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Service Department. Technical Information
Downloaded from www.Manualslib.com manuals search engine

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

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R005620

Golf Variant 2007 ➤ , Jetta 2005 ➤
General body repairs, exterior - Edition 10.2009
Contents
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Assembly overview - lock carrier, service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Removing and installing lock carrier with add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Assembly overview - front wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Removing and installing wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Removing and installing wing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Assembly overview - noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Underbody cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Assembly overview - underbody cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Assembly overview - rear underbody cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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55 - Bonnet, rear lidhoris.e . . . . . . . . . . . . . . . . . . . . . . . . . a.n.tee. . . . . . . . . . . . . . . . . . . . . . . . 16
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1 Bonnetss a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.c . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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1.2 Assembly overview - bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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1.3 Removing and installing bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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1.4 Removing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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1.5 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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1.6 Removing and installing lid hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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1.7 Removing and installing insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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1.8 Assembly overview - bonnet latch and release components . . . . . . . . . . . . . . . . . . . . . . . . 23

1.9 Removing and installing bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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1.10 Disconnecting Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.11 Adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.12 Removing and installing release lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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2 Rear lid (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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2.2 Assembly overview - rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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2.3 Removing and installing rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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2.4 Removing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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2.6 Removing and installing lid hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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2.7 Removing and installing striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.8 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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2.9 Assembly overview - lid lock and lock cylinder carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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2.10 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.11 Removing and installing handle trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.12 Removing and installing lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.13 Rear lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.14 Removing and installing rear lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3 Rear lid (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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3.2 Assembly overview - rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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3.3 Removing and installing rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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3.4 Removing and installing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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3.6 Removing and installing rear lid hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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3.7 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.8 Removing and installing release button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.9 Removing and installing lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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3.10 Rear lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.11 Removing and installing rear lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.12 Registration plate carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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4 Fuel tank flap unit (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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4.1 Assembly overview - tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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4.2 Removing and installing tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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4.3 Removing and installing tank filler flap locking motor V155 . . . . . . . . . . . . . . . . . . . . . . . . 56
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5 Fuel tank flap unit (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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5.1 Assembly overview - tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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5.2 Removing and installing tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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5.3 Removing and installing tank filler flap locking motor V155 . . . . . . . . . . . . . . . . . . . . . . . . 60
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57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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1 Front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.3 Assembly overview - door assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.4 Assembly overview - door hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.5 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.6 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.7 Removing and installing outer panel on door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.8 Installing new outer panel on door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.9 Removing and installing retaining rail on door outer panel . . . . . . . . . . . . . . . . . . . . . . . . 80
1.10 Installation notes for bonding a new outer panel on door . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.11 Minimum curing period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.12 Cleaning off excess adhesive sealing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.13 Assembly overview - door inner part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.14 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.15 Removing and installing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.16 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.17 Removing and installing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.18 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.19 Assembly overview - side impact protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.20 Door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.21 Removing and installing door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.22 Removing and installing door outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2 Central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Fitting location overview - central locking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.2 Adapting keys with remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.3 Assembly overview - battery for folding key with remote control . . . . . . . . . . . . . . . . . . . . 100
2.4 Removing and installing battery for folding key with remote control . . . . . . . . . . . . . . . . . . 101
58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

1 Rear door (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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1.3 Assembly overview - door assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

1.6 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.7 Removing and installing outer panel on door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.8 Installing new outer panel on door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.9 Removing and installing retaining rail on door outer panel . . . . . . . . . . . . . . . . . . . . . . . . 119
1.10 Installation notes for bonding a new outer panel on door . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.13 Assembly overview - door inner part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.17 Removing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.18 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.19 Assembly overview - side impact protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.20 Door inner seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.21 Removing and installing door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2 Rear door (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.2 Assembly overview - rear door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.5 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.6 Assembly overview - assembly carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.7 Removing and installing assembly carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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2.11 Removing kand en AG. V bearing
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does ...................................... 154
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2.12 Removing by V and installing door lock . . . .g.u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ara 155
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2.13 Door tho
ris inner seals . . . . . . . . . . . . . . . . . . . . .nt.ee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
o
155
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2.14 ss aRemoving and installing door inner seal . . . . . r.ac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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1 Sliding/tilting sunroof with glass panel (Meritor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

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1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

spec
1.3 Assembly overview - sliding/tilting sunroof with glass panel . . . . . . . . . . . . . . . . . . . . . . . . 163

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1.4 Removing and installing bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

1.5 Removing and installing sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . 166
1.6 Adjusting height of sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
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1.7 Adjusting panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

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1.8 Renewing panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

1.9 Removing and installing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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ercia
1.10 Removing and installing sliding headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

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1.11 Removing and installing sliding/tilting sunroof glass panel drive . . . . . . . . . . . . . . . . . . . . 171
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1.12 Adjusting drive for sliding/tilting sunroof glass panel (0 position) . . . . . . . . . . . . . . . . . . . . 172
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1.13 Removing and installing sliding/tilting sunroof glass panel automatic preselection switch
his
ate
........................................................................ 172
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1.14 Checking parallel running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

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1.15 Adjusting parallel running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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1.16 Assembly overview - carrier unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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Contents
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1.17 Removing and installing carrier unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

1.18 Operating without current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.19 Removing and installing guide plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.20 Removing and installing guide plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.21 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2 Panorama sliding sunroof (Arvin-Meritor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.3 Establishing reference points of panorama sliding roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.4 Assembly overview - panorama sliding roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.5 Removing and installing front glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.6 Removing and installing rear glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.7 Adjusting height of front and rear glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.8 Renewing seals for rear glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.9 Renewing outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2.10 Renewing inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.11 Removing and installing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.12 Removing and installing wind deflector bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
2.13 Removing and installing preselector for glass panel and sun blind . . . . . . . . . . . . . . . . . . 196
2.14 Removing and installing sliding sunroof motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.15 Removing and installing sun blind motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.16 Removing and installing sun blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.17 Assembly overview - assembly frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.18 Installing and removing motor plate and sun blind cable . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.19 Removing and installing assembly frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.20 Removing and installing rear part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
AG. Volkswagen G d
2.21 Removing and installing
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agen front motor A plate oes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
not
212
ol
2.22 Removing dand by installing tilting mechanism and
V gufront glass panel cable . . . . . . . . . . . . . .
ara 215
e n
2.23 Maintenance
thoris
and care . . . . . . . . . . . . . . . . . . . . t.ee. o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
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2.24 Operating
ss
a without current . . . . . . . . . . . . . . . . . . . . .a.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.25 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
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63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
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1 Front bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

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1.2 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

spec
1.3 Assembly overview - bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

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1.4 Removing and installing front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

1.5 Front bumper cover add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.6 Front bumper cover substructure parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
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1.7 Assembly overview - bumper carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

1.8 Installing small registration plate carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
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2 Front bumper, Cup Edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

nform
2.1 Front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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3 Rear bumper (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

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3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

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3.4 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

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3.5 Rear bumper cover with add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
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3.6 Rear bumper cover substructure parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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240
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4 Rear bumper, saloon, Cup Edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
4.1 Rear bumper cover, saloon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
5 Rear bumper (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
iv Contents

5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

5.4 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
5.5 Rear bumper cover with add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
5.6 Rear bumper cover substructure parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
5.8 Assembly overview - towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
5.9 lkswage and installing towing
Removing es nbracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
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64 - Glazing
tho ............. . . . . . . . . . .nt.ee.o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
au ra
s1
s Flush bonded windows . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

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1.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
itte
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ab
1.3 Assembly overview - windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
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1.4 Assembly overview - plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
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is n
1.5 Removing and installing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
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spec
1.6 Removing and installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
1.7 Assembly overview - rear window (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
t to the co
1.8 Removing and installing rear window (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
1.9 Assembly overview - rear window (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
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1.10 Removing and installing rear window (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.11 Assembly overview - side window (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
1.12 Removing undamaged side window (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
cial p
1.13 Removing broken side window (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nform 273

1.14 Installing side window (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
mer
1.15 Preparing old undamaged window for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

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1.16 Preparing new window for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

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1.17 Touching up paint damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

s
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1.18 Preparing body flange for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

p
cum
for
1.19 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

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2 Front door windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
2.2 Assembly overview- front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
2.3 Removing and installing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
2.4 Adjusting door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
2.5 Assembly overview - window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
2.6 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
2.7 Assembly overview - window channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
2.8 Removing and installing window channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
2.9 Removing and installing window channel trim strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
2.10 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
2.11 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
3 Rear door window (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
3.2 Assembly overview - rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
3.3 Removing and installing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
3.4 Assembly overview - door with fixed window with window channel . . . . . . . . . . . . . . . . . . 297
3.5 Removing and installing door with fixed window with window channel . . . . . . . . . . . . . . . . 297
3.9 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Contents v
3.10 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

4 Rear door window (Variant) . . . .k.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
307
AG. Vol wagen
4.1 Tools . . . . . . . . . . .lk.sw
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307
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4.2 Assembly overview ed b - rear door window . . . . . . . . .u.ar.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.3 Removing andtho installing door window . . . . . . . . . . . . . .e o.r . . . . . . . . . . . . . . . . . . . . . . . . .
ri 308
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4.4 Removing
ss and installing window slot outer seal . . . . . . . . . c. . . . . . . . . . . . . . . . . . . . . . . . .
a a 310
4.5 Assembly overview - door with fixed window with window channel . . . . . . . . . . . . . . . . . . 311
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4.6 Removing and installing door with fixed window with window channel . . . . . . . . . . . . . . . . 312
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66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
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1 Wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
rrectness of i
1.2 Assembly overview - front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
1.3 Removing and installing front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
l purpos
1.4 Assembly overview - rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

1.5 Removing and installing rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
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1.6 Installing protective cover for wheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
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2 Exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
com
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2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
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2.2 Assembly overview - exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
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2.3 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

rp
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2.4 Removing and installing mirror housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
en 328
ng
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2.5 Removing and installing trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Co 329
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2.6 Removing and installing side turn signal repeaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
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2.7 Removing and installing entry light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
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Prote AG.
2.8 Removing and installing adjustment unit with motor for exterior mirror . . . . . . . . . . . . . . . . 331
2.9 Removing and installing exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
3 Roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
3.2 Assembly overview - roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
3.3 Removing and installing roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
4 Radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
4.2 Radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
4.3 Radiator grille, Cup Edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
5 Mouldings and trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
5.2 Removing and installing side panel trim strips on GLI vehicles . . . . . . . . . . . . . . . . . . . . . . 345
5.3 Side member extension, Jetta Cup Edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
6 Special add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
6.1 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
6.2 Fitting notes for extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
6.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
6.4 Special add-on parts, Jetta Cup Edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
6.5 Preparing body kit component for bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
6.6 Preparing new add-on part for bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
6.7 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
7 Protective backing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
7.1 Scuff protection film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
vi Contents

8 Lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
8.2 Installation instructions for lettering and emblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
8.3 Rear lettering dimensions (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
8.4 Rear lettering dimensions (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
8.5 Side lettering dimensions - Individual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
AG. Volkswagen AG d
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Contents vii
AG. Volkswagen AG d
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viii Contents

50 – Body - front
1 Lock carrier
AG. Volkswagen AG d
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♦ Guide pins -T10093-
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1. Lock carrier 1
1.2 Assembly overview - lock carrier, service position
1 - Lock carrier with add-on

parts
❑ Removing and installing wage es n
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1.3 Service position
1.3.1 Moving to service position

– Remove front bumper cover ⇒ page 223 .
– Remove air duct from lock carrier -1- ⇒ Rep. Gr. 24 ; Repair‐
ing injection system .
– Unhook Bowden cable from coupling for bonnet release
⇒ page 24
– If vehicle has charge air cooler, disconnect pressure hoses
⇒ page 4 .
– Unscrew horn -4- with bracket on right side of longitudinal
member ⇒ Electrical system; Rep. Gr. 96 ; Horn .
– Pull connector off high-pressure sender -G65- ⇒ Heating, air
conditioning system; Rep. Gr. 87 .
– Remove bolts -3- from left and right longitudinal members.
2 Rep. Gr.50 - Body - front

– Attach special tool guide pins -T10093- to left and right longi‐
tudinal members.
– Remove bolts -2- on left and right from upper part of lock car‐
rier -1-.
– The lock carrier -1- can be pulled forwards on the guide pins
-T10093- .
Note
If necessary, disconnect upper coolant hose from radiator, but drain coolant first ⇒ Rep. Gr. 19 ; Removing
and installing parts of coolant system .
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1.3.2 Moving from service position

Install in reverse order of removal.
– Align lock carrier on longitudinal members and between wings
⇒ Body Repairs; Rep. Gr. 00 ; Body dimensions .
1. Lock carrier 3
Note
♦ Ensure that the charge air cooler pressure hoses are properly
engaged again.
♦ Hoses and lines must not be pinched.
♦ If necessary, replenish coolant ⇒ Rep. Gr. 19 ; Removing and
installing parts of coolant system .
1.3.3 Releasing pressure hoses

– Release push-on coupling -1- and pull pressure hose -2- in
direction of -arrow- out of coupling.
During installation of pressure hoses, ensure that push-on cou‐
pling engages audibly.
1.4 Removing and installing lock carrier with

add-on parts
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♦ Because the lock carrier is a safety-relevant component, it must not be repaired.
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– Set lock carrier with add-on parts -1- to service position
ole,
spec
⇒ page 2 .
t to the co
– Disconnect all electrical connectors.
– Drain coolant and disconnect coolant hoses ⇒ Rep. Gr. 19 ;
Removing and installing parts of coolant system .
rrectness of i
– Disconnect lines for condenser ⇒ Heating, air conditioning

system; Rep. Gr. 87 .
cial p
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– Together with a second mechanic, unscrew guide pins -

mer
T10093- from left and right longitudinal member and lift lock
a
carrier out -1-.

