for the adhesive bead is sprayed onto this window.
t to the co
– Rub over the precoating with a dry lint-free cloth.
rrectness of i
WARNING
l purpos
Do not prime precoating and do not treat with cleaning agent.

nf
ercia
orm
m
atio
– Apply activator -2- evenly in one stroke using applicator D 009

om
n in
500 25 -1-.
or c
thi
te
sd
• Allow activator to flash off for at least 10 minutes.

iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri by
Activator must not come in contact with paint, or the paintwork will
op Vo
by c lksw
be damaged. cted agen
Prote AG.

Golf 2004 ➤
1.19 Preparing body flange for glazing

– Cut back remaining material on body flange with electric cutter
-V.A.G 1561 A- and scraping blade -V.A.G 1561/8- , but do not
remove completely.
Note
Remaining material serves as adhesion base for newly applied

adhesive sealing compound. Keep dirt and grease off of bonding
surfaces.
WARNING
Activator must not have contact with paint or the paintwork will
be damaged.

tivator D 181 801 A1.
• If the window flange has been repaired or partially renewed,
after painting, the area concerned must be cleaned and
primed again.
Note
It is possible that there is no laser weld seam in the area of the

adhesive bead. In this case the open weld seam must be sealed
with window adhesive before bonding the window.
AG. Volkswagen AG d
agen oes
olksw not
– If the laser weld seam d by -3- on the panel flange -4- is not covered
V gu
ara
be the adhesiveoribead
se -1-, coat the laser weld seam -3- with nte
e
glass/paint primer
aut
h
D 009 200 02 -3- and fill the laser weld seamor a
with window s adhesive DH 009 100 03 -1-.
s c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2004 ➤
1.20 Installation instructionsswagen AG. Volkswagen AG does

k not
Vol gu
– Apply adhesive material to primed by
ed area -1- or to trimmed seal‐
ara
ris nte
ant bead, holding double cartridge
tho gun -VAS 5237- at right eo
angle to window. ss au ra
c
ce
le
un
pt
WARNING
an
d
itte
y li
erm
ab
ility
Window must be installed within 10 minutes, or adhesive prop‐
ot p
wit
erties of window adhesive will be impaired.
is n
h re
ole,
spec
♦ With help of two double suction cups (V.A.G 1344) install glass
t to the co
pane in window aperture, centre and press in to spacing lip.
♦ Secure windscreen during curing time with window adjusters
rrectne
(443 845 631 A).
♦ It is absolutely necessary to install the plenum chamber cover
ss
as described on page ⇒ page 181 .
o
cial p
f in
♦ Replace stickers (e.g. for airbag) which may be installed.
form
mer
atio
♦ Insert seal for rear window wiper motor drive shaft into rear
om
window.
n
c
i
or
n thi
e
♦ The activator must not come into contact with the window
t
sd
va
heater bus bar.

i
o
pr
cum
r
fo
en
ng
♦ Marks have been made to the left and right on the rear window
t.
yi Co
to aid in applying adhesive material. Cop py
ht. rig
rig ht
♦ The sides of the rear window must not project above the con‐ py by
co Vo
tour of the rear lid under any circumstances!
by lksw
cted agen
Prote AG.
♦ Use adhesive tape to secure rear window in position while
curing.
♦ If the adhesive bead is too thick and the adhesive expands
onto the area of the window heating, excess adhesive must
be removed.
WARNING

windows. One of these standards is, for example, that a freshly
bonded windscreen must comply with the safety requirements,
even in an accident, following the minimum prescribed curing
period.
The minimum curing time for the 2-component adhesive DA 004

600 A2 is three hours for all windows.
Minimum curing period is the time from bonding the window until
the vehicle may be used. During this time, the vehicle must stand
on a level surface at room temperature (at least 15 C).
WARNING

completed.

Golf 2004 ➤
1.22 Touching up paint damage

If paintwork is damage, paint structure must be restored accord‐
ing to specifications in the “Paint” workshop manual.

material
– It is recommended to use cleaning solution D 002 000 10 as
AG. Volkswagen G d
a cleaner. Observe the appropriate
lkswsafety
agen precautionsAwhen oes
not
performing this work. d byV
o gu
a
e ran
ris tee
utho or
WARNING ss
a ac
ce
le
un
pt
Glass which has just been installed should not be pressed out‐
an
d
itte
y li
wards whilst cleaning from inside of vehicle.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
D 002 000 10.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
2 Front door windows
2.1 Tools
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Front door windows 193

Golf 2004 ➤
2.2 Assembly overview - front door window
Note

♦ The bolt -4- is accessible from interior and exterior. From exterior the bolt has a right-hand thread. This
means: from exterior the bolt is removed by turning it to left, from interior the bolt is removed by turning it to
right.
1 - Door window
⇒ page 195
2 - Window guide
⇒ page 201
3 - Mounting
G. Volkswagen AG d
4 - Bolt wage
nA oes
Volks not
❑ Accessible from exteriored by gu
ara
(right-hand thread), thre‐
or
is nte
eo
move by turning anti-
au ra
c
clockwise, remove ss door
ce
le
outer panel ⇒ page 94

un
pt
an
d
itte
❑ Accessible from interior, y li

rm
ab
remove by turning it to
pe
ility
right, removing front
ot
wit
, is n
door trim ⇒ General

h re

hole
spec
Rep. Gr. 70 ; Trims, in‐

es, in part or in w
sulation; Door trims

t to the co
❑ Qty. 2
❑ 8 Nm
rrectness of i
5 - Window regulator
l purpos

⇒ page 203
nform
ercia
6 - Cover
m
❑ Qty. 2
com
tion in
r
7 - Window regulator motor

te o
thi
s
iva

do
r
rp
⇒ page 199
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
General body
agenrepairs,
AG. Volksexterior
wagen AG- Edition 04.2008
do
w es n
olks ot g
byV ua
2.3 Removing and installing door window ho
ris
ed ran
tee
t or
au ac
ss
ce
le
Note
un
pt
an
d
itte
y li
erm
♦ The removal and installation sequence is only for the right door
ab
ility
window. The removal and installation of the left door window
ot p
wit
is similar.
is n
h re
ole,
♦ The bolt -4- is accessible from interior and exterior. From ex‐
spec
terior the bolt has a right-hand thread. This means: from
t to the co
exterior the bolt is removed by turning it to left, from interior
the bolt is removed by turning it to right.
rrectne
2.3.1 Removing
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove front door trim ⇒ General body repairs, interior; Rep.

Gr. 70 ; Trim, insulation; Door trims .
– Lever out caps -4-.
– Lower door window -1- until clamping bolts -3- for mounting
-2- are accessible.

Golf 2004 ➤
WARNING
Remove bolt -3- from interior by turning to right.
– Loosen bolts -3- (do not remove) from inside by turning to right
and press clamping jaws apart.
Note
If the work step cannot be carried out because there is a fault with the electric window motor, remove motor to
slide window down. olks
wage es n
o
yV t gu
db ara
ise nte
– Lift rear of door window -1- and swivel out of doorthforwards,
or in eo
-direction of arrow-. s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
2.3.2 Installing
ss o
– Insert door window -1- in door in -direction of arrow-.
cial p
f inform
– Ensure that door window -1- is properly located in window
mer
guides.
atio
om
n
c
i
– The bolt can now be tightened by turning to left.
or
n thi
te
sd
a

iv
o
pr
cum
r
fo
• Then check for correct operation.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2004 ➤
2.4 Adjusting door window
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva

do
r
rp

um
fo
en
ng
t.
yi Co
Cop py
t. rig
– Lower door window -1- until clamping bolts -3- for mounting
gh ht
yri by
-2- are accessible.
cop Vo
by lksw
cted agen
Prote AG.
WARNING
Remove bolt -3- from interior by turning to right.
– Loosen bolts -3- (do not remove) from inside by turning to right
and press clamping jaws apart.

