Skoda Kodiaq Body Repairs Exterior Eng

Service
Workshop Manual
Kodiaq 2017 ➤
Kodiaq 2019 ➤
General body repairs, exterior
Edition 08.2019
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
50 - Body - front
55 - Bonnet, rear lid
57 - Front doors, door components, central locking
58 - Rear doors, door components
60 - Sunroof
63 - Bumpers
64 - Glazing
66 - Exterior equipment
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
General body repairs, exterior - Edition 08.2019
Contents
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Summary of components - Lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Removing and installing lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Adjusting and resetting the service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Summary of components - fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Removing and installing the wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Removing and installing wing strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Front wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Summary of components - plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Removing and installing the plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1 Front flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Summary of components - bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Summary of components - Bowden wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Removing and installing the bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Adjusting the bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Removing and installing flap lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.6 Removing and installing the operating lever for flap lock . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.7 Removing and installing the locking clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.8 Removing and installing the hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.9 Removing and installing the pressurized gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.10 Degassing the pressurized gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.11 Removing and installing Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 Summary of components - tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Removing and installing boot lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3 Adjusting boot lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4 Removing and installing flap lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.5 Removing and installing the control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.6 Removing and installing the hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.8 Removing and installing tailgate seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.9 Removing and installing the pressurized gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.10 Degassing the pressurized gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.11 Removing and installing the drive unit for the tailgate VX69 . . . . . . . . . . . . . . . . . . . . . . . . 36
2.12 Removing and installing the control unit for tailgate J605 . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3 Fuel tank lid unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1 Summary of components - Fuel-tank lid unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2 Removing and installing fuel tank lid unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3 Removing and installing the fuel tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.1 Summary of components - door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.2 Removing and installing the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.3 Door adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.4 Adjusting the locking clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.5 Removing and installing the door retaining strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Door internal parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Contents i
2.1 Summary of components - door internal parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.2 Summary of components - Door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.3 Removing and installing window lifter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.4 Remove and install window lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.5 Removing and installing the inside door cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.7 Removing and installing the door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.8 Door handle with keyless access authorisation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.9 Removing and installing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.10 Removing and installing the door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.11 Removing and installing the window run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.12 Removing and installing the inner window channel strip . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.13 Removing and installing the outer window channel strip . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.14 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.15 Removing and installing the cap on the door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.16 Removing and installing cap - without lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.17 Summary of components - front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.18 Removing and installing the front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.19 Removing and installing the outside door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.20 Removing and installing the inside door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.21 Door edge protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3 Central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.1 Summary of components - ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.2 Removing and installing the battery for the ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.3 Removing and installing the cap on the ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

1 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.1 Summary of components - door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.2 Removing and installing the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.3 Door adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.4 Adjusting the locking clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.5 Removing and installing the door retaining strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2 Door internal parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.1 Summary of components - door internal parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.2 Summary of components - Door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.3 Summary of components - window runs and window channel strips . . . . . . . . . . . . . . . . . . 104
2.4 Removing and installing window lifter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.5 Remove and install window lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.6 Removing and installing the inside door cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.8 Removing and installing the door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.9 Removing and installing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.10 Removing and installing the door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.11 Removing and installing the window run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.12 Removing and installing the outer window channel strip . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.13 Removing and installing the inner window channel strip . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.14 Removing and installing the cap on the door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.15 Summary of components - rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.16 Removing and installing the rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.17 Removing and installing the outside door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.18 Removing and installing the inside door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.19 Door edge protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1 Sun roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
ii Contents
1.1 Summary of components - Sun roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1.2 Summary of components - screen for sliding roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.3 Assembly overview - Air deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.4 Removing and installing sun roof frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.5 Removing and installing the draft deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.6 Removing and installing the glass roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.7 Adjusting the sliding sunroof cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.8 Removing and installing the sliding sunroof control unit J245 . . . . . . . . . . . . . . . . . . . . . . 154
1.9 Removing and installing roof blind control unit J394 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.10 Removing and installing the gasket of the sun roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.11 Removing and installing the sliding roof screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.12 Operating without power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.13 Programming the sliding sunroof control unit J245 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.14 Removing and installing the sliding sunroof roller blind motor V260 . . . . . . . . . . . . . . . . . . 164
2 Water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.1 Summary of components - water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.2 Cleaning the water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.3 Removing and installing water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1 Front bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.1 Summary of components - Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.2 Summary of components - impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.3 Removing and installing bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.4 Removing and installing impact bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.5 Removing and installing mounting parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.6 Cutting out the openings for the parking aid sensors (drill) . . . . . . . . . . . . . . . . . . . . . . . . 175
1.7 Cutting out openings for park steering assistant sender . . . . . . . . . . . . . . . . . . . . . . . . . . 176
1.8 Installing parking aid sender retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2 Rear bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.1 Summary of components - Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.2 Removing and installing bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.3 Removing and installing impact bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.4 Cutting out the openings for the parking aid sensors (drill) . . . . . . . . . . . . . . . . . . . . . . . . 181
2.5 Installing parking aid sender retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.1 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.2 Minimum hardening time for glued windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.3 Window repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.4 Installation instructions for glued windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.5 Preparing windows which have not been damaged for fitting . . . . . . . . . . . . . . . . . . . . . . 187
1.6 Preparing new windows for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.7 Preparing body flange for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.8 Cleaning necessary due to soiling through adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2 Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.1 Summary of components - Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.2 Removing and installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3 Rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.1 Summary of components - rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.2 Removing and installing the rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4 Side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.1 Summary of components - Rear side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.2 Removing and installing rear side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Contents iii
66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

1 Spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.1 Summary of components - spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.2 Removing and installing spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2 Strips / trims / extensions / trim panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.1 Summary of components - Sill panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.2 Removing and installing lower handle panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
2.3 Removing and installing lower handle panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.4 Removing and installing trim strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.5 Removing and installing B-pillar trim from the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
2.6 Removing and installing C-pillar trim from the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2.7 Removing and installing heat shield for underfloor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
3 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.1 Summary of components - Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
4 Underfloor trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.1 Installation location overview - underfloor trim panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.2 Removing and installing underfloor trim panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.3 Removing and installing the tunnel bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
5 Roof strips / roof rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
5.1 Removing and installing roof rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
6 Exterior mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
6.1 Summary of components - exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
6.2 Removing and installing outside mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
6.3 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
6.4 Removing and installing the mirror adjustment unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
6.5 Removing and installing mirror cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
6.6 Removing and installing mirror cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
7 Wheelhouse liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
7.1 Removing and installing the front wheelhouse liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
7.2 Removing and installing the rear wheelhouse liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
8 Letterings and emblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
8.1 Dimensions - Letterings and emblems on rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
8.2 Replacing letterings and emblems on rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
8.3 Removing and installing letterings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
9 Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
9.1 Summary of components - Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
9.2 Removing and installing trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
iv Contents
50 – Body - front
1 Lock carrier
(SRL001452; Edition 08.2019)
⇒ “1.1 Summary of components - Lock carrier”, page 1
⇒ “1.2 Removing and installing lock carrier”, page 2
⇒ “1.3 Adjusting and resetting the service position”, page 4
1.1 Summary of components - Lock carrier

Special tools and workshop equipment required
♦ Guide bars - T10093-
Summary of components
Note
Depending on the model version, slight differences in the mount‐

ing parts are possible.
1. Lock carrier 1
1 - Screw
❑ Tightening torque: 8
Nm.
2 - Air deflector
3 - Screw
Nm.
4 - Screw
Nm.
5 - Screw
Nm.
6 - Screw
Nm.
7 - Cross member
8 - Foam piece
9 - Front bumper bracket
10 - Air guide duct
❑ Clipped into front end.
11 - Top air guide
❑ Clipped into front end.
12 - Connecting piece
Volkswagen Technical Site: http://vwts.ru http://vwts.info

1.2 Removing and installing lock carrier
Removing
2 Rep. gr.50 - Body - front

– Adjusting the service position ⇒ “1.3 Adjusting and resetting

the service position”, page 4 .
– Separate electrical plug connections.
– Remove the guide bars - T10093- (Pos. 1) on the left and right
frame side rails -3- with the help of a second mechanic and
take out the lock carrier with component parts -2-.
Note
♦ The condenser and hydraulic oil cooler must not be tied up to the cables.
♦ The condenser and hydraulic lines must not be kinked.
Installing
1. Lock carrier 3
– Position the lock carrier - 2 - on the frame side rails - 3 -.

– Install the guide bars - T10093- on left and right (Pos. 1).
– Resetting service position ⇒ “1.3 Adjusting and resetting the
service position”, page 4 .
Further installation occurs in reverse order.
• Make sure that the plug connections and the hose connections
are correctly mounted during assembly.
– Take the mean of the lock carrier at the frame side rails and
between the wings ⇒ Body Repairs; Rep. gr. 00 ; technical
data; body gaps; front body .
1.3 Adjusting and resetting the service po‐

sition
Adjusting the service position – removing

– Removing front bumper ⇒ “1.3 Removing and installing

bumper”, page 172 .
– Remove headlights ⇒ Electrical system; Rep. gr. 94 ; Head‐
lights; Removing and installing headlights .
– Pull off the control cable from the lock carrier ⇒ “1.11 Remov‐
ing and installing Bowden cable”, page 24 .
– Remove one screw -2- on the left and on the right frame side
rail respectively.
– Install the guide bars - T10093- -4- in place of the removed
screws -2-.
– Remove the remaining screws -2- on the left and right frame
side rails.
– Remove top screws - 1 -.
– The lock carrier -3- can be pulled forwards onto the guide bar
- T10093- by approx. 10 cm.
Note
When removing the lock carrier, make sure the electrical cabling
and other cables do not get damaged.
1. Lock carrier 5
Installing
– Press the lock carrier onto the frame side rail up to the stop.
– Install screws -1- and -2-.
– Take the mean of the lock carrier with component parts -3- at
the frame side rails and between the wings ⇒ Body Repairs;
Rep. gr. 00 ; technical data; body gaps; front body .
– Tightening torque of screws (Pos. 1): 8 Nm.
– Tightening torque of screws (Pos. 2): 55 Nm.
Note
Hoses and lines must not be pinched.

2 Wing
⇒ “2.1 Summary of components - fender”, page 7
⇒ “2.2 Removing and installing the wing”, page 7
⇒ “2.3 Removing and installing wing strut”, page 8
2.1 Summary of components - fender
1 - Wing strut
❑ Removing and in‐
stalling: ⇒ “2.3 Remov‐
ing and installing wing
strut”, page 8 .
2 - Screw
Nm.
3 - Wing
❑ Removing and installing
⇒ “2.2 Removing and in‐
stalling the wing”, page
7.
4 - Protective cover
5 - Screw
Nm.
6 - Screw
Nm.
7 - Screw
Nm.
2.2 Removing and installing the wing

Removing
2. Wing 7
– Remove front wheelhouse liner ⇒ “7.1 Removing and in‐

stalling the front wheelhouse liner”, page 232 .
– Remove screws -7- that connect the wing to the bumper.
– Remove trim panel -4-.
– Remove screws -2, 5 and 6-.
– Carefully remove the wing -3- from the vehicle.
Installing
– Installation is carried out in the reverse order.
2.3 Removing and installing wing strut

Removing
– Remove wing ⇒ “2.2 Removing and installing the wing”, page
7.
– Remove screws -4- (8 ± 1 Nm) and remove wing support -3-.
Installing
– Install wing support - 3 -.
– Fit wing support.
– Fit wing to bumper ⇒ Body Repairs; Rep. gr. 00 ; Technical
data; body gaps; front body .
2. Wing 9
3 Front wall
⇒ “3.1 Summary of components - plenum chamber cover”,
page 10
⇒ “3.2 Removing and installing the plenum chamber cover”, page
10
3.1 Summary of components - plenum chamber cover
1 - Moulded foam part

2 - Plenum chamber cover - left
side
stalling the plenum
chamber cover”, page
10 .
3 - Plenum chamber cover -
right side
stalling the plenum
chamber cover”, page
10 .
4 - Clip
5 - Moulded foam part
6 - Gasket
3.2 Removing and installing the plenum

chamber cover
Removing
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; removing and installing windscreen
wiper arms .
– Remove the seal -6- along the entire length of the plenum
chamber cover.
– Remove expanded foam insert -1 and 5-.

– Remove clips -4-.
Caution
The plenum chamber cover must not be levered off with a lever
tool (screwdriver, wedge). The washer is damaged and can
subsequently tear.
– Pull out the plenum chamber cover -3- from the fitting section
upwards towards the centre of the vehicle to the edge of the
glass on the left.
– Pull out the plenum chamber cover -2- from the fitting section
upwards towards the centre of the vehicle to the edge of the
glass on the right.
Installing
Caution
Breaking open the plenum chamber cover in the fitting section

of the windscreen can lead to cracks in the windscreen.
Note
♦ An inlay is installed in the fitting section on new windscreens.

This inlay must be removed before installing the plenum cham‐
ber cover.
♦ The plenum chamber cover must be slightly pressed into the
fitting section by hand, but on no account knock or press in
using a tool.
Carry out the following tasks

– Spray the fitting section with soapy water so that the plenum
chamber covers can be pressed in more easily.
– First of all, position the plenum chamber cover -2- on the edge
of the glass on the right before centring to the openings ac‐
cording to the wiper shafts.
– Lightly press on the plenum chamber cover in the centre of the
vehicle towards the edge of the glass on the right until the
cover engages in the fitting section.
– Position plenum chamber cover -3- on the cover -2-.
– Lightly press on the plenum chamber cover in the centre of the
vehicle towards the edge of the glass on the left until the cover
engages in the fitting section.
– Push on clips -4-.
– Install expanded foam insert -1 and 5-.
– Press onto the seal - 6 -.
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; removing and installing windscreen
wiper arms .
3. Front wall 11
55 – Bonnet, rear lid

1 Front flap
⇒ “1.1 Summary of components - bonnet”, page 12
⇒ “1.2 Summary of components - Bowden wire”, page 13
⇒ “1.3 Removing and installing the bonnet”, page 14
⇒ “1.4 Adjusting the bonnet”, page 16
⇒ “1.5 Removing and installing flap lock”, page 19
⇒ “1.6 Removing and installing the operating lever for flap lock”,
page 20
⇒ “1.7 Removing and installing the locking clamp”, page 21
⇒ “1.8 Removing and installing the hinges”, page 22
⇒ “1.9 Removing and installing the pressurized gas strut”, page
22
⇒ “1.10 Degassing the pressurized gas strut”, page 24
⇒ “1.11 Removing and installing Bowden cable”, page 24
1.1 Summary of components - bonnet
12 Rep. gr.55 - Bonnet, rear lid

1 - Flap lock
stalling flap lock”, page
19 .
2 - Pressurized gas strut
3 - Spray nozzles
⇒ Electrical System;
Rep. gr. 92 ; Wind‐
screen wiper system;
removing and installing
spray nozzles .
4 - Bump stop
5 - Locking clamp
stalling the locking
clamp”, page 21 .
6 - Seal for bonnet
7 - Blanket insulator
Removing
– Unclip all the clips for

the damping in se‐
quence.
– Remove the damping

from the bonnet.
Installing
– Installation is carried out

in the reverse order.
8 - Screw
❑ Tightening torque: 20 Nm.
9 - Hinge
❑ Removing and installing ⇒ “1.8 Removing and installing the hinges”, page 22 .
❑ Setting ⇒ “1.4 Adjusting the bonnet”, page 16 .
10 - Release lever for bonnet
❑ Removing and installing ⇒ “1.11 Removing and installing Bowden cable”, page 24 .
1.2 Summary of components - Bowden wire
1. Front flap 13
1 - Front flap lock

2 - Screws to attach lock
3 - Cover for link coil
4 - Link coil
5 - Front flap lock
6 - Unlocking mechanism in
bonnet
7 - Screw
Nm.
8 - Release lever
1.3 Removing and installing the bonnet

Removing

– Disconnect spray nozzles ⇒ Electrical System; Rep. gr. 92 ;

Windscreen wiper system; removing and installing spray noz‐
zles .
– Disconnect the plug connections of the electric cables (de‐
pending on the vehicle equipment).
– Slacken the nuts -1- on the left and right at the hinge -2- (do
not unscrew).
Carry out further removal with the assistance of a second me‐
chanic.
– Only now unscrew the nuts -1- and lift the bonnet out of the
hinges.
Installing
1. Front flap 15
Installing
– Adjust the bonnet ⇒ “1.4 Adjusting the bonnet”, page 16 .
1.4 Adjusting the bonnet
Note
♦ The vehicle must be positioned on the flat ground in order to adjust the bonnet.
♦ The adjusting buffers on the left and right are not used for the adjustment. They have the function to stabilise
or dampen the bonnet.
♦ The bonnet is correctly adjusted if in the closed state it has an overall even gap size, is not positioned too
far outwards or inwards and the contours are aligned.
♦ The bonnet must latch in the flap lock without using increased force.
♦ The nuts are not unscrewed, only slackened.
– Remove screws -4- (9 Nm).

– Remove locking clamps -1 and 3-.

– The bonnet can be centred between the wings by slackening

the nuts -1- on the left and right hinges -2- and shifting in di‐
rection of arrows -A and B-.
1. Front flap 17
– Ensure parallelism of gap dimensions ⇒ Body Repairs; Rep.

gr. 00 ; Technical data; body gaps; front body .
Adjusting the adjusting buffer
Note
♦ Install rubber adjusting buffer on the left and right up to the stop.
♦ Turn the adjusting buffers by 90° if required, in order to pretension the flap.
– After the bonnet has been adjusted, the locking clamps can
be installed and adjusted again.
– The height of the bonnet from the wings can be adjusted at the
front with the flap lock.
– After the flap has been adjusted, the locking clamp has been
installed and all the connections have been tightened, the ad‐
justing buffers can be turned if required.
– After carrying out adjustment work, perform anti-corrosion pro‐
tection measures at the hinges and nuts.
Adjusting the bonnet lock

– If the screws -2- are loosened, the bonnet lock -1- can be ad‐
justed in relation to the bonnet laterally and in height ⇒ Body
Repairs; Rep. gr. 00 ; Body gaps; front body .
– Tightening torque of screws -2- (12 Nm).
1.5 Removing and installing flap lock

Removing
1. Front flap 19
– Remove air guide.