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♦ Do not hang condenser and hydraulic oil cooler from lines.
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♦ Do not kink lines for condenser and hydraulic systems.
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1.4.2 Installing
During assembly, ensure that all connectors and hose connec‐
tions are properly installed.
– Align lock carrier on longitudinal members and between wings
1. Lock carrier 5
2 Wing
2.1 Tools
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1783-
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2.2 Assembly overview - front wing
Note
Only the left side is shown. The right side is similar.
1 - Wing
❑ Removing and installing
⇒ page 7
2 - Bolt
❑ Qty. 2, A-pillar
❑ Qty. 2, side member
❑ Qty. 2, wing bracket
❑ Qty. 3, wing connection
piece
❑ 6 Nm
3 - Foam element
❑ Loosely inserted be‐
tween wing and top of
longitudinal member
4 - Wing bracket
⇒ page 8
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2.3 Removing and installing wing

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The removal and installation sequence is only described for the

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2.3.1 Removing
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– Remove front and rear parts of wheel housing liner
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⇒ page 321 .
– Remove guide ⇒ Item 4 (page 227) .
2. Wing 7
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– Loosen hexagon nut -6- and remove bolts -2-. d by V ua
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– Pull out foam element -3- between wing and longitudinal
utho mem‐ or
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2.3.2 Installing
Ensure parallelism and gap dimensions are maintained ⇒ Body
Repairs; Rep. Gr. 00 ; Body dimensions .
2.4 Removing and installing wing bracket
Note
The removal and installation sequence is described for the left

wing bracket. The removal and installation of the right wing brack‐
et is similar.
2.4.1 Removing
• The wing has been removed.

– Remove bolts -2- and remove wing bracket -1-.
2.4.2 Installing
– Install wing bracket -1-.
Specified torque for bolts -2-: 6 Nm.
Wing and wing bracket mustagbe
n Aaligned
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2. Wing 9
3 Noise insulation
3.1 Tools
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Prote AG.
Rep. Gr.50 - Body - front

3.2 Assembly overview - noise insulation
Note
The removal and installation procedures may have to be modified slightly depending on engine fitted.
1 - Noise insulation
❑ -Arrow- points forwards
❑ To remove, unbolt bolts
⇒ Item 2 (page 11)
2 - Bolt
❑ Qty. 8
❑ 2 Nm
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3. Noise insulation 11
4 Underbody cladding
4.1 Tools
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4.2 Assembly overview - underbody cladding
Note
1 - Underbody cladding
❑ -Arrow- points forwards
❑ To remove, unbolt hex‐
agon nuts
2 - Hexagon nut
❑ Qty. 8
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3 - Cover rised
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4. Underbody cladding 13
4.3 Assembly overview - rear underbody cladding
1 - Bolt
❑ Qty. 3
❑ 2 Nm
2 - Rear underbody cladding
❑ Installed only on right
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5 Plenum chamber bulkhead
5.1 Tools
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5.2 Assembly overview - plenum chamber bulkhead
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1 - Plenum chamber bulkhead
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2 - Hexagon nut
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❑ 8 Nm
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seal
❑ When installing bulk‐
head, ensure seal is cor‐
rrectness of i
rectly seated.
4 - Bolt
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❑ 8 Nm
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5. Plenum chamber bulkhead 15

55 – Bonnet, rear lid

1 Bonnet
AG. Volkswagen AG d
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1.1 Tools
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Special tools
ss and workshop equipment required
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♦ Removal lever -80-200-
form
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16 Rep. Gr.55 - Bonnet, rear lid

1.2 Assembly overview - bonnet
1 - Bonnet
⇒ page 17
❑ Adjusting ⇒ page 25
2 - Adjustment buffer
❑ Qty. 2
3 - Stop buffer
❑ Qty. 2
4 - Insulation
⇒ page 20
5 - Guide
❑ Qty. 2
6 - Lid hinge
⇒ page 19
❑ Adjust bonnet
⇒ page 25 . AG. Volkswagen AG d
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❑ Removing ⇒ page 19 horis nte
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❑ Releasing gas ss
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⇒ page 19
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8 - Seal
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❑ Secured to inner bonnet
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with clips
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1.3 Removing and installing bonnet
cial p
1.3.1 Removing
nform
mer
– Remove left and right washer jets -6- ⇒ Electrical system;

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Rep. Gr. 92 ; Windscreen washer system .

n in
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– Unclip line -2- from bonnet hinge -3- and bonnet -5-.
s
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– Pull line -2- out through aperture in bonnet -5-.

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– Loosen hexagon nuts -1- on left and right (do not remove). t. Co py
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– Disconnect gas strut -4- from bonnet -5- ⇒ page 19 .
1. Bonnet 17
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– Now remove hexagon nuts -1- and lift bonnet
ris
e -5- out of bonnet nte
hinges -3-. ho eo
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1.3.2 Installing
Specified torque for bonnet hexagon nut: 22 Nm.
Adjusting bonnet -1- ⇒ page 25 .
– Route line -2- in an arc -arrow-. If line is installed twisted it will
kink.

1.4 Removing gas strut

– Open bonnet and support it.
– Position a small screwdriver beneath spring clip -2-.
– Raise spring clip -2- until it can be moved over ball socket in
direction of -arrow-.
– Pull gas strut -1- off ball-head pins -3- and -4-.
– Slide spring clip -2- back immediately after removing gas strut
-1-.
WARNING
Proceed with care if gas strut is reused. Spring clip must not
be levered completely out of ball socket, as it will otherwise be
damaged. Gas strut will spring out of mounting, causing dam‐
age or injury to operator.
Specified torque for ball-head pins -3- and -4-: 22 Nm.

Releasing gas from gas strut ⇒ page 19 n AG. Volkswagen AG do
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1.5 Releasing gas from gas strut uthoris tee
or
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– Clamp gas strut in vice in area marked -x- = 50 mm (2 in).
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WARNING
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Clamp gas strut only within area -x-; otherwise danger of ac‐
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is n
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– Saw through cylinder of gas strut within first third of cylinder's
overall length using piston rod end of cylinder as reference
point.
rrectness of i
Note
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♦ Cover area of saw cut with a cloth.

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♦ Dispose of oil and cloth via existing disposal channels.

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1.6 Removing and installing lid hinge

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Note
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The removal and installation sequence is only described for the

left hinge. The removal and installation of the right hinge is similar.
1. Bonnet 19
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1.6.1 Removing
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– Remove front bonnet
au ⇒ page 17 . ra
c
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– Remove bolts -2- and remove bonnet hinge -1-.
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1.6.2 Installing
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– Install lid hinge -1-.
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Specified torque for bolts -2-: 22 Nm. rig ht
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– Install bonnet ⇒ page 18 . Prote
cted AG.
agen
1.7 Removing and installing insulation
1.7.1 Removing
– Lever retaining clips -1- out of insulation -2- using removal
lever -80-200- .

– Pull insulation -2- out of elongated holes.
AG. Volkswagen AG d
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1.7.2 Installing
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– Push insulation -2- underneath gas strut and place assembly

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tongues in elongated holes.

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– Engage all retaining clips -1- in insulation -2-.

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1. Bonnet 21
When installing insulation -2- ensure that retaining clips -1- are
fitted with wider side outwards.
AG. Volkswagen AG d
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1.8 Assembly overview - bonnet latch and release components
1 - Arrester
❑ Adjustment is carried
out by moving arrester
to left or right in elonga‐
ted holes.
2 - Bolt
❑ Qty. 3
❑ 10 Nm
3 - Expanding nut
❑ Qty. 2
4 - Mounting bracket
5 - Bowden cable
❑ Clipped into bearing
bracket
6 - Bolt
❑ Qty. 2
❑ 1.5 Nm
7 - Release lever agen
AG. Volkswagen AG d
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❑ Removing and installing d by
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⇒ page 27 o
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8 - Bowden cable ss
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❑ Clipped onto wheel

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9 - Bowden cable coupling
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hole
spec
10 - Lid lock
es, in part or in w
❑ Removing and installing t to the co

⇒ page 23
rrectness of i
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1.9 Removing and installing bonnet lock

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1.9.1 Removing
n in
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– Open bonnet.
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– Remove radiator grille ⇒ page 337 .

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– Disconnect Bowden cable ⇒ page 24 . Cop py
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1. Bonnet 23
– Disconnect connector -5- for bonnet contact switch -F266- .

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The connector is secured over the right headlight. Volks ot g
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– Unclip wiring for bonnet contact switch -F266- onthorilock carrier tee
or
-3-. au ac
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– Remove bolts -4- (Qty. 3) on lock carrier -3- and remove bon‐
un
pt
net lock -1- upwards.
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– To unclip Bowden cable -2-, press tabs on Bowden cable to‐
pe
ility
gether -arrows-.
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– Fastener is released and Bowden cable -2- can be removed
hole
spec
from bonnet lock -1-.
es, in part or in w
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1.9.2 Installing
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– Clip Bowden cable -2- into bonnet lock -1-.
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– Install bonnet lock -1- into lock carrier -3-.
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Specified torque for bolts -4-: 12 Nm
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– Reconnect connector -5- for bonnet contact switch -F266- and Co py
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clip wiring onto lock carrier -3-.
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– Install Bowden cable -2- ⇒ page 24 . Prote
cted AG.
agen
– Adjust bonnet lock ⇒ page 26 .

Before closing bonnet, check function of release lever and Bow‐
den cable.
1.10 Disconnecting Bowden cable

– Open bonnet.
– Unclip Bowden coupling -1- above right headlight for lock car‐
rier -2-.
– Open Bowden cable coupling -1- upwards and remove Bow‐
den cable -3- in direction of -arrow- out of Bowden cable
coupling.
Note
When installing, ensure that the Bowden cable sleeve is inserted

correctly and the coupling engages.
Before closing bonnet, check function of release lever and Bow‐

den cable.

1.11 Adjusting bonnet

For initial adjustment of bonnet, -1-, the vehicle must be standing
on the ground and the arrester be removed.
– Remove latch hook -9- ⇒ Item 1 (page 23) .
– Disconnect gas strut -2- from bonnet -1- ⇒ page 19 .
– Bonnet -1- can be centred between wings by loosening hex‐
agon nuts -5- and bolt -3- (do not remove) on left and right
bonnet hinges -4-.
– Bonnet -1- can be adjusted in height to wings at rear by means
of adjustment screw -6- on left and right.
– The stop buffers -7- (Qty. 2) are not used for adjustment. They
have the function of stabilising and damping the bonnet -1-.
– The front part of the bonnet -1- can be adjusted to wing height
by using the adjustment buffers -8- (Qty. 2).
Ensure that gaps are uniform ⇒ Body
n AGRepairs;
. VolkswageRep.
n AG dGr. 00 ; Body
dimensions . wage oes
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– After refitting or adjustment
ris
ed work, apply corrosion protection
ran
tee
to bonnet hinge,
autho -4-, hexagon nuts -55- and bolts -3-. or
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1. Bonnet 25
– After adjusting bonnet -1-, install and adjust arrester

⇒ Item 1 (page 23) .
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Volks ot g
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1.11.1 Adjusting bonnet lock

form
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If gaps change when bonnet is closed, minor corrections can be

n in
made via bonnet lock and arrester.