Golf 2004 ➤
– Applying light pressure press door window -1- in clamping

jaws in -direction of arrow- and align door window tension free
at rear window guide.
– When doing so, ensure that door window -1- is positioned par‐
allel to window guide.
– Tighten clamping jaws by turning bolts -3- to left from interior.
Specified torque for bolt: 8 Nm.
• Then check for correct operation.
2.5 Assembly overview - window regulator motor
Note
AG. Volkswagen AG d
agen oes
1 - Window regulator motor Volksw not
gu
by ara
❑ Removing and installing rise
d
nte
⇒ page 199 utho eo
ra
s a c
s
2 - Bolt
ce
le
un
pt
❑ Qty. 3
an
d
itte
y li
❑ 3.5 Nm
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
2.6 Removing and installing window regula‐

tor motor
Note
window regulator. The removal and installation of the left door
window regulator is similar.
♦ The window regulator motor can also be removed with mount‐
ing plate when door outer panel is removed.
2.6.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Secure door window against sliding down with adhesive tape.
– Release connectors -arrows- using a screwdriver in
– Remove the three bolts -2-.

Golf 2004 ➤
– Remove window regulator motor and control unit -1- from

mounting plate.
2.6.2 Installing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Place window regulator motor -1- on and attach connectors

l purpos
-arrows-.
– Move door window lightly up and down so that the splines be‐
nf
ercia
tween motor and cable drum engage easier.

orm
m
atio
– Tighten window regulator motor bolts -2- specified torque (3.5

om
n in
Nm).
or c
thi
e
– Run window twice to upper stop and then down to lower stop.
t
sd
iva
This normalises and readies the window, it also activates the

r
rp
cu
o
pinch/roll-back function.
f
en
ng
t.
yi Co
op
Then perform remaining installation in reverse order of removal. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2004 ➤
2.7 Assembly overview - window guide
Note
olkswagen AG
en AG. V
olks
wag does
not
V gu
by a
♦ For a better representation the illustration
ris
ed is drawn without door outer panel.rante
tho eo
s au ra
c
s
ce
e
nl
1 - Window guide
pt
du
an
itte
y li
2 - Trim
erm
ab
ility
ot p
3 - Bolt
wit
, is n
h re
❑ Qty. 2
hole
spec
❑ 2 Nm
es, in part or in w
t to the co
4 - Window frame on door inner
part
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.8 Removing and installing window guide
Note
♦ The removal and installation sequence is only for the right

window guide. The removal and installation of the left window
guide is similar.
♦ For a better representation the removal and installation is
drawn without door outer panel.

Golf 2004 ➤
2.8.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Remove exterior mirror ⇒ page 227 .

r
te o
thi
s
iva
do
– Pull window guide -1- out of mounting.

r
rp
cum
fo
– Remove bolts -3- (Qty. 2) and pull trim plate -2- off in direction
en
ng
t.
yi
of B-pillar -direction of arrow-.
Co
Cop py
t. rig
gh
– Pull window guide -1- off all around window frame -4- and re‐
ht
pyri by
Vo
o
move upwards out of window slot. by c lksw
cted agen
Prote AG.
2.8.2 Installing
Note
Ensure window guide seats evenly when installing (wind noises).

Golf 2004 ➤
2.9 Assembly overview - window regulator
Note AG. Volkswagen AG d

agen oes
olksw not
yV gu
The right side isiseshown.
d b
The left side is similar. ara
nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
⇒ page 203
ility
ot p
2 - Bolt
wit
, is n
h re
❑ Qty. 4
hole
spec
❑ 8 Nm
es, in part or in w
t to the co
3 - Bolt
❑ Qty. 5 on 4-door models
rrectness of i
❑ Qty. 4 on 2-door models
l purpos
❑ 8 Nm
4 - Drive
nf
ercia
o
5 - Mounting plate
rm
m
atio
om
n in
or c
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Note

window regulator. Removal and installation of the left window
regulator is similar.
♦ The removal and installation procedures may have to be modi‐
fied slightly depending on 2 or 4-door models

Golf 2004 ➤
2.10.1 Removing
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– Remove side impact protection ⇒ page 74
– Remove door window ⇒ page 195 .
– Remove bolts -2- from mounting plate -5-.
– Remove window regulator bolts -3-.
– Remove window regulator -1- with drive -4- and window reg‐
ulator motor mounting plate -5- off door inner part.
– Disconnect window regulator motor connector ⇒ page 199
2.10.2 Installing
• Carry out functional check before installing door outer panel.

Golf 2004 ➤
3 Rear door windows
3.1 Tools
♦ Release tool -T10236-
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3. Rear door windows 205

Golf 2004 ➤
3.2 Assembly overview - rear door window
Note
1 - Door window
⇒ page 206
2 - Window guide
❑ Integral part of fixed
door window
⇒ page 209 . Volkswagen AG
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⇒ page 209 pt
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6 - Spreader plug
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❑ Always renew when

working on door window
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7 - Cover
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⇒ page 215
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⇒ page 212
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3.3 Removing and installing door window
Note
♦ The removal and installation sequence is only for the rear right
door window. The removal and installation of the rear left door
window is similar.
♦ When door outer panel has been removed the spreader pin
and spreader plug to remove door window are accessible from
exterior.

Golf 2004 ➤
3.3.1 Removing
– Remove rear door trim ⇒ General body repairs, interior; Rep.
Gr. 70 ; Trims, insulation; Door trims .
– Lower door window until spreader pin -3- and spreader plug
-4- are accessible in aperture of window regulator.
Note
If the work step cannot be carried out because there is a fault with
the electric window motor, remove motor to slide window down.
– Screw a 5 mm bolt (approx. 70 mm long) into the spreader pin

-3- and pull out from spreader plug -4-.
– Screw an 8 mm bolt (approx. 80 mm long) into spreader plug
-4-. agen
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– Pull spreader plug -4- out of clamping jaws -1- and therefore ility
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– Remove screws -2- and pull trim -1- towards B-pillar

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– Pull door window upwards -arrow- out of window slot.

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♦ When installing door window, always renew spreader plug and
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spec
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♦ Before inserting spreader plug and spreader pin check washer
t to the co
for damage.
rrectness of i
– With door window -1- removed insert spreader plug -3- in mid‐
dle - centralised.
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– Press spreader pin -2- flush into spreader plug -3-.
nf
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– Guide door window -1- into door and place door window on
or
window regulator guide mounting -4-.
m
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– With light pressure from above -arrow-, engage window -1- in

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window regulator guide -4-.
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– Then perform remaining installation in reverse order of remov‐
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Golf 2004 ➤
3.4 Assembly overview - fixed door window with window guide
1 - Window guide
❑ Component part of fixed
door window
⇒ page 209 agen
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⇒ page 209
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3.5 Removing and installing fixed door win‐

dow with window guide
Note

fixed door window with window guide. The removal and in‐
stallation of the left fixed door window with window guide is
similar.
♦ When door outer panel has been removed the spreader pin
and spreader plug to remove door window are accessible from
exterior.
3.5.1 Removing

Golf 2004 ➤
– Pull window guide -1- out of centre rib -3- and guide window
guide inwards.
– Remove bolts -2- and slide centre rib -3- downwards
-arrow a-.
– Pull centre rib -3- off fixed door window seal -arrow b-.
– Release window guide -1- with fixed door window -2- inside
and outside off window frame -4-.
– Using release tool -T 10236- release locking lugs on guide pin
-3- in window frame -4-.
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210
Prote AG.
Rep. Gr.64 - Glazing
Golf 2004 ➤
AG. Volkswagen AG d
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– Pull complete window guide -1- with fixed door window -2- off
window frame -3- in -direction of arrow-.
3.5.2 Installing
Specified torque for bolts on middle frame: 5.5 Nm
Note
When installing fixed door window with window guide ensure it is

seated uniformly (wind noise).

Golf 2004 ➤
3.6 Assembly overview - window regulator motor
Note
1 - Connector
2 - Bolt
❑ Qty. 3
❑ 3.5 Nm
⇒ page 212
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Note
window regulator. The removal and installation of the left door
window regulator is similar.
♦ The window regulator motor can also be removed with mount‐
ing plate when door outer panel is removed.