– Separate the plug connection of the electrical cable.
– Unscrew screws -2-.
– Disconnect Bowden cables.
– Pull flap lock -1- upwards and out.
Installing
– Slide flap lock -1- into the hole in the front wall.
– Connect Bowden cables.
– Install screws -2- (12 Nm).
– Connect plug for electrical wiring.
– Adjust flap lock ⇒ page 18 .
1.6 Removing and installing the operating

lever for flap lock

Removing
– Tighten the operating lever -1- and unlock the bonnet.
– Fit a small screwdriver into the gap between the operating
lever - 1 - and the retaining clip - 2 -.
– Lever the retaining clip -2- out of the operating lever (Pos.
1) -arrow- and detach the operating lever from the bearing
bracket -3-.
When carrying out further work on the bearing bracket - 3 -, re‐
move the bottom A pillar trim panel - 4 -.
Installing
• The bottom A pillar trim panel -4- is installed.
– Push the retaining clip -2- into the operating lever.
– Press the operating lever - 1 - onto the bearing bracket - 3 -.
1.7 Removing and installing the locking clamp
Removing
1. Front flap 21

– Remove the locking clamp - 1 - from the front flap - 2 -.
Installing
– Tightening torque of screws -4- (10 Nm).
– Adjust the locking clamp to the flap lock.
1.8 Removing and installing the hinges

Removing
– Remove bonnet ⇒ “1.3 Removing and installing the bonnet”,

page 14 .
– Remove nuts - 1 - (20 Nm) and screws - 3 - (20 Nm).
– Remove hinge - 2 -.
Installing
1.9 Removing and installing the pressurized gas strut

Removing
– Support the bonnet in a suitable manner.
– Raise the locking element and remove the pressurized gas
strut -2- off the ball pin -1-.
– Raise the locking element and remove the pressurized gas
strut -2- off the ball pin -3-.
– Remove the pressurized gas strut -2- off the ball pin.
– Remove the pressurized gas strut on the other side in the
same way.
Installing
– Clip the pressurized gas strut -2- onto the ball pins -1 and 3-
at top and bottom.
– Clip on the second pressurized gas strut in the same way.
1. Front flap 23
Note
If reusing the pressurized gas strut -1-, the locking element -2-
must not be pulled completely out of the ball pin -3-, as doing so
will damage it.
WARNING
When removing the locking element, always wear safety gog‐

gles!
Always move the release pin into the first stage. Never fully
lever it out of the ball socket. There is risk of injury to the me‐
chanic and risk of damage to the release pin!
1.10 Degassing the pressurized gas strut

– Clamp the pressurized gas strut into the vice on the section
-a = 50 mm-.
WARNING
The pressurized gas strut must only be clamped in this area,

otherwise there is a risk of accident!
– Saw open the strut cylinder in the first third of the total length
of the cylinder, starting from the piston side edge.
Note
♦ Wear safety goggles during the sawing procedure.

♦ Cover the sawn section with a cloth.
♦ Oil and cloth are disposed of in accordance with waste dis‐
posal requirements.
♦ After degassing, the pressurized gas spring can be treated as
scrap.
1.11 Removing and installing Bowden cable

1 - Bonnet lock - right

2 - Link coil for cables
3 - Release lever in engine
compartment
4 - Cover for link coil
5 - Bonnet lock - left
6 - Bowden cable with clips
Removing
– Removing front
bumper ⇒ “1.3 Remov‐
ing and installing
– Remove unlocking lever

⇒ page 25 .
– Separate cables.
– Remove screws for

mounting mechanism (9
Nm).
Installing

7 - Release lever in driver com‐

partment
8 - Release lever in driver com‐
partment

Removing and installing release lever
– Remove by releasing the securing clip -1- in direction of arrow
outwards and by sliding the lever -2- upwards.
1. Front flap 25
Removing Bowden cable for release lever

– Slide Bowden cable -1 and 2- upwards at position of arrows.
– Rotate Bowden cable and slide cable end out of the release
cable.

2 Tailgate
⇒ “2.1 Summary of components - tailgate”, page 27
⇒ “2.2 Removing and installing boot lid”, page 28
⇒ “2.3 Adjusting boot lid”, page 29
⇒ “2.4 Removing and installing flap lock”, page 30
⇒ “2.5 Removing and installing the control”, page 32
⇒ “2.6 Removing and installing the hinges”, page 33
⇒ “2.8 Removing and installing tailgate seal”, page 34
⇒ “2.9 Removing and installing the pressurized gas strut”, page
35
⇒ “2.10 Degassing the pressurized gas strut”, page 36
⇒ “2.11 Removing and installing the drive unit for the tailgate
VX69 ”, page 36
2.1 Summary of components - tailgate
1 - Pressurized gas strut

2 - Ball pin
3 - Cap
4 - Screw
Nm.
5 - Adjusting buffer
6 - Tailgate
– Removing and installing
stalling boot lid”, page
28 .
7 - Adhesive pad
8 - Mounting bracket with ball
stud
9 - Screw
Nm.
10 - Adjusting buffer
11 - Screw
Nm.
12 - Cap
2. Tailgate 27
2.2 Removing and installing boot lid

Removing
– Removing trim panel for tailgate ⇒ Rep. gr. 70 ; Luggage

compartment trim panels .
– Disconnect the plug connections of the existing electrical com‐
ponents.
– Thread the electrical cables out of the tailgate -3-.
– Slacken the screws - 4 - (10 Nm) on the left and right hinges
but do not yet unscrew.
Carry out further removal only with the assistance of a second
mechanic.
Remove pressurized gas struts from the ball pins on the tailgate.
– Only now unscrew the screws - 4 - and remove the tailgate.
– Only if the complete hinge for the tailgate must be removed,
release the nuts - 2 - (20 Nm). In this case the moulded head‐
liner must be unhooked.
Installing

Note
Adjust the tailgate after installing ⇒ “2.3 Adjusting boot lid”, page 29 .
2.3 Adjusting boot lid
Note
♦ The vehicle must be standing on its wheels in order to adjust the tailgate.
♦ The flap lock is directly screwed onto the tailgate. It has no elongated holes and therefore it cannot be
adjusted.
♦ The adjusting buffers on the left and right are not used for the adjustment. They have the function to stabilise
or dampen the bonnet.
♦ The tailgate is correctly adjusted if in the closed state it has an overall even gap size, is not positioned too
far inwards or outwards and the contours are aligned.
♦ The tailgate must latch in the flap lock without using increased force.
2. Tailgate 29
Use a setting gauge for setting or checking the gap sizes ⇒ Body
Repairs; Rep. gr. 00 ; Body gaps; rear body .
– The tailgate can be adjusted in the oversized bores of the
hinges horizontally and vertically by slackening the screws
- 4 -.
– After carrying out adjustment work, perform corrosion protec‐
tion measures at the hinges and screws.
– Adjust the tailgate on the closing wedge ⇒ page 30 .
– Adjust the rubber buffer on the left and right.
Setting the locking mechanism
Note
♦ The closing wedge - 2 - can be adjusted in the oversized bores

of the hinges arrows - a - and arrows - b - by loosening the
screws - 1 -.
♦ Set the locking mechanism - 2 - in such a way that the recess
of the tailgate lock with the catch engages centrally in the
locking mechanism - 2 -.
– Release screws - 1 -.
– Bring the locking mechanism -2- into the upper position and
tighten the screws -1-.
– Close the tailgate and check the setting.
Tightening torque of screws -1- (20 Nm).
2.4 Removing and installing flap lock

Removing

Note
♦ If the tailgate does not open, it can be opened manually using the emergency manual override on the tailgate
trim panel ⇒ Owner's Manual .
♦ The Bowden cable -2- is only installed in vehicles with power latching system.
– Remove tailgate trim ⇒ General body repairs, interior; Rep.

gr. 70 ; Luggage compartment trim; Removing and installing
lower tailgate trim .
– Remove protection against unauthorised use -5- -arrow b-.
– Disconnection connector on the flap lock.
– Unscrew nuts - 4 -.
– Press retaining tabs -6- together -arrows d- and take the flap
lock -1- out of the flap -arrow c-.
Installing
Note
2. Tailgate 31
The Bowden cable -2- is only installed in vehicles with power latching system.
– Position the flap lock -1- in -direction of arrow a- and install

nuts -3-.
– Connect connector to flap lock.
– Slide on the protection mechanism against unauthorised
use -4- -arrow b-.
• Before the tailgate is closed, carry out a functional test of the
release components.
Tightening torque:
♦ Nut: 21 Nm.
2.5 Removing and installing the control

Removing
– Remove the lower rear lid trim ⇒ General body repairs, inte‐
rior; Rep. gr. 70 ; Luggage compartment trim; Remove and
install lower rear lid trim .
– Disconnect the plug connection of the electrical cable.

– Release the retaining tabs of the handle at the position of the

-arrows-.
– Pull the handle -1- out of the flap.
Installing
– Slide the handle -1- into the tailgate.
– The handle must audible lock into the flap.

– Connect plug for electrical wiring.
– Install tailgate trim ⇒ General body repairs, interior; Rep. gr.
70 ; Luggage compartment trim; Removing and installing low‐
er tailgate trim .
Note
After installing the handle with the camera, perform calibration ⇒

Rep. gr. 91 ; Rear view camera system; calibrate rear view cam‐
era system .
2.6 Removing and installing the hinges
2. Tailgate 33
1 - Hinge
Removing
– Remove tailgate ⇒
“2.2 Removing and in‐
stalling boot lid”, page
28 .
– Partially unhook mould‐

ed headliner ⇒ General
body repairs, interior;
Rep. gr. 70 ; Moulded
headliner; Removing
and installing moulded
headliner .
– Remove nut (Pos. 2).
– Remove the hinge for

the tailgate.
Installing

2 - Nut
❑ 20 Nm.
3 - Tailgate
4 - Screw
❑ 10 Nm.
2.7 Removing and installing the locking

clamp
Removing
– Remove lock carrier trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Luggage compartment trims; Removing and in‐
stalling lock carrier trim .
– Unscrew screw -2- and remove the closing wedge -1- from the
luggage compartment wall.
Installing
– Set the locking mechanism ⇒ “2.3 Adjusting boot lid”, page
29 .
2.8 Removing and installing tailgate seal

Removing
– Detach the seal for the tailgate -1- from the body flange.
Installing
– Press the seal -1- evenly onto the body flange.
2.9 Removing and installing the pressurized

gas strut
Removing
– Open tailgate, support and lock it into position.
2. Tailgate 35
– Use a screwdriver to raise the locking element - 2 - and pull

the pressurized gas strut - 1 - off the ball stud at the bracket
- 3 -.
Note
If the pressurized gas strut is to be re-used, do not remove the

locking device fully from the ball socket, otherwise it will be dam‐
aged.
– 1 - Pressurized gas strut

– 2 - Locking device
– 3 - Ball stud
Installing
2.10 Degassing the pressurized gas strut

– Clamp the pressurized gas strut into the vice on the section
-a = 50 mm-.
WARNING
The pressurized gas strut must only be clamped in this area,

otherwise there is a risk of accident!
– Saw open the strut cylinder in the first third of the total length
of the cylinder, starting from the piston side edge.
Note
♦ Wear safety goggles during the sawing procedure.

♦ Cover the sawn section with a cloth.
♦ Oil and cloth are disposed of in accordance with waste dis‐
posal requirements.
♦ After degassing, the pressurized gas spring can be treated as
scrap.
2.11 Removing and installing the drive unit

for the tailgate - VX69-
WARNING
Only drive units from the same manufacturer may be used on

the vehicle! A combination of different manufacturers is not
permitted for safety reasons!
Note
Functional description of the system e.g. ⇒ Vehicle Owner's

Manual .

Removing
– Switch off the ignition and all electrical components.
– Open tailgate, support and lock it into position.
– Unhook moulded headliner ⇒ General body repairs, interior;
Rep. gr. 70 ; Moulded headliner; Removing and installing
moulded headliner .
– Disconnect the plug connections of the spindle drive and pull
the cable guide through the grommet to outside the vehicle.
– Always use a screwdriver first to unlock the locking element
on the tailgate ⇒ “2.9 Removing and installing the pressurized
gas strut”, page 35 and pull the spindle drive -1- off the ball
stud -2-.
WARNING
The spindle drive has pre-tensioned spring inside! Take extra

care when disassembling!
When removing the locking element, always wear safety gog‐
gles!
Always move the release pin into the first stage. Never fully
lever it out of the ball socket. There is risk of injury to the me‐
chanic and risk of damage to the release pin!
– Ball stud (20 Nm) -2-.

– Cap for opening - 3 -.
Installing
Note
After installing the spindle drive, basic setting of the end positions
using ⇒ Vehicle diagnostic tester is necessary.
2.12 Removing and installing the control unit

for tailgate - J605-
Removing
– Remove luggage compartment side trim ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Luggage compartment trim pan‐
els; Removing and installing luggage compartment side trim
panel .
– Disconnect plug for electrical wiring.
2. Tailgate 37
– Remove control unit - 2 - from the supports in the wheelhouse

- 1 -.
Installing

3 Fuel tank lid unit

⇒ “3.1 Summary of components - Fuel-tank lid unit”, page
39
⇒ “3.2 Removing and installing fuel tank lid unit”, page 39
⇒ “3.3 Removing and installing the fuel tank flap”, page 40
3.1 Summary of components - Fuel-tank lid unit
1 - Fuel tank lid unit

stalling fuel tank lid unit”,
page 39 .
2 - Fuel tank lid
– Removing and installing
stalling the fuel tank
flap”, page 40 .
3 - Water drain hose

4 - Electrical plug connection
5 - Screw
❑ Tightening torque: 1.5
Nm.
6 - Positioning element
⇒ “3.3.2 Removing and
installing the setting ele‐
ment”, page 42 .
3.2 Removing and installing fuel tank lid unit

Removing
– Open fuel tank cap.
3. Fuel tank lid unit 39

– E.g. insert removal wedge -3409- -2- in area of arrow -A-.

– Release fuel tank flap unit in area of arrow -B-.
– Pull the fuel tank flap unit out of the flange of the side panel.
– Pull the sleeve over the fuel filler neck and reducing agent filler
neck (depending on engine).
– Tip the fuel tank lid unit -1- out of the side panel.
– Pull out the plug for the adjusting element.
– Pull out the water drain hose.
– Tip out the fuel tank lid unit -1- and pull out to the rear.
Installing
3.3 Removing and installing the fuel tank

flap
⇒ “3.3.1 Removing and installing the fuel tank flap”, page 40
⇒ “3.3.2 Removing and installing the setting element”, page
42
3.3.1 Removing and installing the fuel tank

flap
Removing

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

– Position the fuel tank lid -1- on the fuel tank lid unit -2-
-arrows a-.
– Slide the fuel tank lid into the catches of the fuel tank lid unit
-arrow b-.
3.3.2 Removing and installing the setting element

Removing
– Remove the fuel tank lid unit ⇒ “3.2 Removing and installing
fuel tank lid unit”, page 39 .
– Disconnect electrical plug connection -2-.
– Remove the positioning element -1- from the fuel tank lid unit.
Installing
– Connect the electrical plug connection -2-.
– Position the positioning element -1- on the fuel tank lid unit.
– Install screws -3-.
– Install the fuel tank lid unit ⇒ “3.2 Removing and installing fuel
tank lid unit”, page 39 .

57 – Front doors, door components, central locking

1 Door
⇒ “1.1 Summary of components - door”, page 44
⇒ “1.2 Removing and installing the door”, page 45
⇒ “1.3 Door adjustment”, page 47
⇒ “1.4 Adjusting the locking clamp”, page 48
⇒ “1.5 Removing and installing the door retaining strap”, page
50
1.1 Summary of components - door
Note
Always replace the screws for the door hinges after the removal.
1 - Door
stalling the door”, page
45 .
❑ Setting ⇒ “1.3 Door ad‐
justment”, page 47 .
2 - Multi-point socket head bolt
❑ 40 Nm.
❑ Always replace the
screws after the re‐
moval.
3 - Door hinge
❑ The hinge is divided.
❑ The top part is connect‐
ed to the bottom part of
the hinge by the screw
- 4 -.
4 - Locking bolt for hinge
❑ This screw must be un‐
screwed in order to re‐
move the door from the
hinge.
❑ 23 Nm.
❑ Installed from the inside
of the vehicle.
❑ Remove bottom A-pillar
trim panel ⇒ General
body repairs, interior;
Rep. gr. 70 ; Interior
trim panels; Removing
and installing A-pillar
trim panel .
❑ 30 Nm.
❑ Always replace the screws after the removal.
44 Rep. gr.57 - Front doors, door components, central locking

6 - Door hinge
❑ The bottom part is connected to the top part of the hinge by the screw -4-.
❑ 30 Nm.
8 - Door arrester
9 - Screw
❑ 37 Nm.
10 - Door hinge
❑ The bottom part is connected to the top part of the hinge by the screw -16-.
11 - Locking bolt for hinge
❑ This screw must be unscrewed in order to remove the door from the hinge.
❑ 23 Nm.
12 - Screw
❑ 37 Nm.
❑ This screw must be unscrewed in order to remove the door.
13 - Door hinge
❑ The top part is connected to the bottom part of the hinge by the screw - 12 -.
❑ Installed from the inside of the vehicle.
❑ Remove and install the dash panel for loosening or tightening the screw on the driver's side.
❑ Remove and install the dash panel for loosening or tightening the screw on the front passenger side.
❑ 30 Nm.
❑ 40 Nm.
1.2 Removing and installing the door

Removing
1. Door 45
– Release the bellows - 2 - by pressing on the catch arrow

- a - and detach it from the A pillar.
– Swivel the release lever - 3 - downwards arrow - b - and dis‐
connect the el. plug connection - 4 - from the connector station.
– Undo screws - 7 - from the hinges arrow - d - .
– Remove the screws -9- for the door retaining strap -8-.
– Remove door - 1 - upwards arrow - e - from the hinges - 5 -.
Installing


– Observe the gap sizes of the front door ⇒ Body Repairs; Rep.
gr. 00 ; technical data; body gaps; front body .
1.3 Door adjustment
Note
♦ The vehicle must be standing on its wheels in order to adjust the door.
♦ The door is correctly adjusted if in the closed state it has an overall even gap size, is not positioned too far
outwards or inwards and the contours are aligned.
♦ For checking the gap sizes: ⇒ Body Repairs; Rep. gr. 00 ; Technical data; body gaps; front body .
♦ After carrying out adjustment work, perform corrosion protection measures at the screws and hinges.
1. Door 47
Setting the gap sizes

In order to correctly set the gap sizes, the screws
-2, 5, 7, 12, 14, 15- must be slackened at the A pillar.
– For screw -12-, the bottom A-pillar trim must be removed ⇒
General body repairs, interior; Rep. gr. 70 ; Interior trim pan‐
els; Removing and installing A-pillar trim .
– For screw - 5 - the control panel must be removed ⇒ General
body repairs, interior; Rep. gr. 70 ; Dash panel; Removing and
installing dash panel .
Note
Other measures, such as aligning the doors towards the top are ineffective. The door will drop again at the
following overpressures.
Adjusting the locking clamp ⇒ “1.4 Adjusting the locking clamp”,

page 48 .
1.4 Adjusting the locking clamp

Note
To adjust the locking clamp -2- once the screws -3- are loosened, increased force must be applied.
Note
♦ When closing the door it must lock completely without using

additional force and must have no play.
♦ When adjusting the locking clamp, the door must not be
pressed upwards or downwards.
The locking clamp is used for adjusting the following:

• If the front door adjustment is not flush with the rear door or
the side part.
1. Door 49
– Slacken the locking clamp -1- by loosening the screws -2- at

the B pillar.
– Adjust the door with the locking clamp -2- in such a way that
the front door when in the closed state is flush with the rear
door (wind noise).
– Tighten screws - 2 - of locking clamp - 1 -.
Tightening torque of screws -2- (20 Nm).
1.5 Removing and installing the door retaining strap
Removing
– Remove the screw - 2 - at the A pillar.
– Remove the screws -3- and take out the door retaining strap
-1-.
Installing

– Insert the door retaining strap.