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– Now loosen bolts -1- to correct or adjust gaps at front of bonnet

– Adjust arrester ⇒ Item 1 (page 23) .
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Volks ot g
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1.12 Removing and installing release lever o
ir se
d ran
tee
th or
s au ac
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1.12.1 Removing
pt
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– Pull operating lever -1- and release bonnet.
ab
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– Insert a small screwdriver in gap between release lever -1- and
wit
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clip -2-.
h re
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spec
– Lever clip -2- out of release lever -1- and pull off release lever.
t to the co
rrectness of i
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a
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1. Bonnet 27
1.12.2 Installing
– Slide clip -2- completely into release lever -1-.
– Then press release lever -1- onto mounting in mounting brack‐
et and fasten release lever. gen AG
. Volkswagen AG
d wa oes
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Before closing bonnet, check function ofd b release lever and Bow‐
yV gu
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2 Rear lid (saloon)
2.1 Tools
AG. Volkswagen AG d
♦ Torque wrench -V.A.Glk1331-
swa
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2.2 Assembly overview - rear lid
rrectness of i
1 - Hinge cover
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2 - Wiring harness
nform
mer
3 - Rear lid
a
m
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n in
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⇒ page 30
thi
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4 - Rear lid trim

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❑ Removing and installing Co py
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⇒ General body repairs,
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cop
exterior; Rep. Gr. 70 ;
Vo
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Removing and installing
agen
Prote AG.
rear lid trim
❑ Left and right
❑ When installing, turn 90°
anti-clockwise -arrow-
6 - Hexagon nut
❑ Qty. 2
❑ 22 Nm
7 - Lid hinge
⇒ page 31
8 - Rubber buffer
9 - Bolt
❑ Qty. 3
❑ 22 Nm
10 - Gas strut
❑ Removing ⇒ page 30
❑ Releasing gas
⇒ page 31
2. Rear lid (saloon) 29

11 - Bolt
❑ Qty. 2
❑ 23 Nm
12 - Locking wedge
❑ Removing and installing ⇒ page 32
13 - Pop rivet nut
14 - Base for registration plate
❑ Different versions are possible.
❑ Assignment ⇒ Parts catalogue “ETKA”
2.3 Removing and installing rear lid
2.3.1 Removing
– Open rear lid.
– Remove rear lid trim ⇒ General body repairs, interior; Rep.
Gr. 70 ; Rear lid trim .
– Disconnect connectors -1- and pull wiring -2- with rubber
grommet out of lid.
– Loosen hexagon nuts -3- on left and right lid hinges (do not
AG. Volkswagen AG d
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Further dismantling requires the assistance ris
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tee
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– Detach gas struts -4- on left and right
s
of rear lid ⇒ page 30 .
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– Now, and only now, unbolt bolts -3- and remove rear lid.
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itte
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2.3.2 Installing
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Specified torque for rear lid hexagon nut: 22 Nm.

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co
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or
Adjust rear lid ⇒ page 33 .

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ate
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Before closing rear lid, check function of lid release components.

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2.4 Removing gas strut

t.
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– Open rear lid and support it.
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– Slide spring clip -2- back immediately after removing gas strut
-1-.
WARNING
Releasing gas from gas strut ⇒ page 31
2.5 Releasing gas from gas strut

– Clamp gas strut in vice in area marked -x- = 50 mm (2 in).
wage es n
WARNING Volks ot g
by ua
d ran
rise tee
o
Clamp gas strut only withinau area -x-; otherwise danger of ac‐
th or
ac
cident! ss
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erm
ab
ility
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point.
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t to the co
♦ Wear eye protection when sawing.
rrectness of i

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nform
ercia
2.6 Removing and installing lid hinge

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at
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Note
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ate
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Removal and installation is described for hinge on right of lid.

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Follow same instructions for hinge on left of lid as appropriate.

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2.6.1 Removing
by
y cop Vo
lksw
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cted agen
Prote AG.
– Remove rear lid ⇒ page 30

– Remove bolts -1- and remove lid hinge -2-.
lkswage es n
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2.6.2 Installing ris
ed b ua
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tee
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or
Install in reverse order of removal. au ac
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Specified torque for lid hinge bolts: 22 Nm

nl
pt
du
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itte
Adjust rear lid ⇒ page 33 .
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2.7 Removing and installing striker pin
ole,
spec
t to the co
2.7.1 Removing
– Remove lock carrier cover ⇒ General body repairs, interior;
rrectness of i
Rep. Gr. 70 ; Luggage and load compartment trim .
– Remove bolts -1- and remove striker pin -2-.
cial p
nform
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2.7.2 Installing
c Vo
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Prote AG.
– Install striker pin -2-.
Further installation is performed in reverse order of removal.

2.8 Adjusting rear lid
Note
♦ Vehicle must be standing on the ground to perform the basic

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

Use setting gauge -3371- ⇒ Body Repairs; Rep. Gr. 00 ; Body
dimensions to check or set gap dimensions.
– Remove gas strut ⇒ page 30 .
– Adjust rear lid on rear lid hinges by loosening bolts
⇒ Item 9 (page 29) .
– Adjust rear lid with rear lid hinges by loosening hexagon nut
. Volkswagen AG
⇒ Item 6 (page 29) . swa
gen AG does
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– Adjust adjustment buffer ⇒ page 33 . edb ara
nte
ris
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Note
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nl
pt
du
an
itte
The rear lid is correctly adjusted if, when closed, it is not sunken
y li
erm
ab
or raised, the gap is uniform all around and the contours align.
ility
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2.8.1 Adjusting adjustment buffer
ole,
spec
t to the co
Note
rrectness of i
Only the adjustment for the right adjustment buffer is described.
The adjustment for the left adjustment buffer is similar.
– Loosen grub screw -1- until it is visible in rubber buffer.

cial p
nform
– Now pull detent slide out of adjustment buffer.
mer
a
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tion
co
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or
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ate
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.

– Adjust detent slide to dimension -a- = 12.5 mm.

– Close rear lid to detent position with light pressure at centre of
lid.
– Open rear lid again.

– Screw in adjustment buffer clamping screw -1- to a depth of
dimension -a - = 25 mm.
– Check setting.
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1 - Bowden cable
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❑ From lid lock to lock cyl‐
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2 - Connector
❑ For bonnet lock
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3 - Bowden cable
❑ From lid lock to emer‐
rrectness of i
gency release lever in
interior
❑ Only vehicles with
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4 - Rear lid trim

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⇒ page 36
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8 - Cover
❑ Not supplied with lid lock
❑ Secured on lid lock with
locking lugs
9 - Handle trim
⇒ page 36
10 - Connector
❑ For registration plate
lighting and release but‐
ton on vehicles with a re‐
lease button
11 - Lock cylinder
12 - Connector
❑ For lock cylinder
2.10 Removing and installing lock cylinder
2.10.1 Removing
– Removing rear lid trim ⇒ General body repairs, interior; Rep.

– Disconnect connections -1- on lock cylinder.

– Unhook Bowden cable -2-.
– Remove nuts -3- and remove lock cylinder -4-.
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2.11 Removing and installing handle trim
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2.11.1 Removing
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– Remove lock cylinder ⇒ page 35 .
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– Disconnect connector -5-.
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– Remove nuts -6- and remove handle trim -7-.
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2.11.2 Installing
Specified torque for hexagon nuts: 8 Nm
2.12 Removing and installing lid lock
2.12.1 Removing
– Remove lock cover ⇒ Item 5 (page 35) .

– Remove cover cap -1-.

– Disconnect connector -2- from lid lock -5-.
– Unhook Bowden cable -3-.
– Remove remove hexagon nuts -4- and remove lid lock -5-.
– If lid lock -5- is renewed, Bowden cable -6- must be unhooked.
2.12.2 Installing
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Specified torque for hexagon
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2.13 Rear lid seal
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During production, a sealant is applied to the rear lid seals, the

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Note
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♦ When seals are removed, the sealant will spread to the inside
t to the co
of the seal and the flanks will be bent out slightly. If the seal is
then refitted, a leak-free tight seal is not guaranteed.
♦ Therefore each seal which is removed completely should be
rrectness of i
replaced by a so-called “tap-on” seal.

♦ If a seal has been partially removed, squeeze sides of seal
together before refitting.
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2.14 Removing and installing rear lid seal
2.14.1 Removing
– Pull rear lid seal -1- off body flange.
2.14.2 Installing
– Align rear lid seal -1- so that the vulcanised point -arrow- is
located to the middle of the left tail light cluster.
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3 Rear lid (Variant)
3.1 Tools
♦ Torque wrench 5…50 Nm -V.A.G 1331-
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1 - Rear lid
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hole
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2 - Lid lock
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⇒ page 48
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4 - Striker pin
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8 - Rear lid trim
interior; Rep. Gr. 70 ;
Removing and installing
rear lid trim
9 - Button to release rear lid
⇒ page 47
3. Rear lid (Variant) 39

10 - Registration plate light

⇒ Electrical system; Rep. Gr. 94 ; Lights, bulbs, switches - exterior
11 - Rear window wiper
❑ Removing and installing ⇒ Electrical system; Rep. Gr. 92 ; Window washer/wiper system
3.3 Removing and installing rear lid
3.3.1 Removing
– Remove rear lid window frame trim ⇒ General body repairs,
interior; Rep. Gr. 70 ; Rear lid trim .
– Disconnect all connections in rear lid.
– Release bellows -1- and guide electrical wiring -5- throughagen AG. Volkswagen AG do
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– Loosen bolts -3- on hinge -2- (do not remove).horis tee
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– Remove bolts -3-.
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3.3.2 Installing a
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Further installation is possible only with the help of a second me‐

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– Position rear lid carefully on hinges.

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– Install bolts -3-.

– Guide electrical wiring -5- through opening in rear lid and se‐
cure bellows -1-.
– Adjust rear lid ⇒ page 44 and tighten bolts -3-, specified tor‐
que: 10 Nm.
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– Install rear lid trim ⇒iseGeneral body repairs, interior; Rep. Gr.
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– Install rear lid window frame trim ⇒ General body repairs, in‐
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terior; Rep. Gr. 70 ; Rear lid trim .

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– Check adjustment of rear lid ⇒ page 44 .
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3.4 Removing and installing gas strut
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– Open rear lid and support it.
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After removing gas strut -1-, slide spring clip -2- back immediately.
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Note
Ball sockets -3- and -4- are screwed into rear lid or body, specified
torque: 20 Nm.
– Releasing gas from gas strut ⇒ page 42

3.5 Releasing gas from gas strut

– Clamp gas strut in vice in area marked -x- = 50 mm.
WARNING
Clamp gas strut only within area -x-; otherwise danger of ac‐
cident!

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3.6 Removing and installing rear lid hinge
spec
t to the co
3.6.1 Removing
rrectness of i
– Remove rear lid ⇒ page 40 .
– Remove end strip for moulded headliner ⇒ General body re‐
pairs, interior; Rep. Gr. 70 ; Trim, insulation .
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– Unscrew nuts -2- from studs -1-.

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– Remove hinge -3- from exterior.

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3.6.2 Installing
– Position hinge -3- in vehicle.
– Screw nuts -2- onto studs -1-.
– Install rear lid ⇒ page 40 .
– Align hinge to rear lid.
– Specified torque for nuts -2-: 24 Nm
– Check adjustment of rear lid ⇒ page 44 .
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3.7 Adjusting rear lid
Note
♦ Vehicle must be on the ground to carry out rear lid adjustment.

♦ The rear lid lock -2- is bolted directly to the rear lid -1-. It does not have elongated holes, so it cannot be
adjusted.
♦ The stop buffers -3- on the left and right are not a means of adjustment. Their purpose is to stabilise and
dampen the rear lid -1-.
♦ The rear lid is adjusted correctly if the wgaps/shut
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The rear lid adjustment is described step by step below.

Use setting gauge -3371- ⇒ Body Repairs; Rep. Gr. 00 ; Tech‐
nical data; Body gap dimensions to check or adjust the gap
dimensions.