Golf 2004 ➤
3.7.1 Removing
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– Removing door trim ⇒ General body repairs, interior; Rep. Gr.

spec
es, in part or in w
70 ; Trims, insulation; Door trims .

t to the co
– Secure door window against sliding down with adhesive tape.

– Remove the three bolts -2-.
rrectness of i
– Disconnect connector -1-.

l purpos
– Remove window regulator motor and control unit -3- from

mounting plate.
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Golf 2004 ➤
AG. Volkswagen AG d
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3.7.2 Installing
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– Place window regulator motor -3- on and attach connector

-1-.
– Move door window lightly up and down so that the splines be‐
tween motor and cable drum engage easier.
– Tighten window regulator motor bolts -2-.
– Specified torque for bolts -2- 3.5 Nm
– Run window twice to upper stop and then down to lower stop.
This normalises and readies the window, it also activates the
pinch/roll-back function.
Then perform remaining installation in reverse order of removal.

Golf 2004 ➤
3.8 Assembly overview - window regulator
Note
⇒ page 215
2 - Bolt
❑ Qty. 4
❑ 8 Nm
3 - Mounting plate AG. Volkswagen AG d
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❑ Qty. 2
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❑ 8 Nm
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tor
Note
The removal and installation sequence is only for the right window
regulator. Removal and installation of the left window regulator is
similar.

Golf 2004 ➤
3.9.1 Removing
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– Remove impact protection ⇒ page 111
agen
Prote AG.

– Remove bolts -2- from mounting plate -3-.
– Remove window regulator bolts -5-.
– Remove window regulator -1- with drive -4- and window reg‐
ulator motor mounting plate -3- off door inner part.
– Disconnect window regulator motor connector ⇒ page 213
3.9.2 Installing
• Carry out functional check before installing door outer panel.

Golf 2004 ➤
66 – Exterior equipment
1 Wheel housing liner
1.1 Tools
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1. Wheel housing liner 217

Golf 2004 ➤
1.2 Assembly overview - front wheel housing liner
Note
♦ Only the left side is shown. The procedure for the right side is similar.
♦ The removal and installation procedures may have to be modified slightly depending on variations in equip‐
ment.
♦ The wheel housing liner consists of a front and a rear part.
♦ Vehicles with vermin repellent system ⇒ page 276 .
1 - Wheel housing liner rear

part
❑ Material: PP/EPDM
2 - Bolt
❑ Qty. 7
❑ 2 Nm n AG. Volkswagen AG do
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❑ Material: PP/EPDM au ac
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❑ Qty. 11
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❑ 2 Nm
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❑ Qty. 6
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1.3 Removing and installing front wheel

housing liner
Note
The removal and installation sequence is only for the left wheel
housing liner. Removal and installation of the right wheel housing
liner are similar.
218 Rep. Gr.66 - Exterior equipment

Golf 2004 ➤
1.3.1 Removing
AG. Volkswagen AG d
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Wheel housing liner rear part

– Remove wheel ⇒ Running gear; Rep. Gr. 44 ; Specified tor‐
ques for wheel bolts .
– Remove bolts -2- (Qty 7).
– Pull off rear part of wheel housing liner -1-.
Wheel housing liner front part
– Remove bolts -4- (Qty 11).
– Pull off front part of wheel housing liner -3-.
1.3.2 Installing

Golf 2004 ➤ gen AG
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General body
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1.4 Assembly overview - rear wheel housingac liner
th or e
au
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Note
itte
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Only the left side is shown. The procedure for the right side is similar.
wit
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spec
1 - Wheel housing liner
t to the co
❑ Material: PP/EPDM
2 - Bolt
rrectne
❑ Qty. 9
❑ 2 Nm
ss o
cial p
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3 - Spreader nut
inform
❑ Qty. 4
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Prote AG.
1.5 Removing and installing rear wheel

housing liner
Note
The removal and installation sequence is only for the left wheel
housing liner. Removal and installation of the right wheel housing
liner are similar.

Golf 2004 ➤
1.5.1 Removing
AG. Volkswagen AG d
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– Remove wheel ⇒ Running gear; Rep. Gr. 44 ; Specified tor‐

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– Remove bolts -2- (Qty 9). py by
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– Pull off wheel housing liner -1-.
agen
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1.5.2 Installing

Golf 2004 ➤
2 Exterior mirror
2.1 Tools n AG. Volkswagen AG do

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Special tools and workshop equipment required d byV ua
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♦ Removal lever -80-200- autho
or
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Golf 2004 ➤
2.2 Assembly overview - exterior mirror
Note
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Only the left side is shown. Thed bprocedure for the right side is similar.
o
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1 - Mirror mounting
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⇒ page 227
erm
ab
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wit
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❑ Qty. 3
h re
hole
spec
❑ 8 Nm
es, in part or in w
t to the co
3 - Assembly piece
⇒ page 226
rrectness of i
4 - Bolt
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❑ Qty. 2
❑ 1 Nm
nf
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5 - Bolt
m
atio
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❑ Qty. 2
o
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❑ 1 Nm
thi
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6 - Side turn signal

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⇒ page 226
8 - Mirror glass
⇒ page 223
9 - Mirror housing
❑ Material: ABS
⇒ page 224
2.3 Removing and installing mirror glass
Note
The removal and installation sequence is only for the left mirror
glass. The removal and installation of the right mirror glass is
similar.
WARNING
When doing this repair work, always wear protective goggles

and leather gloves!
2. Exterior mirror 223

Golf 2004 ➤
2.3.1 Removing
– Protect edge of housing -1- against paint damage with e.g.
fabric-reinforced adhesive tape.
– Press bottom of mirror glass -2- into mirror housing -1-.
– Using removal lever -80 - 200- , press mirror glass -2- off
bracket -5- and housing -1- -arrow 6-.
– Swivel mirror glass -2- to side -arrow 4- and detach connectors
-3- for electric dip and mirror heating on rear of mirror glass
-2-.
2.3.2 Installing
wage es n
– Push contacts for mirror heating onto mirror yV
o glass.
lks ot g
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– Press mirror glass centrally onto bracket
horis in housing. tee
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– Mirror glass engages audibly. ss
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2.4 Removing and installing mirror housing ab

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Note
spec
es, in part or in w
t to the co
The removal and installation sequence is only for the left mirror
housing. The removal and installation of the right mirror housing
is similar.
rrectness of i
l purpos
nform
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te o
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en
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Vo
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by
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Prote AG.

Golf 2004 ➤
2.4.1 Removing
AG. Volkswagen AG d
agen oes
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pt
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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nform
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at
om
ion
c
in t
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ate
do
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cum
for
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Prote AG.
– Remove mirror glass ⇒ page 224 .

– Insert removal wedge -3409- between mirror housing -1- and
side turn signal -2-.
– Move removal wedge -3409- in -direction of arrow a- along to
outer side of mirror.
– This releases latches for mirror housing -4- from locking hooks
-3-.
– Pull mirror housing -1- forwards off mirror mounting at front in
-direction of arrow b-.
– Remove mirror housing -1- upwards off mirror mounting in
-direction of arrow c-.

Golf 2004 ➤
2.4.2 Installing
– Place mirror housing -1- on mirror base carrier and press mir‐
ror housing down until the locking hooks -2- engage audibly.
– Install mirror glass again ⇒ page 224
AG. Volkswagen AG d
agen oes
olksw not
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2.5 Removing and installing trim th
au ra
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un
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d
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Note
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The removal and installation sequence is only for the left trim
ot
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plate. The removal and installation of the right trim plate is similar.
h re
hole
spec
es, in part or in w
2.5.1 Removing
t to the co
rrectness of i
– Remove mirror housing ⇒ page 224
l purpos
– Using a screwdriver lever locking hooks -2- out of mirror base

carrier.
nform
ercia
– Pull trim plate -1- off in -direction of arrow-.

m
a
com
tion in
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2.5.2 Installing
c by lksw
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Prote AG.

2.6 Removing and installing side turn sig‐

nals
Note
♦ The removal and installation sequence is only for the left side
mounted turn signal. The removal and installation of the right
side mounted turn signal is similar.
♦ There are no conventional bulbs but rather durable light emit‐
ting diodes (LEDs) installed in the side turn signals.
♦ Therefore, changing bulbs is not necessary. In case of dam‐
age, the entire turn signal must be renewed.