– Install screw -3-, tightening torque 9 Nm.
1. Door 51
2 Door internal parts

⇒ “2.1 Summary of components - door internal parts”, page
52
⇒ “2.2 Summary of components - Door handle and door lock”,
page 53
⇒ “2.3 Removing and installing window lifter motor”, page 54
⇒ “2.4 Remove and install window lifter”, page 57
⇒ “2.5 Removing and installing the inside door cover”, page
58
⇒ “2.7 Removing and installing the door handle”, page 61
⇒ “2.8 Door handle with keyless access authorisation system”,
page 63
⇒ “2.9 Removing and installing bearing bracket”, page 65
⇒ “2.10 Removing and installing the door lock”, page 66
⇒ “2.11 Removing and installing the window run”, page 68
⇒ “2.12 Removing and installing the inner window channel strip”,
page 71
⇒ “2.13 Removing and installing the outer window channel strip”,
page 71
⇒ “2.14 Removing and installing lock cylinder”, page 73
⇒ “2.15 Removing and installing the cap on the door handle”,
page 75
⇒ “2.16 Removing and installing cap - without lock cylinder”, page
77
⇒ “2.17 Summary of components - front door window”, page
81
⇒ “2.18 Removing and installing the front door window”, page
82
⇒ “2.19 Removing and installing the outside door seal”, page
85
⇒ “2.20 Removing and installing the inside door seal”, page
86
⇒ “2.21 Door edge protection”, page 88
2.1 Summary of components - door internal parts

1 - decorative strip
2 - Window run
⇒ “2.11 Removing and
installing the window
run”, page 68 .
3 - Inner window channel strip
installing the inner win‐
dow channel strip”,
page 71 .
4 - Window lifter
5 - Window lifter motor
stalling window lifter
motor”, page 54 .
6 - Nut
Nm.
7 - Loudspeaker
8 - Engine screw
Nm.
9 - Door
stalling the door”, page
45 .
❑ Setting ⇒ “1.3 Door ad‐
justment”, page 47 .
10 - Screw
❑ Tightening torque: 2.5 Nm.
11 - Inner door cover
12 - Screw
13 - Cap
14 - Door edge protection
❑ Removing and installing ⇒ “2.21 Door edge protection”, page 88 .
15 - Screw
16 - External window channel strip
❑ Removing and installing ⇒ “2.13 Removing and installing the outer window channel strip”, page 71 .
17 - B-pillar trim panel
❑ Removing and installing ⇒ “2.5 Removing and installing B-pillar trim from the door”, page 211 .
18 - Door window
❑ Removing and installing ⇒ “2.18 Removing and installing the front door window”, page 82 .
2.2 Summary of components - Door handle and door lock
2. Door internal parts 53

1 - Door lock
installing the door lock”,
page 66 .
2 - Screw
3 - Clamp
stalling the locking
clamp”, page 59 .
4 - Lock cylinder
installing lock cylinder”,
page 73 .
❑ Only installed on the
driver door.
5 - Surface
6 - Cap
installing the cap on the
door handle”, page
75 .
7 - Door handle
stalling the door han‐
dle”, page 61 .
8 - Screw
❑ 1.7 Nm.
9 - Control cable
❑ From door lock -1- to bearing bracket -3-.
10 - Control cable
❑ From the inner door control to the door lock -1-.
❑ With grommet for feeding through at the cover.
11 - Screw
12 - Cap
2.3 Removing and installing window lifter

motor
Removing

– Remove front door trim panel ⇒ Rep. gr. 70 ; Front door trim
panels; removing and installing door trim panel .
– Secure the door window in the top position with adhesive tape
so that it does not slide down.
– Disconnect the plug connection.
– Remove the window lifter motor with the control unit - 2 - from
the supports - 1 -.
Installing
WARNING
On a newly installed window lifter motor, additional functions

must be coded.

– Fit the window lifter motor - 2 - into the supports - 1 -. Lower

the door window slightly and then raise it so that the serration
can slide in better between the motor and the hoisting drum.
– Secure the plug connection.
– The new window lifter motor is coded.
– The further work procedure occurs in the reverse order to the
removal.
Removing the control unit
– Door trim panel has been removed.

– Press the retaining lug of the door control unit in

-direction of arrow A-, swivel the control unit in
-direction of arrow B- and pull the control unit in
-direction of arrow C- out of the door assembly carrier.
Installing
2.4 Remove and install window lifter

Removing
– Release door window.
– Push window pane upwards and secure e.g. with adhesive
tape.

– Remove window lifter motor ⇒ “2.3 Removing and installing

window lifter motor”, page 54 .
– Unlock the catch hooks of the hoisting drum arrows -a- and
slide them into the door.
– Slide the window lifter - 1 - into the door and slightly turn it in
direction of arrow - a -.
– Remove the window lifter through the door cutout arrow -c-.
Installing
– Slide the window lifter -1- through the door cutout.

– Put the window lifter in its fitting position.
– Push the window lifter thread through the door and tighten the
nuts -2-. Tightening torque: 6 Nm.
– Press the hoisting drum through the holes in the door until the
catch hooks arrow - a - lock.
2.5 Removing and installing the inside door

cover

Removing
– Remove front door trim ⇒ General body repairs, interior; Rep.

gr. 70 ; Inner lining of the door panel front; removing and in‐
stalling front door trim .
– Raise the cover at the points provided for pliers.
– Pull cover -1- in direction of arrow -A-.
– Pull cover -2- in direction of arrow -B-.
Note
♦ If the following operations are necessary, pull the Bowden cable -2- with the grommet -4- out of the cover
-1-.
♦ The cables are slackened in the holders -3-.
Installing

clamp

Removing

– Remove the cover ⇒ “2.5 Removing and installing the inside
door cover”, page 58 .
– Remove the lock cylinder or the cap ⇒ “2.14 Removing and
installing lock cylinder”, page 73 .
– Removing the door handle ⇒ “2.7 Removing and installing the
door handle”, page 61 .
– Release screw - 4 - and remove gasket - 3 -.
– Remove bearing bracket - 1 - from the door arrow - a -.
Slacken Bowden cable
– Unlock the bracket - 5 - and swivel out of the support in the
bearing bracket arrow - b -.
– Lift the bolt of the control cable out of the support - c -.
– Swivel out the Bowden cable - 2 - from the bearing bracket
(Pos. 1) arrow - d - .

Installing
Installation is carried out in the reverse order.

– Install screw -2-, tightening torque 1.5 Nm.
2.7 Removing and installing the door handle

Removing

– Remove the cap for lock cylinder, depending on design ⇒

“2.15 Removing and installing the cap on the door handle”,
page 75 , and remove the lock cylinder ⇒ “2.14 Removing
and installing lock cylinder”, page 73 .
– Or remove the cap without the lock cylinder ⇒ “2.16 Removing
and installing cap - without lock cylinder”, page 77 .
– Pull the door handle -1- slightly towards the rear -arrow a- out
of the support of the bearing bracket -2-.
– Swivel the door handle in -direction of arrow b-.
– Remove the door handle at a right angle -arrow c- out of the
bearing bracket -2-.
Installing

– Fit the door handle -1- at a right angle -arrow a- into the bearing
bracket.
– Swivel the door handle -1- to the door -arrow b-.
– Press the door handle forwards -arrow c- into the support of
the bearing bracket -2-.
– Then it is absolutely necessary to perform a functional check
when the door is opened.
2.8 Door handle with keyless access autho‐

risation system
Removing

Notes on door handle with keyless access authorisation system

⇒ Electrical system; Rep. gr. 94 ; Access and start authorisation;
Installation location overview - access and start authorisation
system .
– Remove the cap for lock cylinder, depending on design ⇒
“2.15 Removing and installing the cap on the door handle”,
page 75 , and remove the lock cylinder ⇒ “2.14 Removing
and installing lock cylinder”, page 73 .
– Or remove the cap without the lock cylinder ⇒ “2.16 Removing
and installing cap - without lock cylinder”, page 77 .
– Pull the door handle -1- slightly towards the rear -arrow a- out
of the support of the bearing bracket -2-.
– Swivel the door handle in -direction of arrow b-.
– Open the lock on connector -4- with a screwdriver -3-
-arrow d-.
– Remove the door handle at a right angle -arrow c- out of the
Installing

Notes on door handle with keyless access authorisation system

⇒ Electrical system; Rep. gr. 94 ; Access and start authorisation;
Installation location overview - access and start authorisation
system .
– Fit the door handle -1- at a right angle -arrow a- into the bearing
bracket.
Connect the connector for the keyless access authorisation sys‐
tem when positioning the door handle.
– Swivel the door handle -1- to the door -arrow b-.
– Press the door handle forwards -arrow c- into the support of
the bearing bracket -2-.
– Then it is absolutely necessary to perform a functional check
2.9 Removing and installing bearing bracket

Removing

– Release screws - 2 - and remove locking clamp - 1 -.

Installing
– Position the locking clamp - 1 - at the B pillar - 3 - and tighten
the screws - 2 -, tightening torque: 25 Nm.
– Adjust the locking clamp ⇒ “1.4 Adjusting the locking clamp”,
page 48 .
2.10 Removing and installing the door lock

Removing

– Unclip cap - 3 -.

– Remove the screw (1.7 Nm) and disconnect the connector

-4-.
– Remove lock cylinder ⇒ “2.14 Removing and installing lock
cylinder”, page 73 .
– Remove the lock -1- from the door.
Note
If it is necessary for the following operations, it is possible to slacken the Bowden cable.
Slacken Bowden cable to bearing bracket

– Twist the Bowden cable -5- by 45° and remove it from the
bracket -arrow a-.
– Turn the Bowden cable - b - until it can be pulled out of the lug
in the door lock (Pos. 1) arrow - c -.
Slacken the Bowden cable to the inner door control:
bracket.
– Turn the Bowden cable - d - until it can be pulled out of the lug
in the door lock (Pos. 1) arrow - e -.
Installing

Installing
– Tightening torque of screws (Pos. 2) - 20 Nm.
It is absolutely necessary to perform a functional check because
the door cannot be opened if the adjustment of the Bowden cables
is not accurate and if they are not correctly locked.
2.11 Removing and installing the window run
Note
Do not bend the window seal while removing!
Removing

The exterior mirror and the window channel strip are removed.
– Pull out the retaining clip (Pos. 3) - c -.
– Push away the sealing lip of the window run from the inside
out of the door flange.
– Remove window run - 1 - - arrows - a - from the door flange
- 2 - evenly all around, beginning with the rear area.
– Pull the window run - 1 - out of the supports arrows - b - .
Installing
Note
Before assembly, the gasket contact surfaces must be coated with soapy water so that they can be moved
easily and positioned on the flange more accurately.

– Mask off the openings -4- below the window guide with fabric
adhesive tape.
– Dimensions of adhesive: height = approx. 10 mm, width = ap‐
prox. 40 mm.
– Slide the window run into the supports arrows - a -.
– Press the window run evenly all around against the door flange
-2-.
– Press the sealing lip of the door run from the inside against the
door flange.
– Slide in the retaining clip (Pos. 3)- arrow - b -.
Note
♦ The chamfer of the retaining clips must point to the inside of the vehicle.
♦ If the chamfer of the retaining clips points to the outside of the vehicle, the -crossed-out red colour-, then
the retaining clip must be turned around.
• A functional check must be performed before installing the

door trim panel.

Note
Pay attention to evenly fitting the window run when installing it (wind noise).
2.12 Removing and installing the inner window channel strip
Removing
– Remove gasket -1- evenly -arrows- without bending the flange
-2-.
Installing
Press the window channel strip - 1 - by hand evenly onto the
flange - 2 -.
2.13 Removing and installing the outer win‐

dow channel strip
Removing

Note
♦ The core of the seal consists of a metal insert.

♦ If it is bent, the seal can no longer be straightened. It remains
“warped”.
♦ Therefore the seal must be fitted on uniformly and without
bending it.
– Remove exterior mirror ⇒ “6.2 Removing and installing outside

mirror”, page 223 .
– Remove the seal - 1 - uniformly arrows - b - out of the door
- 2 - up to the exterior mirror.
– Pull out the seal from underneath the exterior mirror - a -.
Installing

– Press the seal - 1 - arrows - a - by hand evenly onto the flange

- 2 -.
– Install exterior mirror ⇒ “6.2 Removing and installing outside
mirror”, page 223 .
2.14 Removing and installing lock cylinder
Note
A lock cylinder is installed only on the driver's door.
Removing

• The cap for the lock cylinder is removed ⇒ “2.15 Removing

and installing the cap on the door handle”, page 75 .
– Lift off the covers -4 and 6-.
– Unscrew screw -5-.
– Fully unscrew the screw -7- so that it exposes the lock cylinder.
– Remove door handle - 2 -.
– Undo the locking cylinder housing - 1 - at a right angle
arrow - b - to the door from the bearing bracket - 3 -.
Installing

– Undo door handle - 2 - arrow - a - .

– Insert the locking cylinder housing - 1 - at a right angle
arrow - b - into the bearing bracket - 3 -.
– Screw the screws -5 and 7- into the bearing bracket.
– Tightening torque of screws -5 and 7- (3.5 Nm).
Note
During the assembly the lock cylinder housing must be pressed against the outer door panel.

• Then it is absolutely necessary to perform a functional check
2.15 Removing and installing the cap on the

door handle
Note

♦ When removing the cap for the lock cylinder, do not turn the
screwdriver and lever with it.
♦ The lock cylinder and the cap for lock cylinder are only installed
on the driver's side.
Removing
– Pull the door handle out of the door a short way.

– Press a small screwdriver -3- slightly -arrow a- into the opening
on the bottom side of the cap for the lock cylinder.
– Slightly pull off the cap of the lock cylinder -1-, together with
the screwdriver, at the bottom side from the door -arrow b-.
– Slide the cap upwards out of the lock cylinder.
Installing

– Pull the door handle -1- out of the door a short way.
– Position the cap for the lock cylinder -2- onto the lock cylinder
-arrow a-.
– Press the cap of the lock cylinder -2- onto the door -arrow b-,
until the cap with the lock cylinder locks into position.
2.16 Removing and installing cap - without

lock cylinder
Note
This cap is installed where the lock cylinder is not installed.
Removing
♦ Assembly tool - T10389- .

– Remove plug over the hole -5-.

– Use the assembly tool - T10389- to guide caps on the lock
hook into the hole in -direction of arrow-.
– Pull the assembly tool - T10389- forwards around 5 mm, until
the hook unlocks.

Pull the door handle -2- out of the door a short way -arrow a-.
Note
Do not press the door handle into the door. This would damage the bearing bracket.
– Pull the cap - 1 - out of the bearing bracket -arrow b-.

Installing

• Pull the door handle -2- out of the door a short way in direction
of -arrow a-.
– Push the cap -1- into the bearing bracket -arrow b-.

– Press the cap -1- gently onto the door.

– For example guide a screwdriver -4- at the lock hooks -3- of
the bearing bracket.
– Press in the screwdriver -arrow- until the hook locks.
– Clip the plug into the hole -5-.
2.17 Summary of components - front door window

1 - Door window
installing the front door
window”, page 82 .
2 - Window lifter
⇒ “2.4 Remove and in‐
stall window lifter”, page
57 .
3 - Nut
4 - Door
motor”, page 54 .
6 - Screw
7 - Window run
run”, page 68 .
8 - Retaining clip
2.18 Removing and installing the front door

window
Removing

– Release cap - 6 -.
– Lower the door window -1- until the expanding pin -4- and the
straddling dowel -5- can be accessed in the window lifter
opening -3-.
Note
If this operation cannot be performed due to a failure at the window lifter -7-, remove the window lifter motor.
Then the door window can be pushed to the required working height.
– Press the expanding pin -5- out of the expanding dowel -4-.
– Then press the straddling dowel -4- out of the window lifter and
pane.

– Lift up the door pane - 1 - at the rear and swivel it forwards out
of the window run - 2 - in - direction of arrow -.
Installing
– Find the centre of the straddling dowel and insert it when the
door window is removed -1-.
– Press the straddle pin into the straddling dowel.
– Guide the pane -1- into the door in -direction of arrow A- and
insert into the window lifter guide -2- in -direction of arrow C-.
– Lock the pane -1- into the window lifter by tapping from above
in -direction of arrow B-.
– It must be pressed until the catch locks audibly into place.
removal.

– Insert door pane - 1 - in direction of arrow - a - into the window

run - 2 -.
Note
Ensure that the door window is correctly inserted in the window run.
– Insert the door window pressureless into the clamping jaws

- b -.
– Align the door pane to the window frame arrow - c -.
– Subsequently proceed in reverse order to removing.
door trim panel.
2.19 Removing and installing the outside door seal

Removing
– Pull the seal -1- off the door.
Installing
– Remove any residues of adhesive, e.g. with a lubricating plate.
– Thoroughly clean the adhesive surface with adhesive remover
D 002 000 10 immediately before sticking on the outer door
seal.
• Adhesive surfaces must be free of dirt and grease, as well as
any residues of adhesive.
– The vulcanised section -2- of the door seal must be at the
centre of the threshold.
– Remove the protective film and insert the door seal in the top
rear radius -arrow-. Do not over-extend the door seal to ensure
that the end of the seal does not lengthen too much.
– Correctly press the adhesive surface for the seal -1- around
circumference onto the door -1- with e.g. a pinch roller - 3356- .

seal

During the installation in series, the inside door seals are provided
with a sealing compound which is placed on the door flange and
subsequently rolled up.
Note
♦ During the removal of the seal, the sealing mass is distributed

on the inside of the seal. While doing so, the sides are slightly
bent open. If the seal is re-installed, leak-tightness and tight fit
can no longer be guaranteed.
♦ For this reason, each seal which was completely removed
must be replaced with a so-called “hammer finish seal”.
♦ If the seals were detached partially, press together the sides
of the seal before installing.
Removing
– In order to remove the inner door seal, remove the following:
A-pillar trim panels ⇒ General body repairs, interior; Rep. gr.
70 ; Interior trim panels; Removing and installing A-pillar trim
panel , sill panel ⇒ General body repairs, interior; Rep. gr.
70 ; Interior trim panels; Removing and installing sill panel and

B-pillar trim panels ⇒ General body repairs, interior; Rep. gr.