– Rear lid can be adjusted within oversized holes of hinge -3- by

loosening nut -2-.
– Rear lid can be adjusted slightly at bolts -3-.

– After completing adjustments, perform corrosion protection
measures on hinge and bolts.
– Adjusting rear lid at striker pin ⇒ page 45 .
– Adjusting left and right adjustment buffer ⇒ page 46 .
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3.7.1 Adjusting striker pin

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Note
♦ Loosen bolts to slide striker pin in over-sized holes.

rrectness of i
♦ Adjust striker pin so that recess of rear lid lock engages with
rotary catch centrally to striker pin.
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– Remove lock carrier cover ⇒ General body repairs, interior;

mer
Rep. Gr. 70 ; Luggage and load compartment trim .

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– Loosen bolts -1-.

– Move striker pin -2- to upper position and tighten bolts -1-.
– Close rear lid and check adjustment.
The rear lid is adjusted correctly if the gaps/shut lines are even
all around, the door is not too deep or does not stand proud and
all contours align when the rear lid is closed.
– Specified torque for bolts -1-: 23 Nm
3.7.2 Adjusting adjustment buffer

– Tighten stop buffer -2-, specified torque for bolt -3-: 10 Nm.
– Pull cover -4- off adjustment buffer.
– Loosen bolt -5- on adjustment buffer -6- slightly until adjust‐
ment buffer can be moved onto stop in direction of -arrow-.
– Close rear lid -1- to first detent position by applying light pres‐
sure to centre area.
– Open rear lid again.
– Tighten bolt -5-, specified torque: 10 Nm.
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– Press cover -4- onto adjustment buffer. tho
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3.8 Removing and installing release button
3.8.1 Removing

– Disconnect connector -3- from connection on release button

-1-.
– Unscrew the two nuts -2- from studs for release button and
take cover -4- off upwards.
– Remove release button -1- from rear lid.
In case of electrical malfunction, rear lid can be opened using lock
emergency release ⇒ page 48 . Emergency release is acces‐
sible through an aperture in rear lid trim.
3.8.2 Installing
Specified torque for nuts: 8 Nm.
3.9 Removing and installing lid lock yV
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Gr. 70 ; Trim, insulation .
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– Disconnect connector -3- on back of lock.
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The rear lid can be opened using emergency release -4- for elec‐
trical malfunctions. Emergency release is accessible through an
aperture in rear lid trim.
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– Reconnect connector -3- on back of lock.

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3.10 Rear lid seal

During production a sealant is applied to the rear lid seals, the
seal is then placed on the body flange and rolled on.
Note
then refitted, a leak-free tight seal is not guaranteed.
♦ If a seal has been partially removed, squeeze the sides to‐
gether before installing.

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3.11 Removing and installing rear lid seal
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3.11.1 Removing
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– Pull rear lid seal -1- off body flange -2-.
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3.11.2 Installing
– Align rear lid seal -1- so that vulcanised point -arrow- faces
centre of left tail light.

Push seal -1- evenly onto body flange -2-.
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3.12 Registration plate carrier
1 - Pop rivet nut

❑ Qty. 2
2 - Registration plate carrier
❑ Assignment ⇒ Parts
catalogue“ETKA”
3 - Bolt
❑ Qty. 2
❑ 4 Nm
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4 Fuel tank flap unit (saloon)
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1 - Fuel filler neck
2 - Tank flap unit
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⇒ page 54
3 - Water drain hose
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9 - Tank filler flap locking motor

-V155-
⇒ page 56
10 - Securing bolt
❑ For tank filler flap lock‐
ing motor -V155-
❑ Qty. 2
❑ 1.5 Nm
11 - Securing bracket
❑ On rear right wheel
housing
4.2 Removing and installing tank flap unit
4.2.1 Removing
Note
If fuel tank filler flap does not open, it can be opened by hand using the release rod -7-. Remove rear right
luggage compartment trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Load area and luggage compartment
trim for this.
– Open fuel tank flap.

– Remove tank cap.
– Remove bolt -4-.

– Pull rubber part of tank flap

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– Pull tankris flap unit -2- with drain hose -3- to rear and
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tankauflap unit out of side panel.
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– Unclip assembly part -5- out of side panel and pull assembly
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4.2.2 Installing
• The mounting part -5- has been pushed in.
– Feed drain hose -3- through aperture in tank flap unit -2- and
pull drain hose through as far as possible.
– Guide drain hose into side panel.
– With hinge side leading, guide tank flap unit -2- into side panel.
– Then swivel tank flap unit completely onto side panel.
Make sure that tank flap unit -2- locking devices engage correctly
in side panel at top and bottom.
– Pull rubber part of tank flap unit over filler neck and tighten bolt
-4-.
4. Fuel tank flap unit (saloon) 55

Specified torque for bolt -4-: 1.5 Nm

– Perform functional check of release components.
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4.3 Removing and installing tank filler flap

locking motor -V155-
4.3.1 Removing
– Remove luggage compartment side trim on right ⇒ General
body repairs, interior; Rep. Gr. 70 ; Load area and luggage
compartment trim .
– Disconnect connector -8- on tank filler flap locking motor -
V155- -9-.
– Loosen bolts -10-.

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– Pulluttank
ho filler flap locking motor -V155- -9- together or with re‐
lease
ss a rod -7- out of seal -6- and fitting -5-. ac
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4.3.2 Installing
4. Fuel tank flap unit (saloon) 57

5 Fuel tank flap unit (Variant)

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1 - Fuel filler neck ss
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2 - Tank flap unit
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⇒ page 58
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3 - Water drain hose
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4 - Bolt
spec
❑ 1.5 Nm urposes, in part or in wh
t to the co
5 - Tank filler flap locking motor
-V155-
rrectness of i
⇒ page 60
6 - Wiring harness
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❑ For tank filler flap lock‐
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ing motor -V155-
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5.2 Removing and installing tank flap unit
5.2.1 Removing
– Open fuel tank flap.
– Remove tank cap.
– Pull rubber part of tank flap unit -2- off fuel tank filler neck
-1-.
– Pull tank flap unit -2- with drain hose -3- to rear and swing fuel
tank flap unit out of side panel.

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– Feed drain hose -3- through aperture in tank flap unit -2- and
pull drain hose through as far as possible.
– Guide drain hose into side panel.
– With hinge side leading, guide tank flap unit -2- into side panel.
– Then swivel tank flap unit completely onto side panel.
Make sure that tank flap unit -2- locking devices engage correctly
in side panel at top and bottom.
– Pull rubber part of tank flap unit over filler neck and tighten bolt
-4-.
Specified torque for bolt -4-: 1.5 Nm
5. Fuel tank flap unit (Variant) 59

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5.3.1 Removing
– Remove tank flap unit ⇒ page 58 .
– Unclip service cover -B- from side panel -A-.

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ris nte
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– Pull service cover -B- au
forwards slightly. ra
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– Disconnect connector -2- on tank filler flap locking motor -
V155- -1- through opening in side panel.
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– Push rubber grommet -4- out of side panel and pull out wiring
harness -3-.
– Pull tank filler flap locking motor -V155- -1- in direction of
-arrow- off side panel.
5. Fuel tank flap unit (Variant) 61

5.3.2 Installing
– Feed wiring harness -3- through opening in side panel.
– Secure rubber grommet -4- on side panel.
– Reconnect connector -2-.
– Slide tank filler flap locking motor -V155- -1- in opposite direc‐
tion of -arrow- onto side panel.
– Install tank flap unit ⇒ page 59 .
– Install luggage compartment side trim on right ⇒ General body
repairs, interior; Rep. Gr. 70 ; Load area and luggage com‐
partment trim .
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57 – Front doors, door components, central locking

1 Front door
1.1 Tools
Special tools and workshop

equipment required
♦ Socket -T10072-
♦ Assembly tool -T10118-
♦ Door alignment tool -3320-
with -3320/1- , -3320/2- and n AG. Volkswagen AG do
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♦ Roller for door insulation rise
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foil -3356- autho
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♦ Setting gauge -3371-
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1. Front door 63
♦ Cartridge gun -V.A.G 1628- n AG. Volkswagen AG do

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♦ Removal wedge -3409- ss
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♦ Assembly tool set -T10237-
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1.2 Materials
♦ 1K or 2K glass adhesive -DH 009 100 01- 1) 2) or -DH 004
600 A2- 1)
♦ Glass primer/paint primer -D 009 200 02- 3)
♦ Cleaning solution -D 009 401 04- 3)
♦ Primer applicator -D 009 500 25- 3)
1) Observe curing period ⇒ page 82

2) Heat according to manufacturer's instructions, using cartridge heater -V.A.G
1939 A- .
3) Materials are stored in box -D 004 700- .
1.3 Assembly overview - door assembly

A new door concept has been introduced with Jetta 2005 ▸, Bora
2005 ▸.
The door consists of an inner part -6- and an outer panel -1-.
The parts are joined by the front -7- and rear -4- retaining rail.
64 Rep. Gr.57 - Front doors, door components, central locking

The retaining rails are bolted to the inner part of the door and en AG. Volkswagen AG
bonded to the outer panel of the door. olks
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utho
window eo
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regulator motor, wiring, window channel, exterior
ss mirror and door c
lock are mounted on the door inner part.
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The outer panel -1- of the door is additionally bolted to the lower
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edge of the inner part. The window slot outer seal, insulation and
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exterior door handle are mounted on the outer panel of the door.
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Caution
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Different securing screws are used for the door outer panel. If
these are fitted in the wrong positions, the outer panel for the
door will be damaged.
rrectness of i
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Note
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The edge protection foil -2- must always be bonded between the door outer panel and the door inner part.
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❑ Is bonded between door
outer panel and door in‐
ner part.
3 - Bolt
❑ Feature: bolt with poin‐
ted end and thinner
washer.
❑ Qty. 6 on lower edge
❑ Qty. 1 in rear section of
door shoulder
❑ 10 Nm
4 - Rear retaining rail
❑ Adhesive -DH 009 100
03-
5 - Bolt
❑ Feature: bolt with no
pointed end and thicker
washer.
❑ Qty. 10 for both retain‐
ing rails
❑ 14 Nm
6 - Door inner part
❑ Assembly overview
⇒ page 84
7 - Front retaining rail
❑ Adhesive -DH 009 100
03-
1. Front door 65
8 - Bolt
❑ Feature: bolt with pointed end and thicker washer
❑ Qty. 1 in area of front section of door shoulder
❑ 10 Nm
9 - Insulation
❑ Self-adhesive
❑ To bond, first heat the insulation and then press on firmly
10 - Clip
❑ Qty. 6
11 - Window slot seal
❑ Must be fitted before fitting door outer panel.
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1.4 Assembly overview - door hinges
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Nut of eccentric bolt -9- should not be loosened under any cir‐
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♦ The right side is shown. The left side isss similar.
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♦ The hinge bolts must always be renewed if loosened.
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♦ Hinges are now one piece.
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1 - Door
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⇒ page 68
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2 - Guide bolt
❑ 10 Nm
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3 - Door hinge with arrester
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4 - Multi-point socket head bolt

m
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❑ 20 Nm + 1/4 turn further
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trim ⇒ General body re‐
pairs, interior; Rep. Gr.
70 ; Pillar and side panel
trim
(90°).
loosening
(90°).
loosening
(90°).
❑ Always renew after loosening
8 - Guide bolt
❑ 10 Nm
9 - Nut
❑ For eccentric pin
❑ Do not loosen
❑ Serves as a means of adjustment during production only
10 - Door hinge
❑ Door hinge is now one piece.
1. Front door 67

❑ 20 Nm + 1/4 turn further (90°).
❑ 20 Nm + 1/4 turn further (90°).
❑ 20 Nm + 1/4 turn further (90°).
1.5 Removing and installing door
Note
The removal and installationagsequence

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1.5.1 Removing
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– Release boot -6- by pressing fastener -arrow a- and pull boot

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– Swing locking lever -7- downwards -arrow b- and separate

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electrical connector -8- from coupling station.

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– Remove bolts -4-, -5- and -11- from hinge using special door
spec
alignment tool -3320- and bit -3320/3- .