Golf 2004 ➤
2.6.1 Removing
– Remove mirror housing ⇒ page 224
– Remove trim ⇒ page 226 .
– Remove bolts -4- and remove assembly piece -1- downwards.
– Detach connector -5- from turn signal -3-.
– Remove bolts -2- and take turn signal -3- off assembly piece
-1-.
AG. Volkswagen AG d
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2.6.2 Installing
s
ce
le
un
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an
d

itte
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rm
ab
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ility
ot
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2.7 Removing and installing exterior mirror
h re
hole
spec
es, in part or in w
t to the co
Note
The removal and installation sequence is only for the left exterior
rrectness of i
mirror. The removal and installation of the right exterior mirror is
similar.
l purpos
2.7.1 Removing
nform
mercia
– Remove front door trim on driver side ⇒ General body repairs,
a
com
tio
interior; Rep. Gr. 70 ; Trims, insulation; Removing and instal‐
n in
r
ling front door trim on driver side .

te o
thi
s
iva
do
– Release cable retainer -2- and detach connector -1- for exte‐
r
rp
cum
rior mirror.
fo
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t.
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co Vo
by lksw
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Prote AG.
– Lever cap -3- out of door and remove bolts -2-.

– Remove exterior mirror -1- and guide wire through aperture in
door.

Golf 2004 ➤
2.7.2 Installing
– Specified torque for exterior mirror bolts: 8 Nm
• Test function before installing door trim.
AG. Volkswagen AG d
agen oes
olksw not
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aut ra
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nl
pt
du
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hole
spec
es, in part or in w
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rrectness of i
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nf
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orm
m
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n in
or c
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Prote AG.

AG. Volkswagen AG d
agen oes Golf 2004 ➤
olksw not
V
d by General body repairs, guexterior -
ara Edition 04.2008
rise nte
tho eo
au ra
s c
3 Radiator grille s
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3.1 Tools
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ility
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hole
spec
es, in part or in w
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3.2 Assembly overview - radiator grille
en
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t.
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1 - Radiator grille cop Vo
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❑ Material: ASA Prote AG.
2 - Retaining hook
❑ Qty. 6
3 - VW emblem
❑ Clipped into radiator
grille
❑ Only remove when the
radiator grille is re‐
moved
❑ Removing: release lock‐
ing hooks on rear of VW
emblem with radiator
grille removed.
❑ Installing: guide VW em‐
blem with locking hooks
into recesses in radiator
grille -arrow b-, then turn
slightly in direction of
-arrow c- until VW em‐
blem engages in radia‐
tor grille.
4 - Bolt
❑ Qty. 2
❑ 2 Nm
3. Radiator grille 229

olkswagen AG
en AG. V
Golf 2004 ➤ ksw
ag does
not
Vol
ed by exterior - Edition 04.2008 gu
ara
ris nte
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ra
3.3 Removing and installing radiator grille
ss
a c
ce
e
nl
pt
du
an
itte
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3.3.1 Removing
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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t.
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Cop py
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Prote AG.

– Release clips -arrows- on lock carrier using a small screw‐
driver.
– Tilt radiator grille -1- backwards slightly and pull locking hooks
-2- upwards out of bumper cover.

lkswage es n
uGolf
ara 2004 ➤
o ot g
byV
d
ir se General body repairs, exterior - Edition nte04.2008
tho eo
au ra
ss c
3.3.2 Installing
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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Prote AG.
– With radiator grille-1- tilted forward slightly place locking hooks

-2- in the bumper cover.
– Clip radiator -1- to lock carrier and engage clips -arrows- in
lock carrier.
– Install bolts -4-.
3.4 Assembly overview - radiator grille for

GTI, GTI special models and GT
Note

♦ The radiator grilles for the Golf GT and the Golf GTI differ only
in their appearance.
♦ The radiator grille for the Golf GTI has a honeycomb pattern,
the radiator grille for the Golf GT has transverse pieces.

Golf 2004 ➤
1 - Radiator grille
❑ Different appearance
for Golf GT and Golf GTI
❑ Material: ASA
2 - Bolt
❑ Qty. 2
❑ 2 Nm
3 - Decorative trim
❑ Only for Golf GTI
❑ Engaged in radiator
grille
4 - Spreader rivet
❑ Qty. 4
AG. Volkswagen AG d
❑ Secured to radiator ksw
agen oes
not
l
grille with spreader clips byV
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ara
ed
❑ For radiator grille with horis nte
eo
no securing holes s aut ra
c
⇒ page 235 s
ce
e
nl
pt
du
6 - VW emblem
an
itte
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erm
ab
ility
grille
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, is n
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hole
spec
moved
es, in part or in w
t to the co
❑ Removing: release lock‐
ing hooks on rear of VW
emblem with radiator
rrectness of i
grille removed.
❑ Installing: guide VW em‐
l purpos
blem with locking hooks

into recesses in radiator grille -arrow b-, then turn slightly in direction of -arrow c- until VW emblem
nf
ercia
engages in radiator grille.
orm
m
7 - Front GTI lettering

atio
om
n in
❑ Engaged in radiator grille
or c
thi
e
❑ Only remove when the radiator grille is removed

t
sd
iva
o
r
❑ Unhook locking hooks from rear

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8 - Bolt
t.
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9 - Retaining hook
❑ Qty. 2
10 - Guide hook
❑ Qty. 4

Golf 2004 ➤
3.5 Removing and installing radiator grilleagen

AG. Volkswagen AG d
oes
for GT, GTI special models and
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olksw not
gu
ar
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ris tee
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Note ss
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nl
pt
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an
The radiator grilles for the Golf GT and the Golf GTI differ only in
itte
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their appearance.
erm
ab
ility
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3.5.1 Removing
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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t.
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Prote AG.
– Remove bolts -3- and -6-.

– Loosen locking hooks -2- and -4-.
– Lift radiator grille -1- up -arrow a- out of guide hooks -5-.
– Tilt upper edge of radiator grille forwards -arrow b-.
– Pull radiator grille out of bumper cover -arrow c-.

Golf 2004 ➤
3.5.2 Installing
lkswage es n
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d ran
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ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Insert lower edge of radiator grille horizontally into bumper

cover -arrow c-.
– Fold radiator grille upwards -arrow b-.
– Guide radiator grille into guide hooks -5- from above
-arrow c-.
Locking hooks -2- and -4- engage audibly.
– Tighten bolts -3- and -6-, specified torque: 2 Nm.

Golf 2004 ➤
3.6 Radiator grille for GTI, GTI special models, GT and R32 - number plate
carrier
1 - Radiator grille
❑ With no securing holes.
❑ For various countries AG. Volkswagen AG d
agen oes
❑ Observe country specif‐ olksw not
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ic legislative dimensions rise
d b ara
nte
o eo
❑ Installing auth
ra
ss c
– Align number plate car‐
ce
e
nl
pt
rier -3-, mark position of
du
an
itte
holes and drill-out
y li
erm
ab
ility
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– Secure number plate
wit
, is n
carrier with clips
h re
hole
spec
3 - Centre line
es, in part or in w
t to the co
4 - Clip
❑ Qty. 4
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
3.7 Assembly overview - radiator grille for R32
1 - Radiator grille
❑ Material: ASA
❑ Removing:
❑ Removing: ⇒ page 237
3 - Bolt
❑ Qty. 6 per side
❑ 1 Nm
4 - Bolt
❑ Qty. 4
❑ 2 Nm
❑ Secured to radiator
grille with spreader clips
❑ For radiator grille with
no securing holes n AG. Volkswagen AG do
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⇒ page 235 by
Volk ot g
ua d ran
se
6 - Spreader rivet tho
ri tee
or
au ac
❑ Qty. 4 ss
ce
le
un

pt
an
d
itte
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erm
ab
ility
ot p
8 - VW emblem
wit
is n

h re
ole,
grille
spec

t to the co

moved
rrectne
9 - R32 front lettering

ss

o
cial p
f i
❑ Only remove when the radiator grille is removed

nform
mer

atio
om
10 - Decorative trim
n
c
i
or
n thi

te
sd
iva
o
pr
11 - Bolt
um
r
fo
en
ng
❑ Qty. 2
t.
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op py
❑ 1 Nm t. C rig
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12 - Bumper cover
co Vo
by lksw
cted agen
Prote AG.