70 ; Interior trim panels; Removing and installing B-pillar trim
panel .
– Detach the inside door seal -1- from the body flange.
Installing
– Align the inside door seal - 1 - with vulcanisation point arrow
- b - at the top bonnet hinge arrow - b -.
– When installing the inside door seal, start in the top radius of
the door cutout arrow - a -.
– Install the following: A-pillar trim panels ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Interior trim panels; Removing and
installing A-pillar trim panel , sill panel ⇒ General body repairs,
interior; Rep. gr. 70 ; Interior trim panels; Removing and in‐
stalling sill panel and B-pillar trim panels ⇒ General body
repairs, interior; Rep. gr. 70 ; Interior trim panels; Removing
and installing B-pillar trim panel .
2.21 Door edge protection

⇒ “2.21.1 Removing and installing”, page 88
⇒ “2.21.2 Adjusting the door protection”, page 90
⇒ “2.21.3 Height adjustment of the protective strip”, page 91
2.21.1 Removing and installing

1 - Door
2 - Activator
3 - Screw
Nm.
4 - Screw
Nm.
5 - Bowden cable with clips
6 - Protective strip
Removing
– Remove door trim ⇒

General body repairs,
interior; Rep. gr. 70 ;
Front door trim panels;
Removing and installing
door trim .
– Remove inside door
cover ⇒ “2.5 Removing
and installing the inside
– Remove the protective

strip -6- from the door to
the outside.
– Release clips -5-.
– Remove activator with

Bowden cable and door protection through the opening in the door.
Installing
– Only clip in the protective strip -6- when adjusting!
Note
♦ When removing the door protec‐

tion, tie the old part with cord,
wire or other means and guide it
through the door. Leave the cord
in the door. Use a cord to pull the
new part through the door back
to the securing hole.
♦ Only adjust after installing!
♦ The inner door cover and the
door trim are only installed once
the door protection has been ad‐
justed and it has been checked
that it is functioning correctly!

2.21.2 Adjusting the door protection
– The screws -4- for the door protection -7- must be loosened.
– Open the door to approx. 9°.
– Slide the protective strip -6- into the guide of the protection
-7-. The protective strip must engage audibly.
– Adjust the protective strip so that it is in contact along the entire
length of the door edge. The door protection can be pushed to
the side.
– If adjusted correctly, tighten the screws to the specified tight‐
ening torque. Start with the bottom screw, then tighten the top
screw.
– Now check that the protective strip is functioning and adjust
the movement.
– Close the door slowly to check whether the edge or back of
the door collides with the protective strip.
– Before adjusting the activator, pull the collar off the activator
tappet to release the adjusting mechanism.

– If the protective strip collides with the door when the door is
moved, the activator tappet -2- must be screwed out.
– If the protective strip is in contact with the door before the door
is closed, the activator tappet -2- must be screwed in.
2.21.3 Height adjustment of the protective strip
– If the height of the protective strip -1- is not in line the edge of
the door -5- (e.g. in the right magnifying glass), it must be ad‐
justed with compensating washers -3- inserted under the top
or bottom screw (between metal and door protection) -2-. This
creates additional space under the door protection -4-.
– If compensating washers have been installed, check that the
door protection is correctly adjusted once again ⇒ “2.21.2 Ad‐
justing the door protection”, page 90 .
– Check that the door protection is functioning correctly several
times.

3 Central locking
⇒ “3.1 Summary of components - ignition key”, page 92
⇒ “3.2 Removing and installing the battery for the ignition key”,
page 92
⇒ “3.3 Removing and installing the cap on the ignition key”, page
93
3.1 Summary of components - ignition key
1 - Transmitter unit
2 - Release
3 - Spare key
4 - Bushing
stalling the cap on the
ignition key”, page
93 .
5 - Screw
❑ 1 Nm.
6 - Battery
stalling the battery for
the ignition key”, page
92 .
7 - Cover of the battery com‐
partment
3.2 Removing and installing the battery for

the ignition key
Removing

– Use a small screwdriver -3- to lift the cover of the battery com‐
partment -2- arrows -a- and -b-.
– Use a small screwdriver -3- to lift the battery -1- arrow -a-.
– Pull the battery -1- out of the battery compartment -2- arrow
-b-.
Installing
Note
♦ Before installing the battery, be sure to press any button for

about 5 seconds.
♦ This resets the transmitter unit to as-new condition, so that a
new battery can be detected.
Observe the polarity and the fitting location when installing the
battery. The positive pole is indicated.
– Insert battery -2- with slight pressure -arrow a- into the battery
compartment.
– Clip together the cover of the battery compartment -1- and the
transmitter unit -3- -arrow b-.

ignition key
Removing
– Raise the cover of the battery compartment.
– Pull cap -1- off the transmitter unit -3- -arrow-.
Installing
Note
A thread is cut out of the new cap with a screw -2-.
3. Central locking 93
– Press the cap -1- onto the transmitter unit -3- -arrow-.
– Clip in the cover of the battery compartment.

58 – Rear doors, door components

1 Door
⇒ “1.1 Summary of components - door”, page 95
⇒ “1.2 Removing and installing the door”, page 96
⇒ “1.3 Door adjustment”, page 98
⇒ “1.4 Adjusting the locking clamp”, page 99
⇒ “1.5 Removing and installing the door retaining strap”, page
100
1.1 Summary of components - door
1 - Rear door
stalling.
❑ Setting.
2 - Screw
❑ This may be unscrewed
once to adjust the door,
then always replace.
❑ 40 Nm.
3 - Door hinge
❑ The bottom part is con‐
nected to the top part of
the hinge by the screw
-8-.
4 - Locating screw
❑ 23 Nm.
5 - Cap
6 - Screw
❑ 30 Nm.
7 - Door hinge
8 - Screw
❑ 30 Nm.
9 - Door arrester
10 - Screw
❑ 9 Nm.
11 - Screw
❑ 37 Nm.
12 - Door hinge
1. Door 95
13 - Locating screw
❑ 23 Nm.
14 - Cap
15 - Screw
❑ This may be unscrewed once to adjust the door, then always replace.
❑ 40 Nm.
16 - Door hinge
17 - Screw
❑ 30 Nm.
18 - Screw
❑ 40 Nm.
1.2 Removing and installing the door

Removing
96 Rep. gr.58 - Rear doors, door components

– Press e.g. the wedge - T10383/1- between the collar -3- and
catch -2- -arrow a-.
– Press the catch -2- with the wedge - T10383/1- upwards,
-arrow b-. Disconnect the electrical connector -3- from the
multi-plug connection -arrow c-.
– Loosen the screws -7- at the hinges -arrow e-, but do not re‐
move.
– Remove the screw -4- for the door retaining strap -6-.
– Slide the door retaining strap -6- towards the inside
-arrow d-.
– Lift the door -1- with the top parts of the hinges-6- upwards
-arrow f- out of the bottom parts of the hinges.
Installing
1. Door 97

– Observe the gap sizes of the front door ⇒ Body Repairs; Rep.
1.3 Door adjustment
Note
♦ The vehicle must be standing on its wheels in order to adjust

the rear door.
♦ The rear door is correctly adjusted if in the closed state it has
an overall even gap size, is not positioned too far inwards or
outwards and the contours are aligned.
♦ Observe the gap sizes of the front door ⇒ Body Repairs; Rep.
♦ After carrying out adjustment work, perform corrosion protec‐
tion measures at the screws and hinges.


To set the gap sizes correctly, the screws -2, 3, 6 and 7- must be
loosened on the B pillar.
– The bottom B pillar trim panels must be removed for the
screws -3 and 7-.
Loosen screws -5 and 9- to set the gap sizes correctly.
Note
Other measures, such as aligning the doors towards the top are ineffective. The door will drop again at the
following overpressures.
Adjusting the locking clamp ⇒ “1.4 Adjusting the locking clamp”,

page 99 .
1.4 Adjusting the locking clamp
1. Door 99
Note
♦ In order to adjust the locking clamp -2- once the screws -3- are loosened (25 Nm), increased force must be
applied.
♦ When closing the door it must lock completely without using additional force and must have no play.
♦ When adjusting the locking clamp, the door must not be pressed upwards or downwards.
1.5 Removing and installing the door retaining strap

Removing
– Remove the screw - 2 - at the A pillar.
– Remove the screws -3- and take out the door retaining strap
-1-.
Installing
– Insert the door retaining strap -1-.
1. Door 101
2 Door internal parts

⇒ “2.1 Summary of components - door internal parts”, page
102
⇒ “2.2 Summary of components - Door handle and door lock”,
page 104
⇒ “2.3 Summary of components - window runs and window chan‐
nel strips”, page 104
⇒ “2.4 Removing and installing window lifter motor”, page 105
⇒ “2.5 Remove and install window lifter”, page 107
⇒ “2.6 Removing and installing the inside door cover”, page
109
⇒ “2.8 Removing and installing the door handle”, page 112
⇒ “2.9 Removing and installing bearing bracket”, page 113
⇒ “2.10 Removing and installing the door lock”, page 115
⇒ “2.11 Removing and installing the window run”, page 117
⇒ “2.12 Removing and installing the outer window channel strip”,
page 118
⇒ “2.13 Removing and installing the inner window channel strip”,
page 119
⇒ “2.14 Removing and installing the cap on the door handle”,
page 120
⇒ “2.15 Summary of components - rear door window”, page
124
⇒ “2.16 Removing and installing the rear door window”, page
126
⇒ “2.17 Removing and installing the outside door seal”, page
128
⇒ “2.18 Removing and installing the inside door seal”, page
130
⇒ “2.19 Door edge protection”, page 131
2.1 Summary of components - door internal parts

1 - Top door trim strip

2 - Window run
run”, page 117 .
3 - Outer trim panel
stalling B-pillar trim from
the door”, page 211 .
4 - Door window
installing the rear door
5 - Door
page 71 .
7 - Nut
Nm.
motor”, page 105 .
9 - Screw
Nm.
10 - Loudspeaker
11 - Window lifter
❑ Removing and installing ⇒ “2.5 Remove and install window lifter”, page 107 .
12 - Screw
❑ Removing and installing ⇒ “2.6 Removing and installing the inside door cover”, page 109 .
14 - Cap
15 - Screw
18 - Outer trim panel
❑ Removing and installing ⇒ “2.5 Removing and installing B-pillar trim from the door”, page 211 .
19 - Fixed side window

2.2 Summary of components - Door handle and door lock
1 - Door lock
installing the door lock”,
page 115 .
2 - Screw
❑ 1.5 Nm.
3 - Clamp
stalling bearing brack‐
et”, page 113 .
4 - Surface
5 - Cap
installing the cap on the
door handle”, page
120 .
6 - Door handle
stalling the door han‐
dle”, page 112 .
7 - Screw
❑ 1.5 Nm.
❑ The bearing bracket is
released from the door
by loosening the screw.
8 - Control cable
❑ From door lock -1- to
9 - Control cable
❑ From the inner door control to the door lock -1-.
❑ With grommet for feeding through at the cover.
10 - Cap
11 - Screw
❑ 18 Nm.
2.3 Summary of components - window runs and window channel strips

1 - Window run
2 - Fixed rear door window
3 - Guide bolt of the fixed win‐
dow
4 - Rear door
5 - Screw
Nm.
2.4 Removing and installing window lifter

motor
Removing

– Remove door trim panel ⇒ Rep. gr. 70 ; Rear door trim pan‐
els; removing and installing rear door trim panel .
– Secure the door window in the top position with adhesive tape
so that it does not slide down.
– Unplug connector -4-.
– Remove screws -2- (3 Nm).
– Remove the window lifter motor -1- from the supports of the
cable drum -3-.
Installing
Caution
On a newly installed window lifter motor (door control unit), the

auxiliary functions must be coded!

– Fit the window lifter motor - 1 - on the supports of the hoisting

drum - 3 -. Raise the door window slightly and then lower it so
that the serration can slide in better between the motor and
the cable drum.
– Secure the plug connection - 4 -.
– The new window lifter motor is coded.
removal.
2.5 Remove and install window lifter

Removing

– Remove door window ⇒ “2.16 Removing and installing the
rear door window”, page 126 .
– Remove window lifter motor ⇒ “2.4 Removing and installing
window lifter motor”, page 105 .
– Unlock the catches - 3 - on the cable drum - 4 - and slide into
the door arrows - a - .
– Slide the window lifter - 1 - into the door.
– Slide the window lifter to the door cutout -5- arrow -b- and take
it out arrow -c-.
Installing


– Press the hoisting drum through the door openings
-arrows c-, until the catches lock into position.

cover
Removing

– Raise the cover -3- at the points provided for pliers.
– Guide the control cable for the inside handle -1- through the
opening of the inside cover.
– Remove the cover -2- from the door -3-.
Note
♦ If the following operations are necessary, pull the Bowden cable -1- with the grommet -2- out of the cover
-3-.
♦ Unclip the cable guide on the mount -5-.
Installing

– Pull the Bowden cable -1- through the cover -3- and secure
the grommet -2-.
– Insert the cover -3- into the door opening -3-.
– Clip the cover into the door.
Note
Secure the cable guide to the cover.

clamp
Removing
– Release screws - 2 - and remove locking clamp - 1 -.
Installing
– Fit the locking clamp - 1 - at the D pillar and position the screws
- 2 -. Tightening torque: 25 Nm.
– Adjusting the locking clamp ⇒ “1.4 Adjusting the locking
clamp”, page 99 .

2.8 Removing and installing the door handle

Removing
– Remove the cap ⇒ “2.14 Removing and installing the cap on

the door handle”, page 120 .
– Lightly pull door handle - 1 - towards the rear arrow - a - out of
the support of the bearing bracket.
– Swivel the door handle in direction of arrow - b -.
– Remove the door handle at a right angle arrow - a - out of the
bearing bracket - 2 -.
Installing

– Insert the door handle - 1 - at a right angle arrow - b - into the

bearing bracket.
– Swivel the door handle - 1 - into the door arrow - b -.
– Forcefully press the door handle forwards arrow - c -into the
support of the bearing bracket.
Install the cap ⇒ “2.14 Removing and installing the cap on the
door handle”, page 120 .
• Then it is absolutely necessary to perform a functional check
2.9 Removing and installing bearing bracket

Removing

– Remove rear door trim panel ⇒ Rep. gr. 70 ; Rear door trim
panels; removing and installing rear door trim panel .
– Remove the cap ⇒ “2.14 Removing and installing the cap on
the door handle”, page 120 and the door handle ⇒ “2.8 Re‐
moving and installing the door handle”, page 112 .
– Release screw - 4 - and remove gasket - 3 -.
– Remove bearing bracket - 1 - from the door arrow - a -.
Slacken Bowden cable
– Unlock the bracket - 5 - and swivel out the mount out of the
support in the bearing bracket arrow - b -.
– Lift the bolt of the control cable out of the support - c -.
– Remove the Bowden cable from the bearing bracket arrow
-d-.
Installing


– Install screw -4-, tightening torque 1 Nm.
2.10 Removing and installing the door lock

Removing

– Remove the lock - 1 - from the door - 2 -.
Slacken Bowden cable to bearing bracket
– Twist the Bowden cable - 5 - by 45° and remove it from the
bracket - a -.
– Turn the Bowden cable - b - until it can be pulled out of the lug
in the door lock (Pos. 1) arrow - c -.
Slacken the Bowden cable to the inner door control:
bracket.
– Turn the Bowden cable arrow - d - until the Bowden cable can
be pulled out of the lug in the door lock (Pos. 1) arrow - e -.
Installing


– Tightening torque of screw (Pos. 4) - 18 Nm.
It is absolutely necessary to perform a functional check because
the door cannot be opened if the adjustment of the Bowden cables
is not accurate and if they are not correctly locked.
2.11 Removing and installing the window run
Note
♦ Before assembly the gasket contact surfaces must be coated

with soapy water so that they can be moved easily and posi‐
tioned on the flanges more accurately.
♦ Do not bend the window run when removing!

Removing
– Remove the screw -5- that secures the fixed window.
– Push the fixed pane out of the pin bolt -3- and carefully remove
the window run with fixed pane from the door web step by step.
– Slide the window run with fixed pane upwards out of the door.
Installing
– Slide the window run with fixed pane into the door.
– Clip the guide bolts into the door.
– Push gasket onto door web.
– Install door trim panel ⇒ Rep. gr. 70 ; Rear door trim panels;
Removing and installing rear door trim panel .
2.12 Removing and installing the outer win‐

dow channel strip
Note

♦ The core of the outer window channel strip consists of a metal

insert.
♦ If the core is bent, the seal can no longer be straightened. It
remains “warped”.
♦ Therefore the seal must be removed uniformly and without
bending it.
Removing
– Remove seal evenly in direction of arrow - a - upwards out of
the door flange - 2 -.
Installing
– Mount the outer window channel strip onto the door flange and
press it on evenly.
Note
Do not use any impact tools!
2.13 Removing and installing the inner window channel strip

Removing
– Detach window channel strip - 1 - evenly - arrows - from the
flange - 2 -.
Installing
– Press the window channel strip - 1 - by hand evenly onto the
flange - 2 -.

door handle
Removing
♦ Assembly tool - T10389- .

– Remove plug over the hole -3-.

– Guide the assembly tool - T10389- into the hole in direction of
the lock hook of the cap.
– Pull the assembly tool - T10389- forwards around 5 mm in
-direction of arrow-, until the hook unlocks.

Pull the door handle -2- out of the door a short way -arrow a-.
Note
Do not press the door handle into the door. This would damage the bearing bracket.
– Pull the cap - 1 - out of the bearing bracket -arrow b-.

Installing

• Pull the door handle -2- out of the door a short way in direction
of -arrow a-.
– Push the cap -1- into the bearing bracket -arrow b-.

– Press the cap -1- gently onto the door.