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– Pull door in direction of -arrow- off guide bolts -2- and -9-.
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1.5.2 Installing
Specified torque for bolts -4-, -5- and -11-: 20 Nm + 1/4 turn further
(90°).
Always renew bolts -4-, -5- and -11-.
1. Front door 69
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Observe front door gap/shut lines ⇒ Body Repairs;
ss
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Rep. Gr. 00 ; ra
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Body dimensions .
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1.6 Adjusting door
Caution
cumstances. Nut cannot be retightened using normal work‐
shop tools.
Note
♦ The door is adjusted correctly if the gaps/shut lines are even all around, the door is not too deep or does
not stand proud and all contours align when the is door closed.
♦ Vehicle must be standing on its wheels when adjustments are performed.
♦ If door outer panel has been removed, door inner part window frame must be adjusted to roof frame and B-
pillar, or rear door.

Observe front door gap/shut lines ⇒ Body Repairs; Rep. Gr. 00 ;

Body dimensions .
To be able to adjust gaps correctly, bolts -5-, -7-, -11- and -12- on
A-pillar must be loosened. For bolt -5-, A-pillar lower trim must be
removed ⇒ General body repairs, interior; Rep. Gr. 70 ; Pillar
and side panel trim .
Other measures such as raising the door have no effect. Subse‐
quent pressure from above will cause the door to sack again.
Bolts -4-, -6- and -13- and also guide bolts -2- and -8- must be
loosened to correctly adjust the flush fitting of the door.
Use door alignment tool -3320- with bit -3320/3- for this.
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Note
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♦ The front door must lock fully when closing without any addi‐ C py
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♦ The front door must not be pushed up or down as a result of cted agen
Prote AG.
the striker pin adjustment.
1. Front door 71
The following can be adjusted at the striker pin:

♦ When the front door does not align with the rear door.
– Loosen striker pin -1- by unbolting bolts -2- on B-pillar.
– Adjust the front door with the striker pin -1- so that the front
door is flush with the rear door when shut (wind noise).
Maximum twist tolerance -A- of striker pin: ± 3°
– Retighten bolts -2-.
Specified torque: 20 Nm
WARNING
Only use this adjustment to adjust door inwards or outwards,

never use for vertical adjustment. Door must not move up‐
wards or downwards when opening and closing. This indicates
that the vertical adjustment is incorrect.
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1.7 d
Removing and installing outer panel on
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1.7.1 Removing
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– Prise out clips -3-, starting at bottom of door -1-, and remove
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cover -2-.
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1. Front door 73
– Remove lock cylinder ⇒ page 86 .

– Remove door handle ⇒ page 86 .
– Remove bolt -1- from bearing bracket -2- which is located be‐
hind door outer panel.
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– Remove all bolts -2-, -3- and -4-.
t to the co
Note
rrectness of i
l purpos
It is possible to find bolt type -4- instead of bolt type -2- in rear upper location on door of some vehicles. If this
is the case, do not replace bolt type -4- with bolt type -2-.
n
ercia
for
– Carefully remove door outer panel.
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1.7.2 Installing
Caution
Bolts of different types are used to secure outer panel of door.

If these are fitted in the wrong positions, the outer panel for the
– Carefully position outer panel on door.

– Insert all bolts -2-, -3- and -4-.
Observe correct usage for the different types of bolts.
♦ Feature for bolt -2-: bolt with pointed end and thinner washer
♦ Feature for bolt -3-: bolt with no pointed end but with thicker
washer.
♦ Feature for bolt -4-: bolt with pointed end and thicker washer.
– Check whether retaining rail guide pins are located in appro‐
priate guide holes in inner part of door. Only then tighten all
bolts -2-, -3- and -4-.
Observe correct specified torque for the different types of bolts.
1. Front door 75
Specified torque for bolt -2-: 10 Nm

Further installation is performed in reverse order of removal
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1.8 Installing new outer panel on door
Caution

Note
Observe installation notes in chapter for bonding new outer panel on door ⇒ page 82
• The old (damaged) outer panel with retaining rails is removed

⇒ page 73 .

– Install front -2- and rear -6- retaining rails on inner part of door
-1-. Use “bolt with no point but with thicker washer” for this.
Specified torque for bolts -3- and -5-: 14 Nm
– Fit two guide bolts -4- in lower edge of door inner part -1-.
AG. Volkswagen AG d
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The painted outer panel for the door is first offered up without
bonding agent.
Assembly blocks -3- from assembly tool set -T10237- are required
when fitting outer panel on door. A strip of double-sided adhesive
tape -6- is applied on the side with a cut-out step. The pin has the
minimum dimension for the gap width. The surface with no ad‐
hesive tape is brought into position on the adjacent panel.
– Stick the assembly block -3- on outer panel -1- of the door.
– Guide outer panel -1- over guide bolts on lower edge of door
inner part.
– Adjust gap to sill and height of outer panel on door using
wedges -4- from assembly tool set -T10237- .
– Lay door outer panel -1- with assembly blocks on adjacent
panels -2- and -5-.
1. Front door 77
– Check gap/shut lines using setting gauge -3371- ⇒ Body Re‐

pairs; Rep. Gr. 00 ; Body dimensions .
If gap dimension cannot be adjusted further, door inner part must
be adjusted ⇒ page 70
– Remove door outer panel again.
AG. Volkswagen AG d
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– Apply a bead of adhesive material -2- using cartridge gun -

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

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Adhesive -DA 004 600 A2- can be used for this procedure and is applied with double cartridge gun -VAS 5237- .
cop by
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There is no requirement to preheat.
agen
Prote AG.

AG. Volkswagen AG d
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Fixing blocks -2- from assembly tool set -T10237- are required
nl
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an
when fitting outer panel on door. Two strips of double-sided ad‐

itte
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hesive tape -5- are applied on the contact surface.

erm
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ility
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inner part.
h re
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spec
– Bring outer panel with assembly blocks -3- into contact with
surrounding components.
t to the co

wedges -4- from assembly tool set.
rrectness of i
– Check gap/shut line using setting gauge -3371- ⇒ Body Re‐

cial p
– Bond short fixing blocks -2- evenly on the replacement door

nform
and the adjacent components.

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Note
o
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do
A waiting period of 90 or 180 minutes must be observed before performing further work on the bonded door
p
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or
⇒ page 82 .
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– Further installation is performed in reverse order of removal
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⇒ page 75 .
by
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1. Front door 79
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1.9 Removing and installing retaining rail on

door outer panel
1.9.1 Removing retaining rail
Caution
The following work steps are to be carried out with great care.
As outer panel is to be reused, dents and scratches must be
avoided.
When cutting through the adhesive bead, always hold the re‐
taining rail and outer panel together as shown in the illustration.
If this is not done, the outer panel will come away from the
retaining rail, thus rendering it useless.
Note
The following procedures should be carried out with the aid of an

assistant.

• Door outer panel with retaining rails is removed ⇒ page 73 .

– Place door outer panel -1- on firm surface and protect door
outer panel against scratches.
– Secure reel -2- on outer panel of door -1-.
– Secure cord -5- on reel -2- and counterhold -4-.
– Hold retaining rail and outer panel of door together securely
when cutting through adhesive bead.
– Cut through adhesive bead of retaining rail -3- and outer panel
-1- with cord up to just over half way.
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– Once adhesive bead has been cut through to just over half
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way in step one, turn reel -2- around and insert cord -5- in side
wit
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hole
spec
– Hold retaining rail -3- and outer panel -1- of door together se‐
es, in part or in w
curely when cutting through adhesive bead further.
t to the co
– Cut through second half of adhesive bead.
rrectness of i
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1.9.2 Installing retaining rail
co Vo
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Prote AG.
– Using extreme care, cut away remainder of adhesive bead to
the utmost minimum on outer panel of door, ensuring that no
damage is caused to the paintwork.
– Remainder of procedure is described in chapter entitled “In‐
stalling new outer panel for door” ⇒ page 76 .
Note
Observe also “instructions for bonding in new outer panel” on door

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

on the door inner part.
– Apply adhesive to new retaining rail
– Tighten screws to secure door panel on lower edge and on
retaining rail still in place.
1. Front door 81
– Secure outer panel for door on new retaining rail with fixing
blocks from assembly tool set -T10237- and double-sided ad‐
hesive tape.
1.10 Installation notes for bonding a new out‐

er panel on door
Note
♦ If front and rear door outer panels must be renewed, they must
be done at the same time. When bonding-in both outer panels,
the long fixing block from assembly tool set -T10237- is stuck
on for the transition from front outer panel to rear outer panel.
♦ If door outer panel CDP coating is damaged on inside in area
to be bonded or it has been painted, this area must be primed
with glass/paint primer -D 009 200 02- .
♦ The 1K glass adhesive -DH 009 100 01- must be heated in
cartridge heater -V.A.G 1939 A- for 20 minutes.
♦ Adhesive -DA 004 600 A2- can be used for this procedure and
is applied with double cartridge gun -VAS 5237- . There is no
requirement to preheat.
– Clean contact surfaces on retaining rails thoroughly using

cleaning solution -D 009 401 04- .
– Apply adhesive material to appropriate surfaces at right angles
to retaining rail using cartridge gun -V.A.G 1628- .
Caution
Door outer panel must be installed within 10 minutes, or ad‐

hesive properties of adhesive will be impaired. AG. Volkswagen AG d
agen oes
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♦ With assistance of both assembly blocks tho
au from assembly tool
or
ac
set -T10237- , place door outer panel
s on retaining rails and
s
ce
e
align with wedges and setting gauge -3371- and press contact
nl
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surfaces of assembly blocks onto adjacent components.

an
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♦ Secure door with fixing blocks from assembly tool set -

ility
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T10237- during curing period.

wit
is n
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♦ After installation door outer panel must align with other com‐
ole,
spec
ponents and gaps must be even.

t to the co
♦ If adhesive bead is too thick and adhesive exudes between

retaining rail and door outer panel, excess adhesive must be
removed.
rrectness of i
1.11 Minimum curing period

cial p
nform
WARNING
mer
atio
m
Special standards must be adhered to when replacing bonded

r co
outer panels for door. One of these standards is, for example,
in
o
thi
e
that a freshly bonded door outer panel must comply with the
t
sd
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safety requirements following the minimum prescribed curing

o
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period, even in an accident.

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For door outer panel: curing period for 1K adhesive -DH 009 100
rig ht
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01- is 180 minutes and for 2K adhesive -DA 004 600 A2- 90 mi‐ by c lksw
cted agen
nutes. Prote AG.

What is meant by minimum curing period is, time from bonding

outer panel on door to time vehicle is taken into use or further
work is carried out. During this time, the
lksvehicle
wage must stand on aes no
level surface at room temperatured(at Vo
by least 15 °C).
t gu
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WARNING ss
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Vehicle is safe to use only after the curing period is completed.
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1.12 Cleaning off excess adhesive sealing
wit
, is n
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material
hole
spec
es, in part or in w
– Use of adhesive remover -D 002 000 10- as a cleaning solution
t to the co
is recommended. Observe the appropriate safety precautions
when performing this work.
rrectness of i
Caution
l purpos
When cleaning vehicle the door outer panel just bonded-in
n
ercia
must not be moved.
form
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– First clean painted surface as much as possible using a dry
r
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cloth. Remove residual excess with adhesive remover -D 002
sd
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000 10- .
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– Cleaning plastic trim: allow adhesive sealant to cure (approx.

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one hour) and then peel off. Cop py
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1. Front door 83
1.13 Assembly overview - door inner part
Note
The right side is shown. The left side is similar.
1 - Door inner part

3 - Loudspeaker
4 - Window regulator motor
5 - Insulation
❑ Qty. 4
❑ 20 mm x 40 mm com‐ n AG. Volkswagen AG do
mercially available tex‐ wage es n
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tile adhesive tape d by ua
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1.14 Assembly overview - door handle and door lock
Note
1 - Cable
❑ To lock release from in‐
terior door handle.
2 - Cable
❑ To release lock from wage es n
Volks ot g
door exterior handle. d by ua
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3 - Bolt auth or
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❑ Qty. 2
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❑ To secure lock to door
an
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❑ 18 Nm
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4 - Door lock
h re
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spec
es, in part or in w
⇒ page 90
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5 - Cover
❑ Not supplied with door
rrectness of i
lock.
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❑ Secured on door lock

with locking lugs
n
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6 - Bearing bracket
form
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⇒ page 89
n in
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7 - Torx bolt
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❑ To secure lock cylinder

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9 - Lock cylinder housing
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❑ Only on driver side.
❑ Passenger side is instal‐
led in a housing.
10 - Cover
❑ For lock cylinder housing
❑ Secured to lock cylinder housing with three locking lugs
11 - Key
❑ Changing battery ⇒ page 100 .
❑ Adapting new or additional key to remote control and immobilizer ⇒ page 100 .
12 - Door handle with base
13 - Base
❑ Part of door handle.
1. Front door 85
14 - Torx bolt
❑ 4.5 Nm
1.15 Removing and installing housing

lksw
agen
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Note aut or
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The removal and installation sequence is only for the right hous‐
un
pt
an
d
ing. The removal and installation of the right lock cylinder is
itte
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similar. rm
ab
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ility
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1.15.1 Removing
h re
hole
spec
– Prise cover ( ⇒ page 73 Fig. N57-10065, item 2) off front door.
es, in part or in w
t to the co
– Lever out caps in front of bolts -1-.
– Pull door handle -2- in direction of -arrow- and unbolt bolt -1-
rrectness of i
onto stop using socket wrench -T10072- .
l purpos
– Pull out housing -3-.
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1.15.2 Installing Cop py
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– Fit housing -3- in door handle -2- bearing bracket at right an‐ cop Vo
by lksw
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Door handle -2- must rest only lightly against door panel.
– Now tighten bolt -1- in bearing bracket using socket wrench -
T10072- .
The door handle -2- locates in the housing -3- with a well audible
click.
Note
During installation, housing must be pressed against door panel.