Golf 2004 ➤
agen General
AG. Volkswagen AG d
oesbody repairs, exterior - Edition 04.2008
olksw not
y V gu
db ara
3.8 Removing and installing radiator grille horise nte
eo
ut
for R32 ss a ra
c
ce
e
nl
pt
du
an
itte
y li
3.8.1 Removing
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Remove bolts -4- and pull air grilles -3 and 6- in

-direction of arrow a- and out of retaining clips in bumper cover.
– Remove bolts -5, 8 and 7-.
– Release locking hooks -arrow b- and pull radiator grille -1- out
of side locking devices -2- in bumper cover.

Golf 2004 ➤
3.8.2 Installing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
– Place radiator grille -1- in bumper cover.

o
n
c
i
or
– The side locking devices and locking hooks -7- must engage
thi
te
sd
a
audibly.
iv
o
pr
cum
r
fo
– Tighten bolts, specified torque for bolts -2- and -5-: 2 Nm and
en
ng
t.
bolt -8-: 1 Nm.
yi Co
Cop py
t. rig
– Press air grilles -3 and 6- into bumper cover. gh ht
pyri by
Vo
co lksw
by
– Tighten bolts, specified torque for bolt -4-: 1 Nm. Prote
cted AG.
agen

Golf 2004 ➤
3.9 R32 radiator grille - company emblem
1 - VW emblem
❑ Removing:
– Release locking lugs
-arrow c-
❑ Installing:
– Position company em‐
blem -arrow a- and turn
in -direction of arrow b-
2 - R32 lettering
❑ Removing:
– Release locking lugs agen
AG. Volkswagen AG d
oes
-arrow d- olksw not
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❑ Installing: horis
eo
aut ra
– Press into mounting in ss c
ce
le
radiator grill until the

un
pt
locking lugs -arrow d-
an
d
itte
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engage
erm
ab
ility
ot p
3 - Radiator grille
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

Golf 2004 ➤
4 Mouldings and trims
4.1 Tools
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
♦ Hot air blower -V.A.G 1416- ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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Vo
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cted agen
Prote AG.

Golf 2004 ➤
4.2 Assembly overview - water deflector
Note

AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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1 - Water deflector hor eo
aut ra
2 - Retaining strip ss c
ce
le
un
pt
3 - Pop rivet
an
d
itte
y li
❑ Qty. 5
rm
ab
pe
ility
4 - Clip
ot
wit
, is n
h re
5 - Bracket
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
4. Mouldings and trims 241

Golf 2004 ➤
4.3 Removing and installing water deflector
4.3.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
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h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
– Lever water deflector -1- out of retaining strip -2- starting at

te
sd
a
top.
iv
o
pr
cum
r
fo
– Pull clip -4- out of retainer -5- in lower area of wing.

en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Golf 2004 ➤
4.3.2 Installing
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
– Attach clip -4- in retainer -5-.

ion
c
in t
or
– Press water deflector -1- into retaining strip -2- from bottom to
his
ate
top.
do
priv
cum
for
en
ng
t.
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Cop py
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Prote AG.

Golf 2004 ➤
4.4 Assembly overview - protective side strips

lkswage es n
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Note ir se
d b ran
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th or
u
Only the left side is shown. The proceduress for the right side is similar.
a ac
ce
e
nl
pt
du
an
itte
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erm
1 - Front door protective side
ab
ility
strip ot p
wit
, is n
h re
hole
❑ Self-adhesive
spec
es, in part or in w
❑ Left and right protective
t to the co
side strips have different
hole patterns
rrectness of i
2 - Side panel protective side
strip
l purpos
❑ Self-adhesive
nform
ercia
❑ Left and right protective

m
at
side strips have different
om
io
hole patterns
n
c
in t
or
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ate
do
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for
en
ng
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Prote AG.

Golf 2004 ➤
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4.5 Renewing side protective mouldings ol ot g
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a ac
ss
Note
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un
pt
an
d
itte
♦ Installation is only described for the left side. The procedure for the right side is similar.
y li
erm
ab
ility
♦ Remove protective backing immediately before installation. Working temperature approx. 21 °C
ot p
wit
is n
♦ Curing time after attaching side protective strips is about 4 hours at a room temperature of about 21° C.
h re
ole,
spec
t to the co
♦ The side protective strips must be bonded in place immediately after cleaning.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Before removing, heat protective side strips -1- and -2- with a
hot air blower -V.A.G 1416- and pull protective side strips off.
mover -VAS 6349- .
– Immediately before bonding the side protective strips, clean
bonding surface thoroughly with adhesive remover D 002 000
10.

Golf 2004 ➤
– Only remove protective backing from side protective strips

-1- and -2- immediately before fitting.
• Bonding surfaces must be free of dust and grease.
– Position protective side strips -1- and -2- on vehicle and press
on using force.
4.6 Removing and installing stone-chip pro‐

tection trim
4.6.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Guide a small screwdriver through the opening on the bottom

nform
ercia
edge of the side trim and release the locking device -2-, by
pressing the screwdriver upwards -arrow a-.
m
at
om
io
– Slide stone chip protection trim -1- forwards -arrow b- until the
n
c
in t
or
screwdriver contacts the securing screw -3-. Now pull screw‐

his
ate
driver out. Slide stone-chip protection trim further until the

do
riv
stone-chip protection trim can be removed from all securing

p
cum
for
screws.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
246
AG.
Rep. Gr.66 - Exterior equipment
Golf 2004 ➤
4.6.2 Installing
Note
♦ The stone-chip protection trim securing screws are corrosion-

resistant. No further secondary treatment is required.
♦ If a screw is overtightened, it is essential to replace it with a
“black” oversize screw.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
• There are no pre-drilled holes for the securing screws.

r
rp
cum
fo
en
– Measure holes according to the table below.

ng
t.
yi Co
op py
– Mark holes for securing screws with centre punch.
. C rig
ht ht
rig by
py
– Drill out holes with a 1.5 mm drill bit.
co Vo
by lksw
cted agen
Prote AG.

Golf 2004 ➤
Note
♦ Dimension -a- is measured including wheel housing liner -2-. The other dimensions -b through i- are always
measured from the centres of the holes.
♦ Dimension -k- can only be measured on 4-door vehicles.
♦ For two-door vehicles, determine dimension -k- in height to the front holes.
The table follows. AG. Volkswagen AG d

agen oes
olksw not
byV gu
Dimension -a- = 855 mm rised ara
nte
o eo
Dimension -b- = 822autmm
h
ra
ss c
Dimension -c- = 617 mm
ce
le
un
pt
Dimension -d- = 411 mm
an
d
itte
y li
Dimension -e- rm = 205 mm
ab
pe
ility
Dimension -f- = 205 mm
ot
wit
, is n
Dimension -g- = 411 mm
h re
hole
spec
Dimension -h- = 617 mm
es, in part or in w
Dimension -i- = 822 mm
t to the co
Dimension -k- = 35 mm
rrectness of i
That was the table.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2004 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
• If all securing screw holes are pre-drilled.

– Screw in self-tapping screws -2- with cordless drill/driver -VAS
nform
ercia
5036- , using the highest speed, until the screw takes hold.
Remove cordless drill/driver from head of screw immediately.
m
at
om
ion
– Tighten screws using lowest torque setting (so that screws are
c
in t
or
not overtightened).
his
ate
do
riv
– Position openings on back of stone-chip protection trim -1-

p
cum
or
evenly -arrow a- over all securing screws -2- until stone-chip

f
en
ng
t.
yi
protection trim contacts side member -3-.
Co
Cop py
t. rig
Use a second mechanic to ensure that all securing screws remain
gh ht
pyri by
in openings when sliding stone-chip protection trim.
o Vo
by c lksw
cted agen
Prote AG.
– Slide stone-chip protection trim forcibly to rear -arrow b- to
stop.