– For example guide a screwdriver -4- at the lock hooks -3- of
the bearing bracket.
– Press in the screwdriver -arrow- until the hook locks.
– Clip the plug into the hole -5-.
2.15 Summary of components - rear door window

1 - decorative strip
❑ Inserted into the window
guide.
2 - Window run
run”, page 117 .
3 - Cover for the B-pillar on the
door
stalling B-pillar trim from
the door”, page 211 .
4 - Door window
installing the rear door
5 - Door
page 119 .
7 - Nut
Nm.
motor”, page 105 .
9 - Screw
10 - Loudspeaker
11 - Window lifter
❑ Removing and installing ⇒ “2.5 Remove and install window lifter”, page 107 .
12 - Screw
❑ Removing and installing ⇒ “2.6 Removing and installing the inside door cover”, page 109 .
14 - Adhesive pad
15 - Screw
16 - Protective door strip
18 - Cover for the C-pillar on the door
❑ Removing and installing ⇒ “2.6 Removing and installing C-pillar trim from the door”, page 213 .
19 - Fixed door window

2.16 Removing and installing the rear door

window
Removing
– Remove inner window channel strip ⇒ “2.13 Removing and
installing the inner window channel strip”, page 119 .
– Removing the window run ⇒ “2.11 Removing and installing the
window run”, page 117 .
– Release cap - 6 -.
– Lower the door window -1- until the expanding pin -4- and the
straddling dowel -5- can be accessed in the window lifter
opening -3-.
Note

If this operation cannot be performed due to a failure at the window lifter motor, remove the window lifter motor
- 8 - ⇒ “2.4 Removing and installing window lifter motor”, page 105 . Then the door window can be pushed to
the required working height.
– Press the expanding pin -5- out of the expanding dowel -4-.
– Then press the straddling dowel -4- out of the window lifter and
pane.
Note
Hold the door window when pressing out the straddling dowel so that the door does not fall down and get
damaged.
– Pull the rear part of the window run -2- out of the supports.
– Pull the door window - 1 - upwards at an angle - arrows - to‐
wards the outside of the vehicle and out of the window chan‐
nel.
Installing

Note
Before inserting the expanding dowel - 3 - and the expanding pin

- 4 -, check the door window - 1 - for damage.
– Take the mean of the centre straddling dowel - 3 - and insert

it when the door window is removed - 1 -.
– Press the straddle pin -4- into the straddling dowel -3-.
– Guide the pane - 1 - into the door - 2 - insert arrows - a - and
into the window lifter guide - 5 -.
– Gently lock the pane -1- from above into the window lifter -5-.
– It must be pressed until the catch locks audibly into place.
removal.
door trim panel.
2.17 Removing and installing the outside door seal

Removing
– Pull the seal -1- off the door.
Installing
Note
Remove protective foil from its wrapping until just before assembly. Processing temperature: approx. 20 °C.
– Remove any residues of adhesive with a lubricating plate.

– Thoroughly clean the adhesive surface with adhesive remover
D 002 000 10 immediately before sticking on the door seal.
• Adhesive surfaces must be free of dirt and grease, as well as
any residues of adhesive.
– The vulcanised section -2- of the door seal must be at the
centre of the threshold.
– Remove the protective film and insert the door seal in the top
rear radius -arrow-. Do not over-extend the door seal to ensure
that it does not lengthen too much.
– Correctly press the adhesive surface for the seal -1- around
circumference onto the door -1- with e.g. a pinch roller - 3356- .


seal
During the installation in series, the inside door seals are provided
with a sealing compound which is placed on the door flange and
subsequently rolled up.
Note
♦ During the removal of the seal, the sealing mass is distributed

on the inside of the seal. While doing so, the sides are slightly
bent open. If the seal is re-installed, leak-tightness and tight fit
can no longer be guaranteed.
♦ For this reason, each seal which was completely removed
must be replaced with a so-called “hammer finish seal”.
♦ If the seals were detached partially, press together the sides
of the seal before installing.
♦ Removing and installing is only carried out for the right inside
door seal. The same applies therefore when removing and in‐
stalling the left inside door seal.

Removing
– Remove B-pillar trim panels ⇒ General body repairs, interior;
Rep. gr. 70 ; Interior trim panels; Removing and installing B-
pillar trim panel , sill panel ⇒ General body repairs, interior;
Rep. gr. 70 ; Interior trim panels; sill panel and removing and
installing C-pillar trim panel ⇒ General body repairs, interior;
Rep. gr. 70 ; Interior trim panels; Removing and installing C-
pillar trim panel .
– Detach the inside door seal - 1 - from the body flange - 2 -.
Installing
– When installing the inside door seal, start in the top radius of
the door cutout arrows - b -.
– Sealant groove at position arrows - a - .
– Install the remove inside trim panels.
2.19 Door edge protection

⇒ “2.19.1 Removing and installing”, page 131
⇒ “2.19.2 Adjusting the door protection”, page 133
⇒ “2.19.3 Height adjustment of the protective strip”, page 134
2.19.1 Removing and installing

1 - Door
2 - Activator
3 - Screw
Nm.
4 - Screw
Nm.
5 - Control cable
6 - Retaining clip
7 - Protective strip
Removing
– Remove door trim ⇒

General body repairs,
interior; Rep. gr. 70 ;
Rear door trim panels;
Removing and installing
rear door trim .
– Remove inside door

cover ⇒ “2.6 Removing
and installing the inside
– Unclip the protective

strip -7- from the door to
the outside.
– Release clips -6-.
– Pull out activator with Bowden cable and door protection through the opening in the door.
Installing
– Only clip in the protective strip -7- when adjusting!
Note
♦ When removing the door protec‐

tion, tie the old part with cord,
wire or other means and guide it
through the door. Leave the cord
in the door. Use a cord to pull the
new part through the door back
to the securing hole.
♦ Only adjust after installing!
♦ The inner door cover and the
door trim are only installed once
the door protection has been ad‐
justed and it has been checked
that it is functioning correctly!

2.19.2 Adjusting the door protection
– The screws -4- for the door protection -8- must be loosened.
– Slide the protective strip -7- into the door protection -8-. The
protective strip must engage audibly.
– Adjust the protective strip so that it is in contact along the entire
length of the door edge. The door protection can be pushed to
the side.
– If adjusted correctly, tighten the screws to the specified tight‐
ening torque. Start with the bottom screw, then tighten the top
screw.
– Now check that the protective strip is functioning and adjust
the movement.
– Close the door slowly to check whether it collides with the door
or the side section.
– Before adjusting the activator, pull the collar off the activator
tappet to release the adjusting mechanism.

– If the protective strip collides with the door when the door is
moved, the activator tappet -2- must be screwed out.
– If the protective strip is in contact with the door before the door
is closed, the activator tappet -2- must be screwed in.
2.19.3 Height adjustment of the protective strip
– If the height of the protective strip -1- is not in line the edge of
the door -5- (e.g. in the right magnifying glass), it must be ad‐
justed with compensating washers -3- inserted under the top
or bottom screw (between metal and door protection) -2-. This
creates additional space under the door protection -4-.
– If compensating washers have been installed, check that the
door protection is correctly adjusted once again ⇒ “2.19.2 Ad‐
justing the door protection”, page 133 .
– Check that the door protection is functioning correctly several
times.

60 – Sunroof
1 Sun roof
⇒ “1.1 Summary of components - Sun roof”, page 135
⇒ “1.2 Summary of components - screen for sliding roof”, page
137
⇒ “1.3 Assembly overview - Air deflector”, page 137
⇒ “1.4 Removing and installing sun roof frame”, page 138
⇒ “1.5 Removing and installing the draft deflector”, page 141
⇒ “1.6 Removing and installing the glass roof”, page 143
⇒ “1.7 Adjusting the sliding sunroof cover”, page 151
⇒ “1.8 Removing and installing the sliding sunroof control unit
J245 ”, page 154
⇒ “1.9 Removing and installing roof blind control unit J394 ”, page
156
⇒ “1.10 Removing and installing the gasket of the sun roof”, page
158
⇒ “1.11 Removing and installing the sliding roof screen”, page
161
⇒ “1.12 Operating without power”, page 163
⇒ “1.13 Programming the sliding sunroof control unit J245 ”, page
163
⇒ “1.14 Removing and installing the sliding sunroof roller blind
motor V260 ”, page 164
1.1 Summary of components - Sun roof
1. Sun roof 135

1 - Outer seal
installing the gasket of
the sun roof”, page
158 .
2 - Glass for sunroof
stalling the glass roof”,
page 143 .
❑ Setting ⇒ “1.7 Adjusting
the sliding sunroof cov‐
er”, page 151 .
3 - Screw
Nm.
4 - Inner seal
❑ Installed on assembly
frame.
5 - Sunroof frame
stalling sun roof frame”,
page 138 .
6 - Screw
❑ For fastening sunroof
frames.
Nm.
7 - Control unit for roof blind
stalling roof blind control
unit J394 ”, page 156 .
8 - Motor for roof blind
❑ Removing and installing ⇒ “1.14 Removing and installing the sliding sunroof roller blind motor V260 ”,
page 164 .
❑ Initialisation ⇒ “1.9.2 Teaching the roof blind control unit J394 ”, page 157 .
9 - Screw
❑ For fastening engines.
10 - Screw for roof blind
11 - Screen for sliding roof
❑ Removing and installing ⇒ “1.11 Removing and installing the sliding roof screen”, page 161 .
12 - Motor and control unit for sliding sunroof -J245-
❑ Removing and installing ⇒ “1.8 Removing and installing the sliding sunroof control unit J245 ”, page
154 .
❑ Initialisation ⇒ “1.8 Removing and installing the sliding sunroof control unit J245 ”, page 154 .
13 - Support clip
14 - Draft deflector frame
15 - Draft deflector
136 Rep. gr.60 - Sunroof

❑ Removing and installing ⇒ “1.5 Removing and installing the draft deflector”, page 141 .
16 - Support clip
17 - Tilting mechanism
❑ For front glass panel, with linkages.
1.2 Summary of components - screen for sliding roof
1 - Screen for sliding roof

installing the sliding roof
screen”, page 161 .
2 - Support
❑ For the cloth of the blind
of the sun roof.
3 - Screw
❑ 2 Nm.
4 - Driver
5 - Tension hoop
6 - Sunroof frame
1.3 Assembly overview - Air deflector
1. Sun roof 137

1 - Draft deflector
stalling the draft deflec‐
tor”, page 141 .
2 - Tension spring
3 - Support clip
1.4 Removing and installing sun roof frame
Note
A second mechanic is required as a minimum to remove and in‐

stall the assembly frame.
Removing

– Remove moulded headliner ⇒ General body repairs, interior;

Rep. gr. 70 ; Moulded headliner; removing and installing
moulded headliner .
– Disconnect the plug connection for the wire harness on the
sunroof motor.
– Remove water drain hoses from the supports.
– Remove screws - 3 - up to the centre screws, right and left.
Note
Hold frame with the assistance of 2 mechanics.
– Only remove the last screws now.

– Take the assembly frame - 2 - from the vehicle -1-.
Installing
1. Sun roof 139

– With the aid of 2 mechanic, lift the assembly frame - 1 - into

the vehicle.
– When installing, align the assembly frame - 1 - with the 2 cylin‐
drical pins (reversed drill ∅ 8 mm) at the front and rear cen‐
tering holes -arrows A and B- and to the roof.
– Insert screws - 2 -, but do not tighten.
– Connect all water drain hoses -arrow C-.
– Connect plug connections -3-.

– Tighten the screws in the specified sequence -1 to 4- alter‐

nately on both sides.
– Tightened the remaining screws -arrows- in any order.
Specified torques
♦ Screws, 8 Nm.
1.5 Removing and installing the draft deflec‐

tor
Removing
1. Sun roof 141

– Open the front glass lid and the sun blind fully.
– Lift the tab with a screwdriver - 2 - out of the frame
- arrow a -.
– Move the air deflectors - 1 - to the front - arrow b - and remove
from the guide.
Installing

– Insert wind deflector - 1 - with the tabs in the holes.

– Push wind deflector backwards until it audibly clicks into place
in the frame.
1.6 Removing and installing the glass roof
1.6.1 Removing and installing the front glass

panel
Removing
1. Sun roof 143

– Open the glass panel - 2 - until the blind - 1 - is accessible.

– Move the trims -1- backwards slightly out of the interior
-arrow A-.
– Remove the caps downwards -arrow B- arrow be from the
cover.
Note
Use a magnetic tool to remove the screws so that the screws do not fall into the mechanism of the panorama
sliding roof.

– Remove gasket - 3 - from body frame.

– Remove the screws - 2 - for glass panel - 1 - left and right.
– Remove the glass panel upwards - arrows - .
Installing
Note
♦ Always use new screws when installing the glass panel.

♦ Use a magnetic tool to install the screws so that the screws do not fall into the guide of the panorama sliding
roof.
1. Sun roof 145

– If necessary, push the folding mechanism - 3 - on both sides

until the markings - 5 - form a line - arrows b - .
– Insert the glass panel - 1 - from the top - arrows a - into the
folding mechanism - 3 -. Insert screws - 2 -, but do not tighten.
– Adjust front glass panel ⇒ “1.7 Adjusting the sliding sunroof
cover”, page 151 .
Specified torques
♦ Screws, 5 Nm.

– Guide to the trim -1- at an angle to the glass panel -2-

-arrow C- and press into the holes -arrow A-.
– Slide the trim forwards up to the stop -arrow B-.
– After all work has been done, carry out a standard run proce‐
dure of the sunroof motor.
1.6.2 Removing and installing the rear glass

panel
Removing
Note
Use a magnetic tool to remove the screws so that the screws do not fall into the guide of the panorama sliding
roof.
1. Sun roof 147


– Remove the screws - 2 - for glass panel - 1 - left and right.

– Lightly slide the rear glass panel - 1 - underneath the front

glass panel - 3 - - arrow a - .
– Remove the rear glass panel - 1 - from the roof cutout - 2 - in
the rear section only - arrows b - .
– Slide the rear glass panel -1- upwards at an angle -arrow C-
above the roof -2- and remove under the front glass panel
-3-.
Installing
Note
♦ Always use new screws when installing the glass panel.

♦ Use a magnetic tool to install the screws so that the screws do not fall into the guide of the panorama sliding
roof.
1. Sun roof 149


– Insert the rear glass panel - 1 - from the top and at an angle
under the front glass panel - 3 -.
– Insert the rear glass panel - 1 - in the rear section downwards
into the roof cutout - 2 - and push to the rear.

– Insert screws -2-, but do not tighten.

– Adjust the rear glass panel - 1 -.
– Tighten the rear screws after adjusting the glass panel.
dure of the sunroof motor.
Specified torques
♦ Screws, 5 Nm.
1.7 Adjusting the sliding sunroof cover

⇒ “1.7.1 Check height adjustment”, page 151
⇒ “1.7.2 Adjust glass panel at front”, page 152
⇒ “1.7.3 Adjusting the rear glass panel”, page 154
1.7.1 Check height adjustment
Note
♦ Only adjust the front glass panel at the front edge and the rear glass panel at the rear edge.
1. Sun roof 151

♦ To achieve the best possible external appearance, it is important to make sure that the left and right ad‐
justment is performed as evenly as possible (symmetrical).
♦ arrow points in direction of travel.
Check height adjustment

– Check the adjustment of the front glass panel - 1 - and the rear
glass panel - 2 - using a gauge block.
♦ Dimension -a- : -1.3 ± 1.1 mm.
♦ Dimension -b- : 1 ± 1.2 mm.
♦ Dimension -c- : 0.9 ± 1.1 mm.
If the measured values differ from the specified values, the cor‐
responding glass panel must be adjusted.
♦ Adjust front glass panel ⇒ “1.7.2 Adjust glass panel at front”,
page 152 .
♦ Adjust rear glass panel ⇒ “1.7.3 Adjusting the rear glass pan‐
el”, page 154 .
1.7.2 Adjust glass panel at front

Note
♦ Height adjustment of the glass panel must be performed after the glass panel was released from the sliding
position.
♦ arrow points in direction of travel.
– Remove the cap ⇒ “1.6.1 Removing and installing the front

glass panel”, page 143 .
– Only undo the two front screws - 4 - left and right for the front
glass panel - 2 -.
– Adjust the front glass panel - 3 - as per the dimensions ⇒
“1.7 Adjusting the sliding sunroof cover”, page 151 .
– Tighten left and right screws - 4 -.
– Install the cap ⇒ “1.6 Removing and installing the glass roof”,
page 143 .
– Place seal - 5 - on assembly frame.
Specified torques
1. Sun roof 153

♦ Screws, 5 Nm.
1.7.3 Adjusting the rear glass panel
Note
arrow points in direction of travel.
– Detach the inner seal - 5 -.

– Release screws - 4 - for rear glass panel - 3 -.
– Adjust the rear glass panel - 3 - as per the dimensions ⇒
“1.7 Adjusting the sliding sunroof cover”, page 151 .
– Tighten left and right screws - 4 -.
– Place seal - 5 - on assembly frame.
Specified torques
♦ Screws, 5 Nm.
1.8 Removing and installing the sliding sun‐

roof control unit - J245-

Removing
Note
The glass panel drive for the sun roof must only be removed and
installed when the roof is closed (zero position).
Removing
– Remove front light unit/control ⇒ General body repairs, inte‐
rior; Rep. gr. 70 ; Moulded headliner; Removing and installing
moulded headliner .
– Switch off the ignition, withdraw ignition key and open the door.
• This condition must remain until the drive is installed.
• The glass panel drive for the sun roof must only be removed
and installed when the roof is closed (zero position).
– Raise the sunroof motor - 1 - downwards a little and swivel
downwards.
– Disconnect plug connections -2-.
Installing
1. Sun roof 155

– Install sliding roof - 1 - and screw in the screws - 3 -. Tightening

torque: 3.5 Nm.
– Connect plug connections -2-.
– Install front light unit/control ⇒ General body repairs, interior;
moulded headliner .
– Code the new control unit ⇒ Vehicle diagnostic tester.
– After all work is done, carry out a standard run procedure of
the sunroof motor ⇒ “1.13 Programming the sliding sunroof
control unit J245 ”, page 163 .
1.9 Removing and installing roof blind con‐

trol unit - J394-
⇒ “1.9.1 Removing and installing roof blind control unit J394 ”,
page 156
⇒ “1.9.2 Teaching the roof blind control unit J394 ”, page 157
1.9.1 Removing and installing roof blind control unit - J394-


moulded headliner .
– Unlock the catches - 3 - - arrows A -.
– Gently lift the control unit -1- and pull out of the mounting
bracket -2- -arrows B-.
– Disconnect the plug connections -4- on the control unit -1-.
– Code the new control unit ⇒ Vehicle diagnostic tester.
1.9.2 Teaching the roof blind control unit -

J394-
Note
♦ After replacing the glass panel, a motor or the folding mecha‐

nism, an initial run procedure must be carried out.
♦ During the initial run procedure, the closing force limiter is
switched off.
Ignition is switched on.
1. Sun roof 157

– Press the “Close” button and keep it pressed during the entire
initial run procedure (approx. 20 s).
Close the sunroof blind completely.
1.10 Removing and installing the gasket of

the sun roof
⇒ “1.10.1 Removing and installing the gasket of the sun roof”,
page 158 .
⇒ “1.10.2 Removing and installing glass panel seal”, page
160 .
1.10.1 Removing and installing the gasket of

the sun roof
Removing
– Remove the installation frame ⇒ “1.4 Removing and installing

sun roof frame”, page 138 .
– Pull the external seal - 3 - with the adhesive surface - 1 - off
the roof - 2 -.
Installing

– Remove any adhesive residues with adhesive remover .