The door handle just rests lightly against the door panel.

Then always check function while door is still open, as an incor‐
rectly fitted and adjusted Bowden cable cannot open the door.
1.16 Removing and installing door handle
Note
The removal and installation sequence is only for the right door
handle. The removal and installation of the left door handle is
similar.

1.16.1 Removing
– Remove housing ⇒ page 86 .
– Lever clip -2- out of door handle -1-.
– Swivel door handle -1- out of door -arrow-.
1.16.2 Installing
– Guide assembly tool -T10118- into door through opening in
door outer panel.
– Use a hand torch to illuminate inside of door for improved vis‐
ibility.
– Hook assembly tool -T10118- in spring -arrow A-.
– Hook spring onto door lock by pulling assembly tool -T10118-
-arrow B-.
The release lever is now secured.
AG. Volkswagen AG d
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1. Front door 87
AG. Volkswagen AG d
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Note d by
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Hooking the spring into thesoperating
aut
lever secures the lock. This prevents incorrect ra
c attachment of the Bowden
cable to the door handle later.
s
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– Swivel door handle -1- into door.

– Pull clip -2- in the panel opening and engage clip in door han‐
dle -1- -arrow-.
Note
♦ Press door handle -1- against door panel when assembling.

♦ Clip -2- must engage audibly in door handle -1-.
– Install housing ⇒ page 86 .


wage es n
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1.17 Removing and installing bearing bracket
ir se
d by
V ua
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o tee
th or
s au ac
s
Note
ce
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nl
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Removal and installation are described only for the right bearing
y li
erm
ab
bracket. The removal and installation of the left bearing bracket
ility
ot p
is similar.
wit
is n
h re
ole,
1.17.1 Removing
spec
t to the co
rrectness of i
– Remove door outer panel ⇒ page 112 .
– Pull retaining rubber -4- upwards off guide pins.
cial p
– Pull bearing bracket -1- in direction of -arrow- with guide pins
nform
-2- out of mountings -3-.
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Cop py
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1. Front door 89
1.17.2 Installing
– Push bearing bracket -1- with guide pins -2- in mountings
-3-.
– Secure retaining rubber -4- to guide pins and securing bolts
on bearing plate mounting.
AG. Volkswagen AG d
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1.18 Removing and installing door lock

nform
mercia
a
m
ti
Note
o
r co
n in
o
thi
te
sd
iva
o
r
lock. The removal and installation of the left door lock is similar.
p
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1.18.1 Removing Co py
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cop
Vo
by lksw
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Prote AG.

– Remove bearing bracket ⇒ page 89 .

– Remove bolts -6-. agen
AG. Volkswagen AG d
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– Release cable -1- from ed brelay
yV lever -8- and remove door lock
gu
ara
-4-. horis nte
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Cover -3- is not supplied
ss with door lock. c
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Prote AG.
1.18.2 Installing
Specified torque for bolts: 18 Nm.
1. Front door 91
1.19 Assembly overview - side impact protection
1 - Side impact protection

❑ To remove and install,
remove outer panel for
door ⇒ page 112
2 - Bolt
❑ Qty. 4
❑ 20 Nm
3 - Insulation
4 - Nut
❑ Qty. 2
❑ 20 Nm
AG. Volkswagen AG d
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1.20 Door inner seal

ole,
spec
During production, a sealant is applied to the door inner seals,

t to the co
which are then placed on the door flange and rolled on.
rrectness of i
Note
cial p
nform
then refitted, a tight seal is not guaranteed.

mer

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tion
o

c
in t
or
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e

at
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t. Co py
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cop by
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1.21 Removing and installing door inner seal
Note
inner seal. The removal and installation of the left door inner seal
is similar.
1.21.1 Removing AG. Volkswagen AG d

agen oes
– Pull door inner seal off body flange. olksw not
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pe
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es, in part or in w
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Prote AG.
1.21.2 Installing
– Align door inner seal so that the vulcanised point -arrow b- is
located at the height of the lower hinge.
1. Front door 93
– Start installing door inner seal at top radius -arrow a- of door

aperture.
AG. Volkswagen AG d
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Prote AG.
1.22 Removing and installing door outer seal
Note
♦ Removal and installation are described only for the right door
outer seal. Removal and installation of the left door outer seal
are similar.
♦ Remove protective backing immediately before installation.
Working temperature approx. 20 °C.

wage es n
Volks ot g
d by ua
ran
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tho
or Golf Variant 2007 ➤ , Jetta 2005 ➤
au ac
ss General body repairs, exterior - Edition 10.2009
ce
e
nl
pt
du
1.22.1 Removing
an
itte
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ab
– Pull door outer seal off door.
ility
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spec
t to the co
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atio
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en
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t.
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by lksw
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Prote AG.
1.22.2 Installing
– Remove adhesive residues with erasure disc of adhesive strip
remover -VAS 6349- .
– Immediately before bonding door outer seal, clean bonding
surface thoroughly with adhesive remover -D 002 000 10- .
• Bonding surfaces must be free of dust and grease and there
should be no adhesive residues.
– Align door outer seal with section -arrow b- towards door lock
securing bolts.
– Door outer seal vulcanised point -arrow c- should then be in
middle of sill.
1. Front door 95
– Pull off protective foil and install seal on door. Do not pull door
outer seal excessively to avoid stretching seal.
wage es n
Volks ot g
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– Press complete bonding surface of seal -3- onto door -1- all
ole,
around using roller -3356- .

spec
t to the co
– To do this, push seal aside -arrow a- so that the roller -3356-

runs directly over the contact surface of the seal.
The roller can apply the necessary force -arrow b- to the bonding
rrectness of i
surface -2- only when procedure described above is followed.

– If the seal has stretched, cut seal to required length and press
on butt joint well.
cial p
nform
– If seal -3- comes loose in small areas again, press seal on well
mer
again using roller -3356- .

atio
m
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Note
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The door must not be closed for a period of 2 hours to ensure the door outer seal does not move or loosen
en
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t.
yi
again.
Co
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ab
ility
ot p
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l purpos
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at
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ate
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Prote AG.
1. Front door 97
2 Central locking
2.1 Fitting location overview - central locking components
1 - Anti-theft alarm horn

❑ Location: under rear
section of wheel hous‐ wage es n
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ua
wheel housing (remov‐ orise ran
tee
ing rear section of wheel auth or
ac
housing liner ss
⇒ page 321 )
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nl
pt
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2 - Coupling station itte
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erm
ab
❑ Location: right A-pillar
ility
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❑ To disconnect connec‐
is n
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tor, release bellows at
ole,
spec
A-pillar ⇒ page 68
t to the co
3 - Convenience system cen‐
tral control unit -J393-
❑ Location: under dash
rrectness of i
panel and behind glove
compartment on front
passenger side (remov‐
ing glove compartment
cial p
nform
mer
a
Compartments, covers
m
tion
o
and trims )
c
in t
or
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4 - Door control unit -J387-

t
iva
do
pr
c
❑ Integrated in window
um
for
regulator motor (remov‐
en
ng
t.
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ing window regulator Cop py
motor ⇒ page 285 ) ht. rig
rig ht
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5 - Door lock
by c lksw
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Prote AG.
❑ Door lock is secured on
inner part of door (re‐
moving door lock
⇒ page 90 )
❑ Electric central locking
is integrated into door
lock
6 - Coupling station
❑ Location: right B-pillar.
❑ To disconnect connector, release boot on B-pillar ⇒ page 107 .
7 - Rear right door control unit -J389-
❑ Integrated in window regulator motor
❑ Removing (saloon) ⇒ page 302
❑ Removing (Variant) ⇒ page 317
8 - Door lock
❑ Electric central locking is integrated into door lock

9 - Tank filler flap locking motor -V155-

❑ Location: behind right trim of luggage compartment
10 - Lock for rear lid
❑ Location: bolted to rear lid
11 - Rear lid handle release button -E234-
❑ Not installed on all vehicles
❑ Integrated in rear handle of rear lid (removing handle on saloon) ⇒ page 36 )
12 - Coupling station, rear lid
❑ Location, saloon: behind luggage compartment side trim on left (removing luggage compartment side
trim on left ⇒ General body repairs, interior; Rep. Gr. 70 ; Load area and luggage compartment trim .
❑ Location, Variant: on rear of moulded headliner (lowering moulded headliner ⇒ General body repairs,
interior; Rep. Gr. 70 ; Roof trims )
13 - Door lock
14 - Rear left door control unit -J388-
❑ Integrated in window regulator motor
age⇒
❑ Removing (saloon) olksw page 302 es n
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❑ Removing ised b(Variant) ⇒ page 317 ran
r tee
ho
15 - Coupling
au
t
station or
ac
ss
❑ Fitting location: left B-pillar
ce
e
nl
pt
du
❑ To disconnect connector, release boot on B-pillar ⇒ page 107 .

an
itte
y li
erm
ab
16 - Door lock
ility
ot p
❑ Door lock is secured on inner part of door (removing door lock ⇒ page 90 )
wit
is n
h re

ole,
spec
17 - Central switch for window regulators

t to the co
❑ Location: installed in door panel

❑ Removing and installing central switch for window regulators ⇒ Electrical system; Rep. Gr. 96 ; Lights,
bulbs, switches - interior
rrectness of i
18 - Door control unit -J386-

❑ Integrated in window regulator motor (removing window regulator motor ⇒ page 285 )
cial p
nform
19 - Coupling station
mer
❑ Fitting location: left A-pillar

a
m
tion
o
❑ To disconnect connector, release bellows at A-pillar ⇒ page 68

c
in t
or
his
te
20 - Bonnet contact switch -F266-

a
do
priv
❑ Anti-theft alarm system contact switch

um
or
f
en
ng
❑ Cannot be replaced as an individual item

t.
yi Co
Cop py
❑ Location: on bonnet lock (removing bonnet lock ⇒ page 23 )
t. rig
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Vo
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Prote AG.
2. Central locking 99
2.2 Adapting keys with remote control

Keys with remote control are adapted using the vehicle diagnosis,
testing and information system -VAS 5051- .
– Select “guided fault finding” in vehicle diagnostic, testing and
information system -VAS 5051- .
– Using the GoTo key, select “Function/component selection”
and the following menu items in succession:
Volkswagen AG
♦ Body (Repair group 01; 27; s50
wag-e97)
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♦ Internal/external installations
sedb (Repair group 01; from 55 77) ara
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♦ 01 - Self-diagnosis
aut ra
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ss
♦ 46 - Convenience system central module
ce
le
un
pt
an
d
itte
♦ Functions
y li
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ab
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♦ Adaption
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2.3 Assembly overview - battery for folding key with remote control
h re
hole
spec
es, in part or in w
t to the co
1 - Key with variable code
transponder
2 - Upper part of transmitter
rrectness of i
unit
l purpos
3 - LED
❑ LED must flash when re‐
n
ercia
fo
mote control is operated
rm
m
atio
❑ If LED does not flash
com
during remote control

n in
r
te o
operation, the battery is

thi
sd
iva
dead and must be re‐

o
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rp
cu
newed.
fo
m
en
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t.
4 - Battery
yi Co
Cop py
❑ Removing battery
t. rig
gh ht
yri
⇒ page 101
p by
co Vo
by lksw
cted
❑ Installing battery
agen
Prote AG.
⇒ page 101
5 - Lower part of transmitter
unit