Golf 2004 ➤
4.7 Assembly overview - side member extension for GTI, GTI special models
and R32
1 - Side member extension

2 - Bolt
❑ Side member extension
to bracket
❑ Qty. 4
❑ 2 Nm
3 - Bolt
❑ Retaining strip to side
skirts
❑ Qty. 9
❑ 1.2 Nm agen
AG. Volkswagen AG d
oes
olksw not
❑ Installing ⇒ page 254db
yV gu
ar
e an
ris tee
4 - Retaining strip utho or
a ac
❑ Removing ⇒sspage 253 ce
e
nl

pt
du
an
itte
y li
5 - Sill
erm
ab
ility
ot p
6 - Bracket
wit
, is n
h re
❑ Secured to underbody
hole
with spreader clip

spec
es, in part or in w
t to the co
7 - Adhesive tape
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2004 ➤
4.8 Removing and installing side member

extension for GTI, GTI special models
and R32
4.8.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
– Before removing, heat side member extension -1- in bonding
cted agen
Prote AG.
surface area -4- with hot air blower -V.A.G 1416- .
– Loosen adhesive tape -4- by carefully inserting a plastic
wedge -5- between side member -3- and side member exten‐
sion -1-.
– As soon as adhesive tape comes loose, lift side member ex‐
tension -1- up -arrow- out of retaining strip.

Golf 2004 ➤
4.8.2 Installing
Note
♦ Installation is only described for the left side. The procedure for the right side is similar.
♦ Remove protective backing immediately before installation. Working temperature approx. 21 °C
♦ Curing period after side member extensions are attached is about 4 hours at a room temperature of about
21 °C.
♦ Adhesive remover -D 002000 10- and cleaning solution -D 009 401 04- must be used exclusively.
Volkswa
♦ Bonding surfaces must beswfree
agenof dust and grease.
AG. gen AG
does
k not
Vol g
♦ The side memberisextensions
ed
by must be bonded in place immediately
ua
ran after being cleaned.
r tee
ho
aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
• Retaining strip is installed ⇒ page 253 .

– Immediately before bonding side member extension, clean
bonding surfaces thoroughly with adhesive remover -D
002000 10- and cleaning solution -D 009 401 04- .

Golf 2004 ➤
– Position side member extension -1- from above -arrows- even‐

ly into retaining strip -3- and press side member extension into
retaining strip until the two parts engage.
– Now pull protective films -2- on side member extension -1- off
upwards and backwards.
– Only now remove film -4- and press side member extension
-1- on forcefully in bonding area.
– Tighten bolts -5-, beginning with front bolt on wing.
4.9 Retaining strip for side member exten‐

sion
4.9.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
• Side member extension removed ⇒ page 251

– Push retaining strip -1- in direction of travel -arrows- from fas‐
tening bolts -3- and remove from side skirts -2-.

Golf 2004 ➤
4.9.2 Installing
Note
♦ The securing screws for the retaining strip are corrosion-re‐

sistant. No further secondary treatment is required.
♦ If a screw is overtightened, it is essential to replace it with a
“black” oversize screw.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
• There are no pre-drilled holes for the securing screws.
– Measure holes according to the table below.
– Mark holes for securing screws with centre punch.
– Drill out holes with a 1.5 mm drill bit.

Golf 2004 ➤
Note
♦ Dimension -a- is measured including wheel housing liner -2-. The other dimensions -b through i- are always
measured from the centres of the holes.
♦ Dimension -k- can only be measured in rear area on 4-door vehicles.
♦ For two-door vehicles, determine dimension -k- in height to the front holes.
The table follows.

Dimension -a- = 855 mm
Dimension -b- = 822 mm
Dimension -c- = 617 mm
Dimension -d- = 411 mm
Dimension -e- = 205 mm
Dimension -f- n AG. Volkswagen AG d = 205 mm
wage oes
Dimension -g- olks not
db
y V gua = 411 mm
se ran
Dimension -h- tho
ri =te617
e o mm
u r
Dimensionss -i-
a = 822acmm
ce
e
Dimension -k- = 37 mm
nl
pt
du
an
itte
That was the table. y li

erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2004 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
• If all securing bolt holes are pre-drilled ⇒ page 254 .

– Screw in self-tapping screws -3- with cordless drill/driver -VAS
5036- , using the highest speed, until the screw takes hold.
Remove cordless drill/driver from head of screw immediately.
– Tighten screws using lowest torque setting (so that screws are
not overtightened).
– Position openings on back of retaining strip -1- evenly
-arrows a- over all securing bolts -2- until retaining strip con‐
tacts side skirts -2-.
So that all securing bolts remain in the apertures when sliding on,
position retaining strip with a second mechanic.
– Slide retaining strip to rear -arrow b- on to stop.

Golf 2004 ➤
5 Roof edge spoiler
5.1 Tools

equipment required
♦ Removal kit for flush bon‐
ded windows -
V.A.G 1474 A-
♦ Suction lifter -V.A.G 1344-
♦ Cutting tool -V.A.G 1351- AG. Volkswagen AG d
agen oes
olksw not
♦ Windscreen removal kit - d byV gu
ara
V.A.G 1755- orise nte
eo
h
ut ra
♦ Hand-cartridge gun - ss a c
V.A.G 1628-
ce
e
nl
pt
du
an
♦ Cartridge heater -
itte
y li
erm
V.A.G 1939-
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
5.2 Materials
♦ 1K window adhesive -DH 009 100 03-
♦ Activator -D 181 801 A1-
♦ Primer -D 009 200 02-
♦ Cleaning solution -D 009 401 04-
♦ Primer applicator -D 009 500 25-
♦ Adhesive remover -D 002 000 10-
♦ Cutting cord -357 853 999 A-
5. Roof edge spoiler 257

Golf 2004 ➤
Note
Observe instructions for use on the information sheet provided by

the manufacturer.
Use double cartridge gun -VAS 5237- to apply two-component

AG. Volkswagen AG d
adhesives. lksw
agen oes
n o ot g
yV ua
Heat one-component window adhesive according ise
db to manufactur‐ ran
er's instructions, using cartridge heateruth-V.A.G
or 1939A- . tee
or
sa ac
Small cartridge, 110 ml, for sealing and/or
s when a 400 ml car‐
ce
e
tridge alone is not sufficient.

nl
pt
du
an
itte
y li
5.3 Assembly overview - roof spoiler for GTI, GTI special models and R32
erm
ab
ility
ot p
wit
, is n
h re
1 - Rear lid
hole
spec
2 - Primer area
es, in part or in w
t to the co
❑ For adhesive bead on
retaining strip
❑ Position of primer area
rrectness of i
must be transferred
l purpos
from indentation for ad‐

hesive bead in retaining
strip
nform
ercia
3 - Primer area
m
at
om
❑ For adhesive bead on
ion
c
roof spoiler
in t
or
his
te
❑ Position of primer area

a
do
riv
must be transferred
p
cum
or
from roof spoiler

f
en
ng
t.
yi Co
op
4 - Retaining strip C py
t. rig
gh ht
yri
❑ With indentation for ad‐ p by
o Vo
by c
hesive bead, bead cross
lksw
cted agen
Prote
section: width = 6 mm;
AG.
height = 10 mm
❑ Installation instructions
⇒ page 264
5 - Foam strip
❑ Self-adhesive
❑ Before installing roof
spoiler, check foam strip
for damage and renew if
necessary
6 - Adhesive tape
❑ Two strips for securing
roof spoiler at sides
7 - Bonding surface
❑ Marked in inner part of roof spoiler
8 - Roof edge spoiler
❑ Material PC/PET

Golf 2004 ➤
❑ Installation instructions ⇒ page 264 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
5.4 Removing and installing roof spoiler for
h
aut ra
ss c
GTI, GTI special models and R32
ce
e
nl
pt
du
an
itte
y li
erm
ab
5.4.1 Removing
ility
ot p
wit
, is n
h re
WARNING hole
spec
es, in part or in w
t to the co
Clean all surrounding parts before beginning work and mask
them with tape.
rrectness of i
Do not use cutting wire to remove the roof spoiler.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Thread cutting thread -6- in between rear lid -1- and roof spoil‐
er -4-.
– Using both handles -5- in “sawing” movements, separate ad‐
hesive tape -2- and adhesive bead -3- on one side.