– The adhesive surface on the roof cutout must be dust- and
grease-free.
– Clean all the bonding surface with cleaning solution - D 009
401 04- .
– Coat the adhesive surfaces on the roof cutout with glass/paint
primer for plastic - D 366 PR1 A1- .
– Leave to dry for 10 minutes.
– Align the new external seal - 1 - through the connection
- arrow - to the middle of rear the roof cutout.
– First place the seal over the entire length of the sliding sunroof
section.
– If the seal is too long or too short, the seal must be recirculated
all round. Do not shorten the seal!
– Press the seal all the way around the bridge.
– If the new seal is ready to be glued, then gradually remove the
protective tape from the tape on the seal. At the same time,
press the seal onto the intended position. The seal can not be
detached and glued on again.
– Proceed all the way around the sliding sunroof as follows.
1. Sun roof 159

– Roll around the outer seal 2x evenly with the contact roller -
3356- .
– Install the installation frame ⇒ “1.4 Removing and installing
sun roof frame”, page 138 .
1.10.2 Removing and installing glass panel seal
Removing
– Remove rear glass panel ⇒ “1.6.2 Removing and installing the
rear glass panel”, page 147 .
– Remove the seal in the side area - 4 - on the side from the rear
glass panel - 1 - - arrow b - .
– Remove the seal from the rear glass panel in the front
region - 3 - - 1 - towards the front - arrow a - .
Installing
– Coat with detergent so that the seal slips more easily into the
mounting.
– Press in seal in the front region - 3 - from the top into the sup‐
port of the glass panel - 1 -.

– Press in seal in the side region - 4 - into the support of the

glass panel - 1 -.
– Install rear glass panel ⇒ “1.6.2 Removing and installing the
1.11 Removing and installing the sliding roof

screen
Removing
Note
♦ In the event of a power failure, the sun blind can be moved manually into the removal position (fully opened)
by turning the motor for the sun blind using a commercially available hexagon wrench
♦ Keep the parts clean when working on the cloth for the sun blind or cover them up. Wear protective gloves,
if necessary.
Removing
– Open the sun blind -1- completely.
1. Sun roof 161

– Remove front glass panel ⇒ “1.6.1 Removing and installing the

front glass panel”, page 143 .
– Remove rear glass panel ⇒ “1.6.2 Removing and installing the
– Remove the sunroof frame ⇒ “1.4 Removing and installing sun
roof frame”, page 138 .
– Remove motor for sun blind ⇒ “1.14 Removing and installing
the sliding sunroof roller blind motor V260 ”, page 164 .
– Slide the sun blind -1- backwards completely in parallel
-arrow A-.
– Swivel the sun blind -1- to the same extent in the front area on
left and right -arrow B-.
– Pull the sun blind -1- out of the installation frame -arrow C-.
Installing
– Guide the sun blind -1- into the assembly frame to the same
extent on the right and left -arrow A-.
– Fit the sun blind -1- into the assembly frame -arrow B-.

– Level the sun blind mounting -3- on left and right to the guides
in the assembly frame -4- -arrows C-.
– Tighten screws -2-.
Specified torques
♦ Tightening torque - 3 Nm.
1.12 Operating without power
Note
♦ In the event of power failure, the sliding/tilting roof with glass panel can be moved at the drive using a
commercially available hexagon wrench.
♦ It must be turned using increased force because the drive does not separate from the gearing mechanism.
– Insert the hexagonal wrench in the screw -3- of the drive -1-.
– Close the glass panel by turning the screw -3-.
1.13 Programming the sliding sunroof control unit - J245-
1. Sun roof 163

Note
♦ After replacing the glass panel, a motor or the folding mechanism, an initial run procedure must be carried
out.
♦ During the initial run procedure, the closing force limiter is switched off.
Standard run procedure of sunroof motor

Ignition is switched on.
– Push the button forward -arrow B- and keep it in this position
during the entire initial run procedure (approx. 20 s).
– During the initial run procedure, the glass panel closes first
and then moves approx. 200 mm backwards.
– After the glass panel has closed again, the initial run procedure
ends and the button can be released.
1.14 Removing and installing the sliding sun‐

roof roller blind motor - V260-
Removing

– Lower moulded headliner ⇒ General body repairs, interior;

moulded headliner .
– Disconnect the plug connection -2- from the motor for the sun
blind -1-.
– Remove the motor for the sun blind -1-.
Installing
– Align the sun blind before installing the motor for the sun blind
so that it is in parallel.
1. Sun roof 165

– Measure and adjust the clearance -dimension a- between arch

support for roller blind - 1 - and roller blind housing - 2 -.
dure of the motor for the sun blind ⇒ “1.9.2 Teaching the roof
blind control unit J394 ”, page 157 .
Specified torques
Component Specified torques
Roller blind case 3.5 Nm

2 Water drain hoses

⇒ “2.1 Summary of components - water drain hoses”, page
167
⇒ “2.2 Cleaning the water drain hoses”, page 167
⇒ “2.3 Removing and installing water drain hoses”, page 168
2.1 Summary of components - water drain hoses
1 - Front water drain hose

❑ Left and right.
❑ Clean ⇒ “2.2 Cleaning
the water drain hoses”,
page 167 .
stalling water drain
hoses”, page 168 .
2 - Rear water drain hose
❑ Left and right.
❑ Clean ⇒ “2.2 Cleaning
the water drain hoses”,
page 167 .
stalling water drain
hoses”, page 168 .
3 - Front grommet for drainage
4 - Brand
❑ The water drain hose
must be inserted into the
grommet for drainage
up to the mark.
5 - Retaining clip
6 - Retaining clip
7 - Brand
❑ The water drain hose
must be inserted into the
grommet for drainage
up to the mark.
8 - Rear grommet for drainage
2.2 Cleaning the water drain hoses
2. Water drain hoses 167

Front water drain hose

The front water drain hoses - 1 - run through the A pillars and end
in the plenum chamber.
– Cleaning in all vehicles is from the bottom grommets for
drainage -3-, e.g. with Bowden cable.
Rear water drain hose
The rear water drain hoses -2- run through the C-pillars and end
in the rear wheel arches.
– Remove wheelhouse liner ⇒ “7.2 Removing and installing the
rear wheelhouse liner”, page 233 .
– Cleaning in all vehicles is from the bottom grommets for
drainage -8-, e.g. with Bowden cable.
2.3 Removing and installing water drain hoses

Remove front water drain hose

moulded headliner .
– Pull front water drain hose -1- out of the retaining clips -5- and
grommets for water drainage -3-.
Remove rear water drain hose
moulded headliner .
– Pull rear water drain hose -2- out of the retaining clips -6- and
grommets for water drainage -8-.
Installing the water drain hose
– Slide the water drain hose -1 and 2- into the grommets for
drainage -3 and 8- up to the marks -4 and 7-.
2. Water drain hoses 169

63 – Bumpers
1 Front bumper
⇒ “1.1 Summary of components - Bumper”, page 170
⇒ “1.2 Summary of components - impact bar”, page 171
⇒ “1.3 Removing and installing bumper”, page 172
⇒ “1.4 Removing and installing impact bars”, page 174
⇒ “1.5 Removing and installing mounting parts”, page 175
⇒ “1.6 Cutting out the openings for the parking aid sensors (drill)”,
page 175
⇒ “1.7 Cutting out openings for park steering assistant sender”,
page 176
⇒ “1.8 Installing parking aid sender retainer”, page 177
1.1 Summary of components - Bumper
Note
Depending on the model version, slight differences must be taken into consideration when removing and in‐
stalling the front bumper.
170 Rep. gr.63 - Bumpers

1 - Screw
Nm.
2 - Screw
Nm.
3 - Front bumper
stalling: ⇒ “1.3 Remov‐
ing and installing
4 - Screw
Nm.
1.2 Summary of components - impact bar
1. Front bumper 171

1 - Front bumper impact bar

2 - Screw for radiator frame
Nm.
3 - Screw
Nm.
4 - Screw
Nm.
5 - Cross member
6 - Top air guide
7 - Air guide duct
8 - Metallic impact absorber
❑ Depending upon vehicle
equipment.
1.3 Removing and installing bumper

Removing

– Remove wheelhouse liners ⇒ “7.1 Removing and installing the

front wheelhouse liner”, page 232 .
– Partially remove wing trim strip ⇒ “2.4 Removing and installing
trim strip”, page 208 .
– Detach the front bumper from the left and right guide parts on
the wing below the headlights.
– Slacken the bumper on the side guides.
– Remove the front bumper - 3 - in parallel from the vehicle with
the assistance of a 2nd mechanic.
ponents.
– Disconnect the hose coupling of the washer fluid lines (if
present) ⇒ Electrical system; Rep. gr. 92 ; Windscreen wiper
system; Summary of components - windscreen wiper system .
Installing
1. Front bumper 173

– Observe the parallelism and the correct gap sizes ⇒ Body Re‐
pairs; Rep. gr. 00 ; Technical data; body gaps; front body .
Note
After installing the bumper on vehicles with automatic distance

control, perform basic setting ⇒ Rep. gr. 44 ; Automatic distance
control; calibrate automatic distance control and code ⇒ Vehicle
diagnostic tester.
1.4 Removing and installing impact bars
Removing
– Removing front bumper ⇒ “1.3 Removing and installing
– Remove impact absorber (depending on vehicle equipment)
(Pos. 7).
– Remove top air guide (Pos. 5).
– Remove air guide duct (Pos. 6).
– Remove cross member (Pos. 4).

– Remove screws (Pos. 2).

– Disconnect plug connection for temperature sensor.
– Remove screws (Pos. 3).
– Remove impact bar (Pos. 1) from vehicle.
Installing
1.5 Removing and installing mounting parts
1 - Top bumper trim

2 - Radiator grille with cover for
automatic distance control
radar (radar for driver assis‐
tance systems - depending on
vehicle equipment)
❑ Clipped into the
bumper.
3 - Decorative frame
bumper.
4 - Bumpers
stalling bumper”, page
172 .
5 - Cap for headlight washer
system
6 - Middle ventilation grid
bumper.
7 - Left grid
bumper.
8 - Cap of parking sensor
9 - Front spoiler
bumper.
10 - Spoiler decorative grid
bumper.
11 - Cap
❑ Cover for towing lug.
12 - Cap of parking sensor
13 - Right grid
❑ Clipped into the bumper.
14 - Cap for headlight washer system
1.6 Cutting out the openings for the parking

aid sensors (drill)
1. Front bumper 175

Drilling openings - front bumper
Note
Avoid damage to the painted bumper side!
– Removing the bumper ⇒ “1.3 Removing and installing

– In the area of the pre-marked axis cross (from inside of
bumper), mark the centres for drilling four openings using a
suitable tool.
– Drill the openings with a diameter of 8 mm.
Openings for the sensors
– Use the cutting tool BEA 000 001 or -VAS 6614/1- to cut out
the opening.
– Use a step drill in order to drill the openings.
– First of all make the openings from the outer side of the bumper
when using a step drill. Complete the work step from the inner
side of the bumper.
– Trim the openings in a suitable manner in order to avoid dam‐
age to the paintwork.
– Procedure for gluing new sensor holder ⇒ “2.5 Installing park‐
ing aid sender retainer”, page 181 .
– After installing the sensors, install the bumper ⇒ “1.3 Remov‐
ing and installing bumper”, page 172 .
1.7 Cutting out openings for park steering

assistant sender
Front bumper
Note
Avoid damage to the painted bumper side!
Cut out opening

stalling the front wheelhouse liner”, page 232 .

– Use screw punch -TME01- or -VAS 895 017- to cut out the
opening.
– The position of the opening for the park steering assistant
sender is marked on the inside of the bumper.
– Before cutting out the opening, first make an opening ∅ 8.1
mm for the guide bolt of the screwdriver (bolt - M8 thread).
– The opening must always be cut from the outside (painted).
– Install screw holes and make an opening for parking and
steering assistant.
– After cutting out the opening, inspect for burrs, if necessary
clean the edges.
– Proceed in the same way on the opposite side of the bumper.
– The work sequence for the removal and installation of the
sender is described in the workshop manual ⇒ Electrical Sys‐
tem; Rep. gr. 94 .
– Install the front wheelhouse liner after installing and connect‐
ing the park steering assistant sender ⇒ “7.1 Removing and
installing the front wheelhouse liner”, page 232 .
Rear bumper
stalling the rear wheelhouse liner”, page 233 .
– Use screw punch - 2 - -TME01- or -VAS 895 017- to cut out

the opening.
– The position of the opening for the park steering assistant
sender is marked on the inside of the bumper - 1 -.
– Before cutting out the opening, first make an opening ∅ 8.1
mm for the guide bolt of the screwdriver (bolt - M8 thread).
– The opening must always be cut from the outside (painted).
– Install screw holes and make an opening for parking and
steering assistant.
– After cutting out the opening, inspect for burrs, if necessary
clean the edges.
– Proceed in the same way on the opposite side of the bumper.
– The work sequence for the removal and installation of the
sender is described in the workshop manual ⇒ Electrical Sys‐
tem; Rep. gr. 94 .
– Install the rear wheelhouse liner after installing and connecting
the park steering assistant sender ⇒ “7.2 Removing and in‐
stalling the rear wheelhouse liner”, page 233 .
1.8 Installing parking aid sender retainer

The sender holders for the front bumper cover are installed in
exactly the same way as for the rear bumper cover ⇒ “2.5 In‐
stalling parking aid sender retainer”, page 181 .
1. Front bumper 177

2 Rear bumper
⇒ “2.1 Summary of components - Bumper”, page 178
⇒ “2.2 Removing and installing bumper”, page 178
⇒ “2.3 Removing and installing impact bars”, page 180
⇒ “2.4 Cutting out the openings for the parking aid sensors (drill)”,
page 181
⇒ “2.5 Installing parking aid sender retainer”, page 181
2.1 Summary of components - Bumper
1 - Lateral guide section

2 - Screw
– Tightening torque: 3
Nm.
3 - Guide section
4 - Mounting bracket
5 - Nut
– Tightening torque: 2.2
Nm.
6 - Guide section
7 - Lateral guide section
8 - Expanding nut
9 - Screw
– Tightening torque: 20
Nm.
10 - Bumper bracket
Removing and installing ⇒
“2.3 Removing and installing
impact bars”, page 180 .
11 - Body-bound rivet
12 - Rear bumper
13 - Screw
– Tightening torque: 1.5
Nm.
2.2 Removing and installing bumper

Removing

– Remove tail lights ⇒ Electrical System; Rep. gr. 94 ; Tail

lights; Removing and installing tail lights .
– Partially unclip wing panel (there is a screw underneath) ⇒
“2.4 Removing and installing trim strip”, page 208 .
– Remove the screws -7- (1.5 Nm) in the area of the left and right
wheelhouse.
– Remove screws -8- (1 ± 5 Nm).
– Remove the screws -9- from below.
– Removing body-bound rivet -10-.
– Unclip bumper cover strip -3-.
– Remove the two nuts (1.5 Nm) under the bumper cover strip
-3-.
Carry out further installation only with the assistance of a second
mechanic.
– Release catches -arrows B-.
– Remove rear bumper -4- from the catches on the guide sec‐
tions.
– Remove the rear bumper from the vehicle in parallel arrows
- C -.
2. Rear bumper 179


ponents.
Installing
– Attach the existing plug connections.
– Install the rear bumper with the assistance of a 2nd mechanic.
Note
When fitting the rear bumper, make sure to guide it parallel at the
left and right guide sections.
– Press the rear bumper onto the centre guide section and the
left and right guide section until they lock audibly together.
– Observe the parallelism and the correct gap sizes ⇒ Body Re‐
pairs; Rep. gr. 00 ; Technical data; body gaps; rear body .
– Install screws and tighten to the specified tightening torque.
Note
After installing the rear bumper, perform coding on vehicles with

function for contactless opening of tailgate ⇒ Vehicle diagnostic
tester.
2.3 Removing and installing impact bars

Removing
– Remove the rear bumper ⇒ “2.2 Removing and installing
– Slide impact bar backwards.
Installing
2.4 Cutting out the openings for the parking

aid sensors (drill)
The openings for the sensors are produced in the same way as
the front bumper ⇒ “1.6 Cutting out the openings for the parking
aid sensors (drill)”, page 175 .
2.5 Installing parking aid sender retainer

Materials
♦ Cleaning solution - D 009 1) 1
401 04-
2. Rear bumper 181

1) Follow the treatment instructions according to the manufacturer's specifications

in the enclosed attachment.
Install retainers
Note
♦ The retainers are installed after the bumper cover is painted.

♦ Encoder brackets are fitted without double-sided adhesive
tape. Therefore, prior to installation, stick the double-sided ad‐
hesive tape - Akl 440 025 - onto the brackets. Roughen surface
slightly before gluing, clean and degrease.
– Drill holes for parking aid retainers ⇒ “1.6 Cutting out the open‐
ings for the parking aid sensors (drill)”, page 175 .
– Clean and degrease the adhesive surfaces on the bumper

cover -4- thoroughly.
– Remove the protective foil of the double-sided adhesive
tape -3- from the bracket.
– Fix the bracket - 2 - accurately on the specific point.