2.4 Removing and installing battery for fold‐

ing key with remote control
2.4.1 Removing
– Insert a screwdriver in slot between transmitter unit -1- and key
-2-.
– Twist screwdriver in -direction of arrow- to separate transmitter
unit from key.
– Press upper part of transmitter unit and lower part of transmit‐

ter unit apart in direction of -arrow-.
AG. Volkswagen AG d
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– Unclip battery -1- from retainers -2- with a screwdriver in di‐
es, in part or in w
t to the co
rection of -arrow-.
rrectness of i
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2.4.2 Installing
fo
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op
Note polarity and correct position when installing battery.
C py
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– Place battery -1- in transmitter unit -2- with positive terminal
co Vo
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cted
downwards (positive terminal is marked on housing).
agen
Prote AG.
– Engage battery in lower part of transmitter unit by pressing

down lightly.
– Fit upper part of transmitter unit and lower part of transmitter
unit together (do not damage seal).
– Then clip transmitter unit to key.
2. Central locking 101

58 – Rear doors, door components

1 Rear door (saloon)
1.1 Tools
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Special tools and workshop Volks ot g
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equipment required ir se
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or
♦ Socket -T10072- s au ac
s
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♦ Assembly tool -T10118-
nl
pt
du
an
itte
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♦ Door alignment tool -3320-
erm
ab
with -3320/1- , -3320/2- and
ility
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-3320/3-
wit
is n
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♦ Roller for door insulation
ole,
spec
foil -3356-
t to the co
1331-
rrectness of i
cial p
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mer
a
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tion
co
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or
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ate
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or
f
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t.
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Cop py
ht. rig
ht
rig by
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Prote AG.
102 Rep. Gr.58 - Rear doors, door components

♦ Cartridge gun -V.A.G 1628-

♦ Cartridge heater -V.A.G
1939 A-
♦ Removal wedge -3409-
♦ Assembly tool set -T10237-
lkswage es n
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is n
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t to the co
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cial p
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1.2 Materials
en
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♦ 1K or 2K glass adhesive -DH 009 100 01- 4) 5) or -DA
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Prote
AG.

1939 A- .
1.3 Assembly overview - door assembly

A new door concept has been introduced with Jetta 2005 ▸, Bora
2005 ▸.
The door consists of an inner part -6- and an outer panel -1-.
The parts are joined by the front -7- and rear -4- retaining rail.
1. Rear door (saloon) 103

lkswage es n
o ot g
yV
Golf Variant 2007 ➤ ed, Jetta 2005 ➤
b ua
ran
ris tee
utho exterior - Edition 10.2009 or
a ac
ss
The retaining rails are bolted to the inner part of the door and
ce
e
nl
pt
du
bonded to the outer panel of the door.
an
itte
y li
erm
ab
The inner part -6- of the door functions basically as the previously
ility
ot p
known assembly carrier. Loudspeaker, window regulator, window
wit
, is n
regulator motor, wiring, window channel, exterior mirror and door
h re
lock are mounted on the inner part of the door.
hole
spec
es, in part or in w
The outer panel -1- of the door is additionally bolted to the lower
t to the co
edge of the inner part. The window slot outer seal, insulation and
exterior door handle are mounted on the outer panel of the door.
rrectness of i
Caution
l purpos

nform
ercia

m
a
m
tio
r co
n in
o
thi
te
sd
a
1 - Door outer panel

iv
o
pr
cu
or
m
f
en
ng
door outer panel

i t.
py Co
⇒ page 112 t. Co py
rig
gh ht
yri by
2 - Edge protection y cop Vo
lksw
b
cted agen
❑ Between door outer Prote AG.
panel and door inner
part.
3 - Bolt
❑ Feature: bolt with poin‐
ted end and thinner
washer.
❑ Qty. 4 on lower edge
❑ Qty. 1 in rear section of
door shoulder
❑ 10 Nm
4 - Rear retaining rail
❑ Adhesive: -DH 009 100
03-
5 - Bolt
❑ Feature: bolt with no
pointed end and thicker
washer.
❑ Qty. 11 on both retaining
rails
❑ 14 Nm
6 - Door inner part
⇒ page 123
7 - Front retaining rail
❑ Adhesive: -DH 009 100
03-
8 - Bolt
❑ Feature: bolt with pointed end and thicker washer
❑ Qty. 1 in area of front section of door shoulder
❑ 10 Nm

9 - Insulation
❑ Self-adhesive
❑ To bond, first heat the insulation and then press on firmly
10 - Clip
❑ Qty. 5
❑ Must be fitted before fitting door outer panel.
Caution
shop tools.
wage es n
Volks ot g
by ua
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pt
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ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness of i
cial p
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o
thi
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sd
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for
en
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i t.
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t. Co py
rig
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Prote AG.

Note
♦ The right side is shown. The left side is similar.

1 - Door
⇒ page 107
2 - Guide bolt
❑ 10 Nm
(90°).
AG. Volkswagen AG d
❑ Always renew after lksw
agen oes
not
loosening d by
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5 - Multi-point socket head bolt utho eo
ra
a c
❑ 20 Nm + 1/4 turn further ss
ce
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nl
(90°).
pt
du
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itte
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ab
loosening
ility
ot p
wit
, is n
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hole
spec
(90°).
es, in part or in w
t to the co
loosening rrectness of i

l purpos
(90°).
nform
ercia

loosening
m
at
m
io
8 - Guide bolt
r co
n in t
o
❑ 10 Nm
his
ate
d
iv
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r
9 - Nut
p
cu
or
m
f
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ng
❑ For eccentric pin i t.

py Co
❑ Do not loosen t. Co py
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10 - Door hinge
Prote AG.
❑ Hinge no longer comprises of more than one part.

❑ 20 Nm + 1/4 turn further (90°).
❑ 20 Nm + 1/4 turn further (90°).


❑ 20 Nm + 1/4 turn further (90°).
Note
The removal and installation sequence is only for the right door.
The removal and installation of the left door is similar.
1.5.1 Removing
– Release boots -6- by pressing fastener -arrow a- and pull
boots off B-pillar.
– Swing release lever -7- downwards -arrow b- and disconnect
– Remove bolts -4-, -5- and -11- from hinge using special door
wage es n
Volks ot g
d by ua
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pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Pull door -1- in direction of -arrow- off guide bolts -2- and -9-.
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
1.5.2 Installing
t to the co

rrectness of i
l purpos
(90°).
nform
mercia
a
m
tio
r co
n in
o
thi
te
sd
iva
o
pr
cu
or
m
f
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

Observe rear door gap/shut lines ⇒ Body Repairs; Rep. Gr. 00 ;

Body dimensions .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ir se nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
t.
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Cop py
1.6 Adjusting door

ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Caution
shop tools.
Note
♦ If the door outer panel has been removed, the door inner part window frame must be adjusted to the roof
frame, C-pillar and front door.


Body dimensions .
To be able to adjust gaps correctly, bolts -6-, -7-, -11- and -12-
must be loosened.
Bolts -4-, -5- and -13- and also guide bolts -2- and -8- must be
loosened to correctly adjust the flush fitting of the door.
lkswage es n
o ot g
byV ua
d ran
rise tee
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ss
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
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tion
co
in t
or

his
ate
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or
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ng
i t.
Note py Co
t. Co py
rig
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♦ The rear door must lock fully when closing without any addi‐
by
y cop Vo
lksw
tional force being required and must not have any play.
b
cted agen
Prote AG.
♦ The rear door must not be pushed up or down as a result of


♦ When rear door does not align with side panel.

– Loosen striker pin -1- by loosening bolts -2- on side panel.
– Adjust rear door at striker pin -1- so that rear door is flush with
rear side panel when shut (wind noise). wage
e
olks s no
yV t gu
Maximum twist tolerance -A- of striker pin: ± 3° edb ara
ris nte
– Retighten bolts -2-. ho eo
aut ra
ss c
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e
nl
pt
du
an
itte
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WARNING
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
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lksw
b
cted agen
Prote AG.

1.7 Removing and installing outer panel on

door
1.7.1 Removing
– Prise out clips -3-, starting at bottom of door -1-, and remove
rear cover -2-.
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
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tion
co
in t
or
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te
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do
pr
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

n AG. VolkswaGolf Variant
gen AG 2007 ➤ , Jetta 2005 ➤
wage doe
Volks General body repairs,s exterior
not
gu - Edition 10.2009
by ara
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– Remove housing ⇒ page 124 . au
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– Remove bolt -1- from bearing bracket -2- which is located be‐
itte
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– Remove all bolts -2-, -3- and -4-.
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1.7.2 Installing
Caution

– Carefully position outer panel on door.

– Insert all bolts -2-, -3- and -4-.
Observe correct usage for the different types of bolts.
♦ Feature for bolt -2-: bolt with pointed end and thinner washer
♦ Feature for bolt -3-: bolt with no pointed end but with thicker
washer.
♦ Feature for bolt -4-: bolt with pointed end and thicker washer. AG. Volkswagen A
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– Check whether retaining rail guide pins are locatedbin olks
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priate guide holes in inner part of door. Only thenir se tighten all
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Observe correct specified torque for the different
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Further installation is performed in reverse order of removal
AG. Volkswagen AG d
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1.8 Installing new outer panel on door
Caution

Note
Observe section preparing door outer panel for bonding ⇒ page 121
• The old (damaged) outer panel with retaining rails is removed

⇒ page 112 .
– Install front -2- and rear -6- retaining rails on inner part of door
-1-. Use “bolt with no point but with thicker washer” for this.
Specified torque for bolts -3- and -5-: 14 Nm

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– Fit two guide bolts -4- in lower edge of door inner part
Vol
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The painted outer panel for the door is first offered up without
bonding agent.
Assembly blocks -3- from assembly tool set -T10237- are required
when fitting outer panel on door. A strip of double-sided adhesive
tape -6- is applied on the side with a cut-out step. The pin has the
minimum dimension for the gap width. The surface with no ad‐
hesive tape is brought into position on the adjacent panel.
– Stick the assembly block -3- on outer panel -1- of the door.
inner part.
wedges -4- from assembly tool set -T10237- .
– Lay door outer panel -1- with assembly blocks on adjacent
panels -2- and -5-.
– Check gap/shut lines using setting gauge -3371- ⇒ Body Re‐
If gap dimension cannot be adjusted further, door inner part must
be adjusted ⇒ page 123

– Remove door outer panel again.
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– Apply a bead of adhesive material -2- using cartridge gun -

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

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Adhesive -DA 004 600 A2- can be used for this procedure and is applied with double cartridge gun -VAS 5237- .
There is no requirement to preheat.
rrectness of i
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117
Prote AG.
1. Rear door (saloon)

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Fixing blocks -2- from assembly tool set -T10237- are required cted agen
Prote AG.
when fitting outer panel on door. Two strips of double-sided ad‐
hesive tape -5- are applied on the contact surface.
inner part.
– Bring outer panel with assembly blocks -3- into contact with
surrounding components.
wedges -4- from assembly tool set.
– Check gap/shut line using setting gauge -3371- ⇒ Body Re‐
– Bond short fixing blocks -2- evenly on the replacement door
and the adjacent components.
Note
A waiting period of 90 or 180 minutes must be observed before performing further work on the bonded door
⇒ page 121 .
– Further installation is performed in reverse order of removal

⇒ page 114 .

AG. Volkswagen AG d
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1.9 Removing and installing retaining rail on
AG.
door outer panel
1.9.1 Removing retaining rail
Caution
The following work steps are to be carried out with great care.
As outer panel is to be reused, dents and scratches must be
avoided.
When cutting through the adhesive bead, always hold the re‐
taining rail and outer panel together as shown in the illustration.
If this is not done, the outer panel will come away from the
retaining rail, thus rendering it useless.
Note
The following procedures should be carried out with the aid of an

assistant.

• Door outer panel with retaining rails is removed ⇒ page 112 .

– Place door outer panel -1- on firm surface and protect door
outer panel against scratches. Volkswa
AG. gen AG
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– Secure reel -2- on outerVopanel
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– Hold retaining
ss rail and outer panel of door together securely c
when cutting through adhesive bead.
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– Cut through adhesive bead of retaining rail -3- and outer panel
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-1- with cord up to just over half way.
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– Once adhesive bead has been cut through to just over half
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– Hold retaining rail -3- and outer panel -1- of door together se‐
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curely when cutting through adhesive bead further.