Golf 2004 ➤
– Repeat adhesive tape and adhesive bead separation on the

other side.
Note
The middle hook is present only on vehicles from 02.05.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Push several wedges -3409- between rear lid -1- and roof
spoiler -arrows a- until all hooks -2- are released. A clear click
can be heard.
The hooks on the sides are -dimension c- = 260 mm and
-dimension d- = 400 mm from the centre.
– Reach between roof spoiler and rear lid, press roof spoiler
-3- forcefully against rear lid and release roof spoiler upwards
-arrows b- from fasteners -4- of retaining strip.

Golf 2004 ➤
5.4.2 Installing
Note
Check all hooks for damage and renew the roof spoiler if necessary.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
• Retaining strip -6- installed ⇒ page 263 .

en
ng
t.
yi Co
op
• Brake light in roof spoiler is installed ⇒ Electrical system; Rep. C py
t. rig
Gr. 94 ; Lights, bulbs, switches - exterior; Auxiliary brake
gh ht
pyri by
lights; High level brake light bulb - M 25 - removed and instal‐
co Vo
by lksw
cted
led, Golf GTI .
agen
Prote AG.
• Areas on roof spoiler -3- and rear lid -2- have been primed.
– Apply adhesive bead onto primed area -3- on roof spoiler.
– Place roof spoiler -5- onto retaining strip -6-.
– Align roof spoiler -5- with rear lid -1- and press roof spoiler into
retaining strip detents.
– With new roof spoilers, now pull protective film off from adhe‐
sive tape -4- and firmly press roof spoiler onto rear lid.

Golf 2004 ➤
– If roof spoilers are re-used, secure corners of roof spoiler to

rear lid with commercially available adhesive tape.
5.5 Retaining strip
5.5.1 Removing retaining strip
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
• Roof spoiler is removed ⇒ page 259 .

nf
ercia
orm
– Separate adhesive bead -2- using cutting thread and handles.

m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
5.5.2 Installing retaining strip
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
• Bonding areas -2- on retaining strip and rear lid have been
an
itte
y li
primed.
erm
ab
ility
ot p
– Apply adhesive bead to retaining strip recess.

wit
, is n
h re
– Align retaining strip -4- with original cut-out for brake light -3-.
hole
spec
– Secure retaining strip with commercially available adhesive

es, in part or in w
t to the co
tape.
5.6 Preparing body kit component for bond‐

rrectness of i
ing
l purpos
Note
nf
ercia
orm
Remaining material serves as adhesion base for newly applied

m
atio
m
adhesive sealing compound. Keep dirt and grease off of bonding

o
n in
c
surfaces.
or
thi
te
sd
iva
o
r

rp
cu
o
m
f

en
ng
t.
yi
tivator -D 181 801 A1- .
Co
Cop py
t. rig
gh ht
yri by
263
op Vo
by c lksw
Prote
cted AG.
agen 5. Roof edge spoiler
Golf 2004 ➤
WARNING
Activator must not have contact with paint or the paintwork will agen AG. Volkswagen AG do
be damaged. Vol
ksw es n
ot g
y ua
db ran
rise tee
tho or
au ac
ss
ce
le
Note
un
pt
an
d
itte
y li
If the body kit part has been repaired or partially renewed, the
erm
ab
ility
area concerned must be cleaned and primed again after painting.
ot p
wit
is n
h re
ole,
5.7 Installation instructions
spec
The surfaces to be primed for the body kit parts should be com‐
t to the co
pletely clean.
– Adhesive residue should be removed using adhesive remover
rrectne
-D 002 000 10- .
– Soak cloth in silicon remover -LSE 020 100 A3- .
ss o
cial p
f
– Clean area of application for adhesive bead twice thoroughly
inform
using cloth applied with solution and allow to dry.
mer
atio
– Now apply primer using applicator -D 009 500 25- equally in
om
n
one stroke.
c
i
or
n thi
te
sd
♦ Drying time approx. 10 minutes
iva
o
pr
cum
r
– Adhesive material should be applied to the primed areas of the

fo
en
ng
body kit parts.

t.
yi Co
Cop py
t. rig
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WARNING
op Vo
by c lksw
cted agen
Prote AG.
Body kit parts should be installed within 10 minutes, or bonding
properties of adhesive will be impaired.
♦ Gap dimensions should be kept to an absolute minimum, up

to approx. 1 mm.
♦ Use adhesive tape to secure body kit part in position while
curing.

The minimum curing time for newly bonded attaching parts is 3
hours.
The minimum curing time is the period between bonding the ac‐
cessory parts to installation. During this time, the vehicle must
stand on a level surface at room temperature (at least 15 °C).
WARNING

completed.
5.9 Touching up paint damage

Paint structure must be restored according to specifications in the
“Paint” workshop manual.

Golf 2004 ➤

material
– Use of adhesive remover -D 002 000 10- as a cleaning solution
is recommended. Observe the appropriate safety precautions
when performing this work.
cloth. Remove residue using adhesive remover -D 002 000
10- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
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un
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an
d
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ility
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
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fo
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Vo
o
by c lksw
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Prote AG.

Golf 2004 ➤
6 Protective backing
6.1 Attachment notes for protective backing
Note
♦ Before removal, heat the scuff protection film with a hot air
blower -V.A.G 1416- .
♦ Use only adhesive remover -D 002 000 10- to remove residual
adhesive.
♦ Ensure that the adhesive surfaces are free of dust and grease.
♦ Bond scuff protection film immediately after cleaning.
♦ Pull protective film off only directly prior to installation.
♦ The working temperature is approx. 21 °C.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
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un
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d
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pe
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
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tion in
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co lksw
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Prote AG.

Golf 2004 ➤
6.2 Renewing scuff protection film
Note
Renewing scuff protection films is described only for the left side. The right side is similar.
lkswage es n
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byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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r
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t.
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co lksw
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Prote AG.
Removing
– Removing inner seal for front door in area of side member
⇒ page 75 or inner seal for rear door ⇒ page 114
– Heat scuff protection film at the font -1- or at the rear -3- using
a hot air blower -V.A.G 1416- and pull scuff protection film from
sill.
Installing
– Clean installation area with adhesive remover -D 002 00 10- .
– Pull off protective film -2-.
– Position scuff protection film at the front -1- or at the rear -3-
on the references points -arrows- and press it smooth using a
plastic blade wrapped in a soft paper towel.
6. Protective backing 267

Golf 2004 ➤ . Volkswage
General body repairs, exterior w gen AG 04.2008n AG doe
- aEdition
olks s no
yV t gu
db ara
rise nte
tho eo
7 Lettering ss au ra
c
ce
e
nl
pt
du
an
itte
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7.1 Tools
erm
ab
ility
ot p
wit
, is n
h re
♦ Hot air blower -V.A.G 1416-
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
at
om
ion
c
in t
or
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ate
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riv
7.2 Installation instructions for lettering and

p
cum
for
emblems
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ng
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Note
c by lksw
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Prote AG.
♦ Before removal, heat the lettering or the emblem with a hot air
blower -V.A.G 1416- .
♦ Use only adhesive remover -D 002 000 10- to remove residual
adhesive.
♦ Ensure that the adhesive surfaces are free of dust and grease.
♦ Bond lettering or emblem immediately after cleaning.
♦ Pull protective film off only directly prior to installation.
♦ The working temperature is approx. 21 °C.