– Forcefully press on the bracket in the area of the adhesive

surface -3-.
– You may only continue to work on the bumper cover once the
minimum hardening time has passed.
You may only continue to work on the bumper cover and retainers
once the minimum hardening time of 2 hours has passed.
You must observe the minimum hardening time for the adhesive
tape to adhere completely.
The bumper cover must stay at the workstation during this time
and must not be moved.
2. Rear bumper 183

64 – Glazing
1 Repair instructions
⇒ “1.1 Materials”, page 186
⇒ “1.2 Minimum hardening time for glued windows”, page 186
⇒ “1.4 Installation instructions for glued windows”, page 187
⇒ “1.5 Preparing windows which have not been damaged for fit‐
ting”, page 187
⇒ “1.6 Preparing new windows for fitting”, page 188
⇒ “1.7 Preparing body flange for installation”, page 188
⇒ “1.8 Cleaning necessary due to soiling through adhesive”, page
189
Special tools needed
Note
The removal of the glued windows is described in the separating

device for glued windows - V.A.G 1474A- . The corresponding
tools from the separating device for glued windows - VAS 6452- ,
-VAS 6888- , -VAS 861 001 - or -VAS 861 001A- can also be used.
184 Rep. gr.64 - Glazing

Special tools and workshop

equipment required
♦ Separating device for glued windows - V.A.G 1474A- , or sep‐

arating device for glued windows - VAS 6452- or separating
device for glued windows - VAS 6888- or separating device for
glued windows - VAS 861 001- or -VAS 861 001A- .
♦ Suction cup - V.A.G 1344-
♦ Cutting tool - V.A.G 1351-
♦ Window removal set - V.A.G 1755-
♦ Hand pressure gun - V.A.G 1628-
♦ Cartridge heater - V.A.G 1939-
♦ Power knife - V.A.G 1561A-
♦ Cutting knife - V.A.G 1561/2-
♦ Setting gauge - 3371-
♦ Double cartridge gun - VAS 5237-
♦ Cutting thread - 357 853 999 B-
♦ Cutting cord - 357 845 955-
1. Repair instructions 185

1.1 Materials
Note
The part numbers of the materials are provided in the ⇒ Elec‐

tronic Catalogue of Original Parts - ETKA .
♦ 2K window pane adhesive 2) 1 3) 2 5) 4 7) 6
♦ 1K window pane adhesive 2) 1 3) 2 4) 3 6) 5
♦ Activator 2) 1
♦ Glass/paint primer 2) 1
♦ Cleaning solution 2) 1
♦ Primer applicator 2) 1
♦ Adhesive remover 2) 1
2) Observe the handling instructions in accordance with the specifications of the

manufacturer in the package insert.
3) Observe minimum hardening time.
4) According to manufacturer's instructions heat up e.g. with cartridge heater -
V.A.G 1939- .
5) Use for example the double cartridge gun - VAS 5237- for processing this
material.
6) Small cartridges 180 ml for sealing work, or if 400 ml cartridge is not adequate.
7) When using a 2K window pane component adhesive, remove the first 10 cm of
the pressed out adhesive in order to ensure the correct mixture of both compo‐
nents.
1.2 Minimum hardening time for glued win‐

dows
WARNING
Comply with special requirements when replacing glued win‐

dows. Among these are for example, that a newly glued wind‐
screen must fulfil the operational safety in the event of an
accident after a prescribed minimum hardening time.
The minimum hardening time is specified by the manufacturer on

the packaging insert.
With the minimum hardening time is meant the time from the mo‐
ment the window is glued until the vehicle is used. During this
time, the vehicle must stand on a flat surface at room temperature
(at least 15 °C).
WARNING
The vehicle is only safe for driving after the minimum hardening
time has expired.
1.3 Window repairs

Note
♦ In case of damage to the windscreen, it must be clarified

whether the glass can be repaired before replacing the wind‐
screen.
♦ Damaged windscreens can be repaired using the window re‐
pair set - VAS 6092- .
♦ The damage must not exceed a certain size and location.
♦ An instruction manual is enclosed with each pane repair kit.

♦ Pane repair kit - VAS 6092- or -VAS 6093- .
1.4 Installation instructions for glued win‐

dows
WARNING
For safety reasons, re-using a cut-out windscreen is not permis‐

sible. The windscreen must always be replaced with a new orig‐
inal part. The cut-out rear and side windows can be re-used after
a thorough inspection.
WARNING
The window must be inserted within 10 minutes as otherwise

the adhesion of the window adhesive may be poor.
Do not apply the adhesive bead too thick and do not press the
windows too hard on the body flange. Oozed adhesive can be
seen in the area of the joints because the windows do no longer
have any sealing lips.
♦ Apply the adhesive cement all around at a right angle to the

window.
♦ Insert the window into the body flange, for example using the
suction cup - V.A.G 1344- , take the mean and press in up to
the spacer web.
♦ Re-stick any existing stickers (for example for airbag).
1.5 Preparing windows which have not been

damaged for fitting
Cut back the adhesive bead

Note
♦ Cut back the remaining glue sealing material to 1-2 mm just

prior to adhering again. While doing so, do not damage the
glass/primer and ceramic layer.
♦ The remainder of the sealant serves as a base for the newly
applied glue sealing material.
WARNING
Do not prime the adhesive surface and do not treat with clean‐
ing solution. Keep the adhesive surfaces free of dirt or grease.
Exception: If the bonding is not carried out immediately after cut‐

ting back, the sealing compound must be activated with the
activator ⇒ “1.1 Materials”, page 186 .
1.6 Preparing new windows for fitting

All the windows are not pre-layered as a spare part.
Note
♦ The area where the adhesive bead is applied is neither pre-

layered nor primed.
♦ The sealing lip is a component part of a new windscreen.
– Clean the window edge all around up to a width of 30 mm using

the cleaning solution ⇒ “1.1 Materials”, page 186 .
– Then wipe the window edge e.g. with cleaning cloths -G 052
522 A2- .
WARNING
The ceramic layer on the window is no glass/paint primer! It is

absolutely essential to prime it before applying the sealing ma‐
terial! Only use glass/paint primer D 009 200 02!
– Now apply the glass/paint primer with the applicator uniformly

in one go.
♦ Minimum hardening time approx. 10 minutes.
1.7 Preparing body flange for installation


– Cut back the sealing compound on the body flange using the
U-shape cutting knife - V.A.G 1561/3- . However do not re‐
move completely.
Note
The remainder of the sealant serves as a base for the newly ap‐
plied glue sealing material. Keep the adhesive surfaces free of
dirt or grease.
WARNING
The activator must not come into contact with paintwork, oth‐
erwise there will be paint damage.
Exception: If the bonding is not carried out immediately after cut‐

ting back, the sealing compound must be activated with the
activator ⇒ “1.1 Materials”, page 186 .
♦ If the body flange was reworked or only partly replaced, clean
this area again after painting and treat it with glass/paint
primer.
– If the laser welding seam -3- at the metal flange -4- is not cov‐
ered with an adhesive bead -1-, coat the laser welding
seam -3- with glass/paint primer -3-. Then fill up the laser
welding seam with window pane adhesive -1-.
1.8 Cleaning necessary due to soiling

through adhesive
– We recommend using glue remover for cleaning. Observe
safety regulations while working.
WARNING
When cleaning the vehicle interior, the window which was just
inserted must not be pressed towards the outside.
– Clean the paint surfaces with a dry cloth. Remove the glue
residue with glue remover ⇒ “1.1 Materials”, page 186 .
– Clean plastic fillings: leave glue sealing material to harden
(approx. 1 hour) and then pull off.

2 Windscreen
⇒ “2.1 Summary of components - Windscreen”, page 190
⇒ “2.2 Removing and installing windscreen”, page 190
WARNING
For safety reasons, re-using a cut-out windscreen is not permis‐

sible. The windscreen must always be replaced with a new orig‐
inal part.
2.1 Summary of components - Windscreen
1 - Windscreen
windscreen ⇒ “2.2 Re‐
moving and installing
windscreen”, page
190 .
2 - PUR - glue sealing material
❑ Adhesive bead cross-
section: width - b - = 6.5
mm height - a - = 10 mm
(including the sealing
section, residual sealant
on window and window
flange).
❑ Minimum hardening
time ⇒ “1.2 Minimum
hardening time for glued
windows”, page 186 .
3 - Body flange
4 - Fitting section
❑ Is part of the wind‐
screen.
5 - Window pane adjuster
❑ Remove the window
pane adjuster at the ear‐
liest 120 minutes after
pane.
6 - Gap sizes
❑ a = 2 ± 0.5 mm with set‐
ting gauge - 3371- .
❑ b = 17 + 3 mm (primed
area).
❑ c = 14 + 3 mm (primed
area).
❑ Side gap = 7.5 mm.
2.2 Removing and installing windscreen

Removing
– Remove A pillar trim panel ⇒ Rep. gr. 70 ; Trim panels; inte‐
rior; removing and installing A pillar trim .

– Remove sun visors ⇒ Rep. gr. 68 ; Fittings; Summary of

components - sun visors .
– Remove interior mirror ⇒ Rep. gr. 68 ; Interior mirror; remov‐
ing and installing interior mirror .
– In vehicles with front camera for driver assistance systems -
R242- remove the front camera ⇒ Electrical system; Rep. gr.
96 ; Electrical system; Front camera for diver assistance sys‐
tems .
– Disconnect plug connections for heated windscreen (depend‐
ing upon vehicle equipment).
– The moulded headliner can now be lowered sufficiently so that
the windscreen can be cut out without damaging the moulded
headliner.
– Remove the plenum chamber cover ⇒ “3.2 Removing and in‐
stalling the plenum chamber cover”, page 10 .
– Slide the protective film between the windscreen and the dash
panel.
– Pull the end of the cutting thread - 2 - through the sealing ma‐
terial into the vehicle interior using the awl.
– Secure the end of the cutting thread with handle against pulling
out.
– Insert the cutting thread - 2 - with the help of the pipe - 1 - into
the window frame.
– Insert the cutting thread around the windscreen.
– Ensure that the cutting thread is laid at the corners under the
windscreen.
2. Windscreen 191
– Attach the second end of the cutting thread e.g. to the spooler
- V.A.G 1654A- .
– Position the spooler - V.A.G 1654A- in “position l”.
– Move the spooler - V.A.G 1654A- in steps if required and cut
out the windscreen.
– During the cutting procedure, press the cutting thread with a
plastic wedge against the windscreen in order to create a
clearance between the window flange and the dash panel.
Installing
Prepare new windscreen for fitting ⇒ “1.6 Preparing new windows
for fitting”, page 188 .
Prepare body flange for fitting ⇒ “1.7 Preparing body flange for
installation”, page 188 .
Installation instructions ⇒ “1.4 Installation instructions for glued
Minimum hardening time ⇒ “1.2 Minimum hardening time for
glued windows”, page 186 .
In vehicles with front camera for driver assistance systems -
R242- , install the front camera ⇒ Electrical system; Rep. gr. 96 ;
Electrical system; Front camera for diver assistance systems and
calibrate the front camera ⇒ Chassis, axles, steering; Rep. gr.
44 ; Front camera for diver assistance systems; Calibrating the
front camera for driver assistance systems .
On vehicles with rain sensor, glue and adjust ⇒ Rep. gr. 92 ;
windscreen wiper system; removing and installing the sensor for
rain and light detection and perform coding ⇒ Vehicle diagnostic
tester after replacing the window (the sensor).

3 Rear window
⇒ “3.1 Summary of components - rear window”, page 193
⇒ “3.2 Removing and installing the rear window”, page 193
WARNING
The cut-out rear window can be re-used after a thorough inspec‐

tion.
3.1 Summary of components - rear window
1 - Rear window
stalling the rear win‐
dow”, page 193 .
2 - Seal on the top edge of the
window
3 - Spacer
4 - Polyurethane adhesive
sealing mass
❑ Cross-section of the
tape: Width
-dimension a- = 6.5 ±
0.5 mm, height
-dimension b- = 10 ± 1
mm (including coating
and residue on the win‐
dow and window
flange).
❑ Minimum hardening
time ⇒ “1.2 Minimum
hardening time for glued
❑ The start and end of the
adhesive bead at
-arrow A-.
5 - Gap sizes
❑ Top gap 3 ± 0.5 mm.
❑ Bottom gap 1.5 ± 0.5
mm.
❑ Side gap 3.6 ± 0.5 mm.
❑ a = 13 ± 2 mm (primed
area).
❑ b = 13 ± 2 mm (primed
area).
❑ c = 13 ± 2 mm (primed area).
3.2 Removing and installing the rear win‐

dow
Note
3. Rear window 193

The removal of the glued windows is described using the sepa‐

rating device for glued windows - V.A.G 1474A- .
Removing damaged window
WARNING
It is essential to wear protective goggles and gloves when cut‐

ting hardened PUR adhesive sealing material and when han‐
dling the cutting cord.
– Protect vehicle interior from glass splinters.

– Remove high-level brake light ⇒ Electrical System; Rep. gr.
94 ; High-level brake light; removing and installing high level
brake light .
– Remove rear window wiper (if present) ⇒ Electrical System;
Rep. gr. 92 ; Rear window wiper; removing and installing
windscreen wiper arm .
– Disconnect the plug connections of the heated rear window
and press the contact tabs onto the window.
– Cover the painted surfaces along the window with textile ad‐
hesive tape.
– Remove glass pieces up to the glue sealing material.
– Cut back the adhesive sealant e.g with electrical cutting tool -
V.A.G 1561A- to approx. 1 mm thickness.
– Suction off glass residues in the vehicle as well as in the hol‐
lows of the tailgate with a vacuum cleaner.
Removing undamaged window
WARNING

– Remove high-level brake light ⇒ Electrical System; Rep. gr.

94 ; High-level brake light; removing and installing high level
brake light .
– Remove rear window wiper (if present) ⇒ Electrical System;
Rep. gr. 92 ; Rear window wiper; removing and installing
windscreen wiper arm .
– Disconnect the plug connections of the heated rear window
and press the contact tabs onto the window.
hesive tape.
– Pull the cutting thread with the awl through the sealing material
towards the inside.

– Secure the end of the cutting thread with the pull handle
against pulling out.
– Lay the cutting thread around the rear window - 1 - and guide
the second end of the thread towards the inside.
– Attach the end of the cutting thread e.g. to the spooler -
V.A.G 1654A- .
– Slide the cover foil carefully between the rear window and the
moulded headliner.
– Position the spooler - V.A.G 1654A- in the indicated position

(l and Vl).
– Move the spooler - V.A.G 1654A- in steps if required and cut
out the rear window.
– During the cutting procedure, press the cutting thread with a
wedge against the rear window to create a clearance at the
window flange.
– Use the suction cup to remove the window from the vehicle.
Note
A second mechanic is required for removing the window.
Installing
– Prepare new window for fitting ⇒ “1.5 Preparing windows
which have not been damaged for fitting”, page 187 .
– Prepare new windscreen for fitting ⇒ “1.6 Preparing new win‐
dows for fitting”, page 188 .
– Prepare body flange for fitting ⇒ “1.7 Preparing body flange for
installation”, page 188 .
– Place the window in the fitting location on the body flange with
the help of two suction cups.
– Installation instructions ⇒ “1.4 Installation instructions for
– Minimum hardening time ⇒ “1.2 Minimum hardening time for
3. Rear window 195

4 Side windows
⇒ “4.1 Summary of components - Rear side window”, page
196
⇒ “4.2 Removing and installing rear side window”, page 196
WARNING
The cut-out panoramic roof side window can be re-used after a

thorough inspection.
4.1 Summary of components - Rear side window
1 - Side section
2 - Guide bolt
❑ Is part of the side win‐
dow. When removing
cut through with cutting
thread.
3 - Sealing section
❑ Is part of the side win‐
dow.
4 - Side window
5 - Glue sealing material
4.2 Removing and installing rear side win‐

dow
Removing damaged window
WARNING


– Protect vehicle interior from glass splinters.

– Remove upper C-pillar trim panel ⇒ General body repairs, in‐
terior; Rep. gr. 70 ; Interior trim panels; Removing and in‐
stalling C-pillar trim panel .
– Remove connector from the window aerial (where fitted).
– Remove glass pieces up to the glue sealing material.
hesive tape.
– Cut back the adhesive sealant e.g with electrical cutting tool -
V.A.G 1561A- to approx. 1 mm thickness.
– Suction vacuum glass residues in the vehicle with a vacuum
cleaner.
Removing undamaged window
WARNING

– Remove upper C-pillar trim panel ⇒ General body repairs, in‐

terior; Rep. gr. 70 ; Interior trim panels; Removing and in‐
stalling C-pillar trim panel .
– Remove connector from the window aerial (where fitted).
hesive tape.
Note
♦ In order to facilitate the insertion of the cutting cord, apply lu‐

bricant (e.g. detergent) on the outer side of the window flange.
♦ In order to avoid damage to the paintwork, the cord ends must
be inserted correctly into the needle from below, at the same
time a protective foil should be glued in the area of the pierced
cement.
♦ Check several times the correct fitting of the cutting cord dur‐
ing assembly.
Note
Slipping of the awl tip can lead to serious injuries!
– Separate the circular profile on the body in the awl exit area
with e.g. A dismantling wedge -3409- - 1 - - 2 -.
4. Side windows 197

– Puncture the adhesive sealing material, e.g. with awl - 3 - in

the area of - arrow A -.
– Puncture the adhesive sealing material, e.g with awl - 3 - in
the area of - arrow B -.
– Pull the cutting cord - 5 - through the awl.
– Insert cutting cord -5- all around the side window behind the
sealing profile.
– Fasten the suction lifter from the set, e.g. Separating device
for glued panes - V.A.G 1474A- on the spooler e.g. Separating
device for glued panes - VAS 6452- - 1 - and fasten the end
of the cord - 3 - In the coil at the front - 2 -.
– Insert both ends of the cutting wire into the spooler rollers for
panes - 2 - Separating device for glued panes - VAS 6452- .
– Cut through the adhesive sealant in areas - a - and - b -.

– Removing the spooler.

– Cut through Residual adhesive sealant with hand devices
- 4 - and cutting cord - 3 - as shown.
– The guide pins are part of the side window. When removing
the bolts, must be cut with cutting thread.
– They are no longer required to remove the disc.
4. Side windows 199

– Remove the side pane from the body.

– Remove adhesive tapes.
Installing side window
Prepare flange for fitting ⇒ “1.7 Preparing body flange for instal‐
lation”, page 188 .
Installation instructions ⇒ “1.4 Installation instructions for glued
Minimum hardening time ⇒ “1.2 Minimum hardening time for
– After glueing on the window, mount the plug of the window
aerial (if present).

66 – Exterior equipment
1 Spoiler
⇒ “1.1 Summary of components - spoiler”, page 201
⇒ “1.2 Removing and installing spoiler”, page 201
1.1 Summary of components - spoiler
1 - Rear spoiler
2 - Double-sided adhesive
tape
3 - Glue sealing material
1.2 Removing and installing spoiler
1. Spoiler 201
Removing
– Cover the painted surfaces along the spoiler with textile ad‐
hesive tape.
– Cut off spoiler from the tailgate (cut through glue sealing ma‐
terial) and cut off double-sided adhesive tape, e.g. with cutting
cord -357 853 999 B - .
– Remove the spoiler.
Installing
Note
You must apply adhesive to the spoiler at room temperature after having left the vehicle to stand for at 2 hours!
– Thoroughly clean the adhesive surfaces e.g. with cleaning so‐

lution D 009 401 04.
– Apply glass/paint primer to the window surface near the con‐
tact surface of the glue sealing material -3- and leave to dry
for at least 2 minutes.
– Apply glue sealing material D 004 660 M2 at the correct point
(Pos. 3) on the spoiler. Diameter of the applied adhesive bead
= 5 + 1 mm.
202 Rep. gr.66 - Exterior equipment

– Partially unglue the protective foil from the adhesive tape on

the edges.
– Stick on the spoiler within 15 minutes after applying the glue
sealing material!
– Position the spoiler evenly onto the tailgate.
– Remove the protective foil from the adhesive tape.
– Press the spoiler evenly onto the tailgate.
– Secure spoiler against moving with adhesive tape.
Note
♦ The glue sealing material must dry for at least 2 hours. Do not drive the vehicle in this time.
♦ Do not drive through the carwash within 24 hours of gluing on the spoiler.
1. Spoiler 203
2 Strips / trims / extensions / trim pan‐

els
⇒ “2.1 Summary of components - Sill panel”, page 204
⇒ “2.2 Removing and installing lower handle panel”, page
205
⇒ “2.3 Removing and installing lower handle panel”, page
207
⇒ “2.4 Removing and installing trim strip”, page 208
⇒ “2.5 Removing and installing B-pillar trim from the door”,
page 211
⇒ “2.6 Removing and installing C-pillar trim from the door”, page
213
⇒ “2.7 Removing and installing heat shield for underfloor”,
page 213
2.1 Summary of components - Sill panel
1 - Grommet
2 - Front door sill panel
3 - Rear door sill panel
4 - Double-sided adhesive
tape

2.2 Removing and installing lower handle

panel
Installation instructions for glued trims
Note
♦ Before removing, heat up the strip with the hot-air blower.