Golf 2004 ➤
AG. Volkswagen AG d General body repairs, exterior - Edition 04.2008
agen oes
olksw not
y V gu
7.3 Rear lettering dimensions
d b ara
rise nte
tho eo
au ra
ss c
1 - Dimension a = 50 mm
ce
le
un
pt
an
d
❑ From outer edge of rear
itte
y li
lid to lettering
rm
ab
pe
ility
2 - Dimension b = 90 mm
ot
wit
, is n
h re
❑ From lower edge of rear
hole
lid to lower edge of let‐
spec
es, in part or in w
tering
t to the co
3 - Lettering
❑ Model designation
rrectness of i
4 - Lettering
l purpos
❑ Engine designation
nform
mercia
a
com
tion in
r
te o
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Prote AG.
7. Lettering 269
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
ise nte
Golf 2004 ➤ thor eo
u ra
ss a exterior - Edition 04.2008 c
ce
e
nl
pt
du
7.4 Rear lettering dimensions for GTI and R32
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
lid to lettering
es, in part or in w
t to the co
rrectness of i
tering
l purpos
3 - Lettering
nf
ercia
orm
m
atio
om
n in
or c
thi
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t.
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t. rig
gh ht
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co lksw
by
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Prote AG.

AG. Volkswagen AG d Golf 2004 ➤
agen oes General body repairs, exterior - Edition 04.2008
olksw not
byV gu
ara
ed
ris nte
7.4.1 aut
ho Rear lettering dimensions for GTI special models eo
ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
lid to lettering
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
tering
3 - Lettering
rrectness of i
l purpos
nf
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orm
m
atio
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n in
or c
thi
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Prote AG.
7. Lettering 271
Golf 2004 ➤
7.5 Rear lettering dimensions - USA
lid to lettering
tering
3 - Dimension c = 15 mm
❑ From emblem to letter‐
ing
AG. Volkswagen AG d
agen
4 - Lettering “Rabbit” olksw
oes
not
byV gu
ara
d
5 - Lettering orise nte
eo
h
aut ra
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an
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rrectness of i
l purpos
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tion in
r
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Prote AG.

Golf 2004 ➤
7.6 Side lettering dimensions - Individual
7.6.1 Dimensions of emblem, left wing
❑ Transfer the
-dimension a - from the
underside of the wing to
the wing.
❑ Transfer -dimension b-
from end point of dimen‐
sion a to end point of
emblem.
3 - Dimension c = 70 mm AG. Volkswagen AG d
agen
❑ Use -dimension c- to Volksw
oes
not
gu
check distance from up‐ ed by ara
nte
per edge of emblem tothoris
eo
the edge of wing. s au ra
c s
ce
e
4 - Dimension d = 92 mm
nl
pt
du
an
❑ Use -dimension d- to
itte
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erm
check distance from
ab
ility
lower edge of emblem to
ot p
wit
edge of wing.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
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for
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Cop py
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rig ht
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Prote AG.
7. Lettering 273
Golf 2004 ➤
7.6.2 Dimensions of emblem, right wing
❑ Transfer the
-dimension a - from the
underside of the wing to
the wing.
2 - Dimension b = 30 mm agen
AG. Volkswagen AG d
oes
olksw not
❑ Transfer -dimension b- d by
V gu
ara
from end point of orise nte
eo
-dimension a- to corner aut
h
ra
point of emblem. ss c
ce
e
nl
pt
3 - Dimension c = 86 mm
du
an
itte
y li
❑ Use -dimension c- to
erm
ab
check distance from up‐
ility
ot p
per edge of emblem to
wit
, is n
the edge of wing.
h re
hole
spec
4 - Dimension d = 92 mm
es, in part or in w
t to the co
❑ Use -dimension d- to
check distance from
lower edge of emblem to
rrectness of i
edge of wing.
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
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cum
for
en
ng
t.
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Cop py
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Prote AG.

Golf 2004 ➤
7.6.3 Dimensions of R-line emblem
Note
♦ The dimensions of the R-line emblem are described only for the left side. The right side is similar.
♦ The dimensions -b- and -c- indicate the inclination of the logo. The logo must be bonded parallel to the lower
edge of the wing.
❑ From lower edge of wing
to corner point of em‐
blem
AG. Volkswagen AG d
❑ From rear lower wing agen oes
olksw not
corner to -dimension a- d by
V gu
ara
ise nte
r
3 - Dimension c = 510 mm ut
ho eo
ra
s a c
❑ From front lower wing s
ce
le
corner to corner point of

un
pt
an
emblem
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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t.
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Prote AG.
7. Lettering 275
Golf 2004 ➤
8 Vermin repellent system

Volkswagen Individual optional equipment
8.1 Assembly overview - vermin repellent system
Note
♦ The items 2 to 5 are also installed on the passenger side.

♦ The system prevents access for vermin. n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
1 - Protective part for vermin utho
or
repellent system ss
a ac
ce
❑ Various versions de‐ e
nl
pt
du
pending on engine type
an
itte
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erm
ab
2 - Bolt
ility
ot p
❑ Qty. 2
wit
, is n
h re
❑ 2 Nm
hole
spec
❑ 5 x 20
es, in part or in w
t to the co
3 - Upper protective part for
vermin repellent system
❑ Material: PP (polypropy‐
rrectness of i
lene) in brush form
l purpos
4 - Front protective part for ver‐

min repellent system
nform
ercia
m
lene) in brush form
at
om
io
❑ With 3 speed nuts
n
c
in t
or
his
e
5 - Bolt
at
do
priv
c
❑ Qty. 3
um
for
en
ng
❑ 2 Nm
t.
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op py
❑ 5 x 16
t. C rig
gh ht
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Vo
6 - Noise insulation
co lksw
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Prote
AG.
lene)
⇒ page 13
8.1.1 Removing
Note
The suspension strut is not shown in the illustration for reasons

of clarity.

Golf 2004 ➤
General
gen AG. Vbody repairs,
olkswagen AG d
exterior - Edition 04.2008
wa oes
olks not
yV gu
– Unscrew bolts -1-. ed
b ara
nte
ris
ho eo
– Remove parts from vehicle. au
t ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Remove bolts -2- from protective part -1-.
ss o
Note
cial p
f inform
mer
The protective parts may have a different appearance depending
atio
m
on engine fitted.
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
8.1.2 Installing
by lksw
cted agen
Prote AG.
– Insert front protective part for vermin repellent system; when

doing this, pay attention to guide -arrow-.
– Screw in bolts -1- (2 Nm).
– Screw in bolts -2- for protective part -1- (25 Nm).
8. Vermin repellent system 277

Service: Golf 2004

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Copyright © 2010 Volkswagen AG, Wolfsburg K0058991620

5.2 Assembly overview - plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.2 Assembly overview - bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.3 Removing and installing bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.5 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.6 Removing and installing flap hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.9 Removing and installing bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.10 Separating Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.11 Adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.12 Removing and installing release lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.12 Cleaning off excess adhesive sealing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

1.15 Removing and installing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

1.16 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1.18 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

1.6 Front bumper substructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

1.7 Assembly overview - bumper carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1.8 Assembly overview - number plate carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

2.2 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

2.3 Assembly overview - bumper cover for GTI, GT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

2.5 Front bumper attachments for GT, GTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

2.11 Front bumper attachments for GTI special models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

2.12 Front bumper substructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

2.13 Assembly overview - bumper carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

3 Rear bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

3.5 Rear bumper attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

1.3 Repairing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

1.6 Removing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

1.7 Installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

1.8 Assembly overview - rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

1.9 Removing undamaged rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

3.3 Removing and installing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

3.9 R32 radiator grille - company emblem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

4 Mouldings and trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

4.2 Assembly overview - water deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

4.3 Removing and installing water deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

4.4 Assembly overview - protective side strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

4.5 Renewing side protective mouldings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

5 Roof edge spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

5.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

5.5 Retaining strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

5.6 Preparing body kit component for bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

7.2 Installation instructions for lettering and emblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

7.4 Rear lettering dimensions for GTI and R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

8.1 Assembly overview - vermin repellent system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

1.2 Assembly overview - lock carrier, service position

1 - Lock carrier with add-on

– Remove front bumper ⇒ page 140 , GTI ⇒ page 147 , R32

1.3.2 Moving from service position

add-on parts f inform

4 Rep. Gr.50 - Body - front

– Set lock carrier with add-on parts -1- to service position

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

6 Rep. Gr.50 - Body - front