♦ Only use the adhesive remover - D 002 000 10- .
♦ Make sure that the adhesive surfaces are free from dust and
grease.
♦ The trims to be glued must be glued on immediately after
cleaning.
♦ Remove protective foil from its wrapping until just before as‐
sembly.
♦ Processing temperature: approx. 21 °C.
Removing
Front door strip
2. Strips / trims / extensions / trim panels 205

– Heat up the strip in the area of the adhesive tape -4-, using the
hot-air blower.
– Unclip strip from grommets -1-.
– Slide strip -2- out from edge of door.
Rear door strip
– Heat up the strip in the area of the adhesive tape -4-, using the
hot-air blower.
– Unclip strip from grommets -1-.
– Slide strip -3- out from edge of door.
Installing
Note
♦ Thoroughly clean and degrease the adhesive surfaces before

installation!
♦ If the strip is reused, remove the old adhesive tape and attach
a new one (eg Akl 440 025).
♦ Thoroughly clean and degrease adhesive surfaces before ap‐
plying a new adhesive tape.

Front door strip

– Check all inserts -1- and clips for damage and replace if nec‐
essary.
– Remove the protective foil from the adhesive tape -4-.
– Slide strip -2- with clips into the edge of the door and press
onto the inserts -1-.
– Press the strip onto the door with force in area of adhesive
tape -4-.
Rear door strip
– Check all inserts -1- and clips for damage and replace if nec‐
essary.
– Remove the protective foil from the adhesive tape -4-.
– Slide strip -3- with clips into the edge of the door and press
onto the inserts -1-.
– Press the strip onto the door with force in area of adhesive
tape -4-.
2.3 Removing and installing lower handle panel

1 - Lower handle panel

Removing
– Unclip retaining clips

one by one from all
openings.
Installing
– Clip in retaining clip one

by one.
Note
Before installing the lower handle

panel, check the anti-corrosion pro‐
tection.
2 - Retaining clip
2.4 Removing and installing trim strip

Front wing strip

Removing
front wheelhouse liner”, page 232 .
– Heat up the strip in the area of the bonded double-sided ad‐
hesive tape -4- before removal using the hot-air blower.
– Release the catches in order from the inside. Start from the
edges towards the middle. To release, use pliers or e.g. a long
socket insert SW 8 to push out the clips.
– Remove strip -3- from wing.
Installing
– Clean and degrease the surface to stock on new double-sided
adhesive tape -4-. Stick new double-sided adhesive tape onto
the applicable area.
– Clip the strip in order into the grommets -2- and into the open‐
ings in the wing.
Note

Replace damaged grommets with new grommets before installing.
Rear wing strip
Removing
rear wheelhouse liner”, page 233 .
– Release the catches in order from the inside. Start from the
edges towards the middle. To release, use pliers or e.g. a long
socket insert SW 8 to push out the clips.
– Remove strip -3- from wing -1-.
Installing
– Clip the strip in order into the grommets -2- and into the open‐
ings in the wing.
Note

Replace damaged grommets with new grommets before installing.
2.5 Removing and installing B-pillar trim

from the door
Front door trim panel
Removing
– Lower door window.
– Pull window run in the area of the B-pillar trim out of the door
frame.
– Remove screws -2- (2,5 Nm).
– Slide B-post trim -1- downwards and pull out of the window
run.
– Pull B-pillar trim -1- upwards out of the door.
Installing
– Slide the B-pillar trim -1- into the door.
– Insert the B-pillar trim -1- at bottom and adjust the position.

– Slide the B-post trim -1- upwards until the trim is in contact with
the window run.
– Slide the window run into the door.
Removing and installing B-pillar trim from the rear door
Removing
– Pull window run in the area of the B-pillar trim out of the door
frame.
– Slide the B-pillar trim -2- downwards and remove from the door
frame.
– Pull the B-pillar trim -2- upwards.
Installing
– Insert the B-pillar trim -1- at bottom and adjust the position.

– Slide the B-post trim -1- upwards until the trim is in contact with
the window run.
– Slide the window run into the door.
2.6 Removing and installing C-pillar trim from the door
Remove trim panel -5-.- -

– Remove seal so that you can remove the screws -4-.
– Pull the pillar trim -5- off the door frame.
Installing
2.7 Removing and installing heat shield for underfloor

Note
stalling.
Removing
– Remove underbody panel ⇒ “4.2 Removing and installing un‐
derfloor trim panels”, page 216 .
– Remove tunnel bridge ⇒ “4.3 Removing and installing the tun‐
nel bridge”, page 219 .
– Disconnect and unhook exhaust system.
– Loosen the lock washers -2- and remove the tunnel heat shield
-1- from the vehicle.
Installing

3 Noise insulation
⇒ “3.1 Summary of components - Noise insulation”, page 215
3.1 Summary of components - Noise insulation
Note
stalling.
1 - Noise insulation - front

2 - Noise insulation
Removing
– Remove screws - 3 -
and - 4 - and push out
the noise insulation to‐
wards the rear.
Installing

3 - Screw
Nm.
4 - Screw
Nm.
Note
Use new screws each time it is re‐

moved!
3. Noise insulation 215

4 Underfloor trim panel

⇒ “4.1 Installation location overview - underfloor trim panels”,
page 216
⇒ “4.2 Removing and installing underfloor trim panels”, page
216
⇒ “4.3 Removing and installing the tunnel bridge”, page 219
4.1 Installation location overview - underfloor trim panels
Note
Depending on the equipment variant, slight differences must be taken into consideration when removing and
installing.
1 - Underfloor trim panel - rear

underfloor trim panels”, page
216 .
2 - Underfloor trim panel - lat‐

eral
underfloor trim panels”, page
216 .
3 - Screw
Nm.
4 - Plastic nut
Nm.
4.2 Removing and installing underfloor trim panels

Underfloor trim panel - lateral

Removing
– Remove plastic nuts - 4 -.
– Remove heat shield from vehicle.
Installing
Heat shield for front tunnel
4. Underfloor trim panel 217

– Remove lock washers -arrows-.

– Remove heat shield from vehicle.
Installing
Underfloor trim panel - rear

Removing
– Remove screws -3- and lock washers.
– Slide the underfloor trim panel floor -2- towards the rear out of
the vehicle.
Installing
4.3 Removing and installing the tunnel bridge
4. Underfloor trim panel 219

Removing
– Release underfloor trim panel and press downwards slightly.
– Release nuts -2- (20 Nm).
– Remove the tunnel bridge -1- from vehicle.
Installing

5 Roof strips / roof rack

⇒ “5.1 Removing and installing roof rack”, page 221
5.1 Removing and installing roof rack
Caution
Do not use any impact screwdrivers during installation and re‐

moval! When removing, use a manual wrench. When installing,
use a manual torque wrench!
Removing
– Unhook moulded headliner ⇒ General body repairs, interior;
moulded headliner .
– Unscrew nuts -2- (13 ± 1.3 Nm).
– Remove roof rack - 1 - from the vehicle.
Installing
5. Roof strips / roof rack 221


6 Exterior mirrors
⇒ “6.1 Summary of components - exterior mirror”, page 223
⇒ “6.2 Removing and installing outside mirror”, page 223
⇒ “6.3 Removing and installing mirror glass”, page 227
⇒ “6.4 Removing and installing the mirror adjustment unit”, page
228
⇒ “6.5 Removing and installing mirror cover”, page 229
⇒ “6.6 Removing and installing mirror cap”, page 230
6.1 Summary of components - exterior mirror
1 - Adjustment unit with motor

stalling the mirror ad‐
justment unit”, page
228 .
2 - Mirror cover - top
stalling mirror cover”,
page 229 .
3 - Screw
Nm.
4 - Lighting and turn signal
light.
5 - Mirror base support
stalling outside mirror”,
page 223 .
6 - Mirror cover - bottom
7 - Screw
Nm.
8 - Mirror cover - bottom
stalling mirror cover”,
page 229 .
9 - Mirror glass
stalling mirror glass”, page 227 .
10 - Screw
6.2 Removing and installing outside mirror

Removing
6. Exterior mirrors 223


– Disconnect the plug connection - 4 - of the electrical line - 3 -
for the exterior mirror - 1 -.
– Remove screw -2- (15 Nm).

– Swivel out the exterior rear-view mirror - 1 - in the lower area

from the door and pull out of the window run - 2 - -arrow-.
– Guide the cable - 3 - through the opening in the door.
Installing

– Guide the electrical cable - 3 - through the opening in the door.

– Insert the exterior mirror - 1 - into the window run - 2 -.

– Fit the screw - 4 - into the mirror housing - 1 -. Tightening

torque: 15 Nm.
– Attach el. line - 3 -.
– Connect the plug connection - 2 -.
door trim panel.
Note
After installing the mirror on a vehicle with surround-view camera function, perform calibration ⇒ Rep. gr. 91 ;
Surround-view camera; installation location overview - surround-view camera .
6.3 Removing and installing mirror glass
WARNING
Wear protective gloves and protective goggles when working!

Removing
– Protect the edges of the housing for damage, e.g. cover with
textile adhesive tape.
– Swivel the mirror glass - 1 - in the maximum position.
– Press off the mirror glass - 1 - from the holder - 2 - and the
housing arrow - a - for example using a wide plastic wedge.
Installing
– Press the mirror glass in the centre onto the holder in the
housing.
The mirror glass clicks audibly into place.
• Subsequently perform a functional test.
6.4 Removing and installing the mirror adjustment unit

Removing
– Remove mirror glass ⇒ “6.3 Removing and installing mirror
glass”, page 227 .
– Swivel the adjustment unit with motor -1- to the side and dis‐
connect the plug -3-.
Installing
mirror glass.
6.5 Removing and installing mirror cover

Removing
– Remove mirror cap ⇒ “6.6 Removing and installing mirror
cap”, page 230 .
– Press off the retaining tabs -arrows B- and remove cover -1-.
– Press off the retaining tabs arrow -A- in direction of arrow -B-
and lower cover -1- slightly.
Installing
– Fit mirror cover -1- and push into the retaining tabs until it au‐
dibly clicks into place.
6.6 Removing and installing mirror cap

Removing
– Remove mirror glass ⇒ “6.3 Removing and installing mirror
glass”, page 227 .
– Detach and remove cover -1- from the retaining tabs,
arrows -A- and -B-.
– Remove cap -1-.
Installing

7 Wheelhouse liner
⇒ “7.1 Removing and installing the front wheelhouse liner”, page
232
⇒ “7.2 Removing and installing the rear wheelhouse liner”,
page 233
7.1 Removing and installing the front wheel‐

house liner
Removing

– Remove wheel ⇒ Rep. gr. 44 ; Wheels, tyres, wheel change .
– Removing body-bound rivet -4-.
– Pull out wheelhouse liner -1-.
Installing
Note

Check the expanding nuts - 2 - for damage, replace them if necessary.
– Insert wheelhouse liner -1- into the wing and bumper -5-.
– Install screws -3-. Tightening torque: 2 Nm.
– Install body-bound rivet -4-.
7.2 Removing and installing the rear wheel‐

house liner
Removing
7. Wheelhouse liner 233

– Remove wheel ⇒ Rep. gr. 44 ; Wheels, tyres, wheel change .

– Pull out rear wheelhouse liner - 1 -.
Installing

DANGER!
Check the expanding nuts - 2 - for damage, replace if neces‐

sary.
The expanding nuts seal the interior from exhaust gases. In
case of damage, they must absolutely be replaced.
– Insert the rear wheelhouse liner -1- into the wheelhouse.

– Install screws -3-. Tightening torque: 2 Nm.
– Install wheel ⇒ Rep. gr. 44 ; Wheels, tyres, tightening torque
of the wheel screws .
7. Wheelhouse liner 235

8 Letterings and emblems

⇒ “8.1 Dimensions - Letterings and emblems on rear”, page
236
⇒ “8.2 Replacing letterings and emblems on rear”, page 236
⇒ “8.3 Removing and installing letterings”, page 238
8.1 Dimensions - Letterings and emblems on rear
1 - Škoda lettering
❑ a = 22.9 ± 0.5 mm
❑ b = 116.4 ± 0.5 mm
❑ c = 116.3 ± 0.5 mm
2 - Tailgate
3 - Superb lettering
❑ d = 115.8 ± 0.5 mm
❑ e = 112.4 ± 0.5 mm
❑ f = 26.4 ± 0.5 mm
8.2 Replacing letterings and emblems on

rear
8.2.1 Replacing lettering and emblems at the rear (to CW 25 2019)

Removing
– Warm up the emblem - 1 - with a hot-air blower before remov‐
ing.
– Remove the logo from the tailgate - 2 -.
Installing
– Thoroughly clean and degrease the adhesive surfaces before
gluing.
– Remove the protective foil.
– Place the emblem - 1 - with the centering pins into the em‐
bossed area of the tailgate - 2 -.
– Forcefully press on the emblem.
8.2.2 Replacing lettering and emblems at the rear (from CW 25 2019)
8. Letterings and emblems 237

1 - Tailgate
2 - ŠKODA lettering
❑ a = 41.7 ± 1 mm
Note
For ŠKODA lettering, only the dimension below the letter O is

indicated. The dimensions of the outer letters are to be measured
so that they are symmetrical.
8.3 Removing and installing letterings

Removing
– Warm up the letterings with a hot-air blower before removing.
– Remove glue residues e.g. with adhesive remover - D 002 000
10- .
– The letterings cannot be removed without being damaged.
Installing
– Remove grease, dust and dirt from the surfaces e.g. with
cleaning solution D 009 401 04 before gluing.
– The letterings must be glued on immediately after cleaning.
– Remove protective foil from its wrapping until just before as‐
sembly.

– Glue on the lettering as per the specified dimensions.

– Press onto the tailgate with reasonable force.
– The processing temperature is about 21 ℃.
8. Letterings and emblems 239

9 Trailer coupling
⇒ “9.1 Summary of components - Trailer coupling”, page 240
⇒ “9.2 Removing and installing trailer coupling”, page 240
9.1 Summary of components - Trailer coupling
Note
♦ Depending on the design, slight differences must be taken into account.

♦ The tightening torques are only applicable to trailer couplings installed in production.
♦ The applicable manufacturer must be contacted for tightening torques for other trailer couplings.
♦ The control unit for trailer detection can be found under ⇒ Electrical system; Rep. gr. 94 ; Trailer coupling;
Removing and installing the control unit for trailer detection - J345- .
1 - Trailer coupling
❑ Folding trailer coupling.
2 - Screw
❑ Screw plugs. They seal
the interior against ex‐
haust gases and they
must be installed in all
cases.
Nm.
3 - Electrical plug connection
4 - Screw
Nm + 180°.
Note
Always use new screws after disas‐

sembly!
9.2 Removing and installing trailer coupling

Removing

– Remove the rear bumper ⇒ “2.2 Removing and installing

Remove luggage compartment side trim panel and disconnect
connector for trailer coupling ⇒ General body repairs, interior;
Rep. gr. 70 ; Luggage compartment trim panels; removing and
installing luggage compartment trim panel .
– Disconnect the plug connection of the electrical cable -3-.
– Pull the trailer coupling -1- level off the frame side rails.
Installing
9. Trailer coupling 241


– A functional check must be performed after installing the trailer
coupling.

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Service

Service Department. Technical Information

55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.1 Summary of components - door internal parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

1.1 Summary of components - Sun roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

1.1 Summary of components - Lock carrier

Depending on the model version, slight differences in the mount‐

Volkswagen Technical Site: http://vwts.ru http://vwts.info

2 Rep. gr.50 - Body - front

– Adjusting the service position ⇒ “1.3 Adjusting and resetting

– Position the lock carrier - 2 - on the frame side rails - 3 -.

1.3 Adjusting and resetting the service po‐

4 Rep. gr.50 - Body - front

– Removing front bumper ⇒ “1.3 Removing and installing

Hoses and lines must not be pinched.

6 Rep. gr.50 - Body - front

2.1 Summary of components - fender

2.2 Removing and installing the wing

– Remove front wheelhouse liner ⇒ “7.1 Removing and in‐

2.3 Removing and installing wing strut

8 Rep. gr.50 - Body - front

3.1 Summary of components - plenum chamber cover

1 - Moulded foam part

3.2 Removing and installing the plenum

10 Rep. gr.50 - Body - front

– Remove clips -4-.

Breaking open the plenum chamber cover in the fitting section

♦ An inlay is installed in the fitting section on new windscreens.

Carry out the following tasks

55 – Bonnet, rear lid

1.1 Summary of components - bonnet

12 Rep. gr.55 - Bonnet, rear lid

– Unclip all the clips for

– Remove the damping

– Installation is carried out

1.2 Summary of components - Bowden wire

1 - Front flap lock

1.3 Removing and installing the bonnet

14 Rep. gr.55 - Bonnet, rear lid

– Disconnect spray nozzles ⇒ Electrical System; Rep. gr. 92 ;

1.4 Adjusting the bonnet

– Remove screws -4- (9 Nm).

16 Rep. gr.55 - Bonnet, rear lid

– The bonnet can be centred between the wings by slackening

– Ensure parallelism of gap dimensions ⇒ Body Repairs; Rep.

18 Rep. gr.55 - Bonnet, rear lid

1.5 Removing and installing flap lock

– Remove air guide.

1.6 Removing and installing the operating

20 Rep. gr.55 - Bonnet, rear lid

1.7 Removing and installing the locking clamp

– Unscrew screws -4-.

1.8 Removing and installing the hinges

– Remove bonnet ⇒ “1.3 Removing and installing the bonnet”,

1.9 Removing and installing the pressurized gas strut

22 Rep. gr.55 - Bonnet, rear lid

When removing the locking element, always wear safety gog‐

1.10 Degassing the pressurized gas strut

The pressurized gas strut must only be clamped in this area,

♦ Wear safety goggles during the sawing procedure.

1.11 Removing and installing Bowden cable