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1.9.2 Installing retaining rail

– Using extreme care, cut away remainder of adhesive bead to
the utmost minimum on outer panel of door, ensuring that no
damage is caused to the paintwork.
– Remainder of procedure is described in chapter entitled “In‐
stalling new outer panel for door” ⇒ page 115 .
Note
Observe also “instructions for bonding in new door outer panel”

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

on the door inner part.
– Apply adhesive to new retaining rail
– Secure outer panel for door to lower edge and fitted retaining
rail.

– Secure outer panel for door on new retaining rail with fixing
blocks from assembly tool set -T10237- and double-sided ad‐
hesive tape.
1.10 Installation notes for bonding a new out‐

er panel on door
Note
♦ If front and rear door outer panels must be renewed, they must
be done at the same time. When bonding-in both door outer
panels, the long fixing block from assembly tool set -T10237-
is stuck on for the transition from front door outer panel to rear
door outer panel.
♦ If door outer panel CDP coating is damaged on inside in area
to be bonded or it has been painted, this area must be primed
with glass/paint primer -D 009 200 02- .
♦ The 1K glass adhesive -DH 009 100 01- must be heated in
cartridge heater -V.A.G 1939 A- for 20 minutes.
♦ Adhesive -DA 004 600 A2- can be used for this procedure and
is applied with double cartridge gun -VAS 5237- . There is no
requirement to preheat.
– Clean contact surfaces on retaining rails thoroughly using

– Apply adhesive material to appropriate surfaces at right angles
to retaining rail using cartridge gun -V.A.G 1628- .
agen
Caution
AG. Volkswagen AG d
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Door outer panel must risebe
d installed within 10 minutes, or ad‐ ara
nte
hesive properties ofut adhesive will be impaired.
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♦ With assistance of both assembly blocks from assembly tool

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align with wedges and setting gauge -3371- and press contact
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♦ Secure door with fixing blocks from assembly tool set -

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T10237- during curing period.

t to the co
♦ After installation door outer panel must align with other com‐
ponents and gaps must be even.
♦ If adhesive bead is too thick and adhesive exudes between
rrectness of i
retaining rail and door outer panel, excess adhesive must be

removed.
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WARNING
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outer panels for door. One of these standards is, for example,
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For door outer panel: curing period for 1K adhesive -DH 009 100
01- is 90 minutes and for 2K adhesive -DA 004 600 A2- 180 mi‐
nutes.
What is meant by minimum curing period is, time from bonding
outer panel on door to time vehicle is taken into use or further
work is carried out. During this time, the vehicle must stand on a
level surface at room temperature (at least 15 °C).
WARNING
1.12 Cleaning off excessaadhesiven AG. Volkswasealing

gen AG
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material d by Volks not
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– Use of adhesive remover tho -D 002 000 10- as a cleaning solution or
s au
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When cleaning vehicle the door outer panel just bonded-in
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1.13 Assembly overview - door inner part
Note

2 - Insulation
❑ Qty. 4
❑ 20 mm x 40 mm, com‐
mercially available tex‐
tile adhesive tape.
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General body repairs, exterior - Edition 10.2009 n AG. Volkswagen AG do
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⇒ page 129
2 - Cable
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terior door handle.
3 - Cover cial p
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❑ Not supplied with door
mer
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❑ Secured on door lock

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6 - Base
Prote AG.

⇒ page 125
8 - Cover
❑ For housing
❑ Secured on housing
with locking lugs
9 - Housing
⇒ page 124
10 - Base
11 - Torx bolt
❑ For locking housing ⇒ Item 9 (page 150)
12 - Bolt
❑ 18 Nm
13 - Cable
❑ To release lock from door exterior handle.
Note
Removal and installation sequence is only for right housing. Re‐

moval and installation of left housing is similar.

1.15.1 Removing
olkswagen AG
en AG. V
– Prise rear cover ( ⇒ pageolk112
swa Fig. M58-0054, item
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– Lever out capsauin
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– Pull housing -3- out of door handle bearing bracket at right
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1.15.2 Installing
– Fit housing -2- in door handle -1- bearing bracket at right an‐
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T10072- .
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Note
similar.
1.16.1 Removing

1.16.2 Installing
– Guide assembly tool -T10118- into door through opening in
door outer panel.
ibility.
-arrow B-.
Note
olksw
Hooking the spring into the operatingwaglever
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V
the lock.
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dle -1- -arrow-.
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1.17 Removing bearing bracket
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Note
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1.17.1 Removing
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– Pull retaining rubber -4- off upwards from guide pins and re‐ ht.
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– Pull bearing bracket -1- with guide pins -2- out of mountings
-3-.
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1.17.2 Installing
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– Push bearing bracket -1- with guide pins -2- in mountings

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– Secure retaining rubber -4- to guide pin and retaining pin on
rig by
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mounting.
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wage General body repairs, ot g exterior - Edition 10.2009
es n
Volks
by ua
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Further installation is performed inthreverse
or
is order of removal. tee
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Note
1.18.1 Removing

– Remove bearing bracket ⇒ page 127 .

– Separate connector -4-.
– Release cable -3- from relay lever -5- and remove door lock
-1-.
Cover -2- is not supplied with door lock.
AG. Volkswagen AG d
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1.18.2 Installing
rrectness of i
Specified torque for bolts: 18 Nm.
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1.19 Assembly overview - side impact protection
1 - Side impact protection

❑ To remove and install,
remove outer panel for
door ⇒ page 112 AG. Volkswagen AG d
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2 - Bolts byV
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❑ Qty. 2 horis nte
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❑ Qty. 2
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4 - Door inner part
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1.20 Door inner seals

Note

Note
inner seal. The removal and installation of the left door inner seal
is similar.
1.21.1 Removing
– Pull door inner seal off body flange.
AG. Volkswagen AG d
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1.21.2 Installing
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– Align door inner seal so that the vulcanised point -arrow b- is

a
m
located at the height of the lower hinge.

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aperture.
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133
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1. Rear door (saloon)
agen
Prote AG.

1.22.1 Removing
– Pull door outer seal -1- off door -2-.
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1.22.2 Installing
ole,
spec

t to the co

– Immediately before bonding outer seal for door, clean bonding
rrectness of i

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– The vulcanised point -arrow b- of door outer seal -1- must be

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located in centre of sill.

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– Pull off protective backing and start fitting seal in upper radius
-arrow a- of door. Do not pull door outer seal excessively to
avoid stretching seal.
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around using roller -3356- . Prote AG.

on butt joint well.
Note
again.

Golf Variant 2007 ➤ ,AG Jetta
. Volk2005
swagen➤
AG do
gen exterior - Edition
General bodyolkrepairs,
swa e10.2009
s no
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2 Rear door (Variant)
Note
The rear doors of the Variant are of a different concept when

compared with the rear doors of the saloon. The door outer panel
is no longer removable. The window lifter and the door lock are
accessible via a removable assembly carrier.
2.1 Tools

equipment required
♦ Socket -T10072-
olkswagen AG
en AG. V
♦ Assembly toololk-T10118-
swa
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2. Rear door (Variant) 137

2.2 Assembly overview - rear door
1 - Door
⇒ page 140
❑ Adjusting door
⇒ page 142 n AG. Volkswagen AG do
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2 - Door handle with base d by
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⇒ page 151 ss au ac
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⇒ page 151
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4 - Door lock
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❑ The door lock can be re‐
es, in part or in w
t to the co
moved only together
with the assembly carri‐
er
⇒ Item 5 (page 138) .
rrectness of i
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⇒ page 155
5 - Assembly carrier
nform
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m
at
⇒ page 145
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6 - Door hinge
o
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⇒ page 138
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⇒ page 138 copy Vo
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Caution
shop tools.

olksw
exterior - Edition 10.2009
n AG. V agen AG
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1 - Door
t to the co
⇒ page 140
❑ Adjusting door
rrectness of i
⇒ page 142
2 - Guide bolt
❑ 10 Nm
cial p
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mer
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❑ 20 Nm + 1/4 turn further by c lksw
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(90°).
loosening
(90°).
loosening
(90°).
loosening
8 - Guide bolt
❑ 10 Nm
9 - Nut
❑ For eccentric pin
❑ Do not loosen
10 - Door hinge
❑ Hinge no longer comprises of more than one part.
❑ 20 Nm + 1/4 turn further (90°).
❑ 20 Nm + 1/4 turn further (90°).

❑ 20 Nm + 1/4 turn further (90°).
2.4.1 Removing
Note
The removal and installation sequence is only for the right door. The removal and installation of the left door is
similar.

boots off B-pillar. agen
AG. Volkswagen AG d
oes
olksw not
– Swing release lever -7- downwards -arrow b- and disconnect ed byV gu
ara
electrical connector -8- from coupling station. horis nte
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ss door c
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– Pull door -1- in direction of -arrow- off guide bolts -2- and -9-.
AG. Volkswagen AG d
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2.4.2 Installing
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mer
matio
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(90°).
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Body dimensions .
AG. Volkswagen AG d
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2.5 Adjusting door
Caution
shop tools.
Note

Body dimensions .

To be able to adjust gaps correctly, bolts -6-, -7-, -11- and -12-
must be loosened.
. Volkswagen AG
Bolts -4-, -5- and -13- and also guide bolts -2- and -8- must be kswagen AG does
not
loosened to correctly adjust the flush fitting of the door. Vol gu
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Prote AG.
Note
♦ The rear door must lock fully when closing without any addi‐
tional force being required and must not have any play.
♦ The rear door must not be pushed up or down as a result of

♦ When rear door does not align with side panel.

wage es n
olks
– Loosen striker pin -1- by loosening bolts -2- on side panel. d by
V ot g
ua
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– Adjust rear door at striker pin -1- so that rear door th is flush with
o
or
rear side panel when shut (wind noise). s au ac
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nl
Maximum twist tolerance -A- of striker pin: ± 3°
pt
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2.6 Assembly overview - assembly carrier

m
at
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Note
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❑ Qty. 2
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❑ 18 Nm
2 - Door lock
⇒ page 155
⇒ page 145
4 - Bolt
❑ Qty. 8
❑ 8 Nm
5 - Cover

⇒ page 317
2.7 Removing and installing assembly car‐

rier
Note
The removal and installation sequence is only for the right as‐
lkswagen AG
sembly carrier. The removal and installation
swagen
AG. Voof the left assembly
does
carrier is similar. by
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Window regulator, doorau lock
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The door lock can be removed only together with the assembly
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carrier.
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If door window cannot be lowered on electric window version, first
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determine the cause of the fault.
is n
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To do this, read the fault memory of the convenience system us‐
spec
ing vehicle diagnostic, testing and information system -VAS 5051
t to the co
A- or -VAS 5052- ⇒ Vehicle diagnosis, testing and information
system VAS 5051.
If an electrical fault exists, rectify it first.
rrectness of i
If an electric fault occurs on window regulator motor, it can be
unscrewed from assembly carrier and door window can be slid by
hand in the necessary repair position.
cial p
nform
2.7.1 Removing
mer
a
m
tion
o
Remove door handle ⇒ page 152 .

c
in t
or
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– Remove door trim ⇒ General body repairs, interior; Rep. Gr.

at
do
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70 ; Roof trims .
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– Lever out caps -5-.

– Lower door window -1- until spreader pin -3- and spreader plug
-4- are accessible in cut-out of window regulator.
Note
If the procedure cannot be carried out. Vbecause there is a fault with

olkswage AG
the electric window regulator,
sw aremove
gen AG electric nwindow
does motor to
slide window down. by Volk not
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– Screw a 5 mm au bolt (approx.
t
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-3-. ss
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– Pull bolt and spreader pin out of spreader plug -4-.
an
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– Screw an 8 mm bolt (approx. 80 mm long) into spreader plug
ility
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-4-.
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spec
Note
t to the co
Do not exert too great a pressure on the plug because otherwise
the plug will fall into the door.
rrectness of i
– Pull spreader plug -4- out of clamping jaws -2- and therefore
out of door window.
cial p
– Push window -1- upwards and secure in position (e.g. with
nform
adhesive tape).
mer
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boots off B-pillar.

thi
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– Swing release lever -5- downwards -arrow b- and disconnect

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– Unscrew bolts -2- from door lock -3-. Cop py
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– Unscrew bolts -arrow- from assembly carrier -1-. p by
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by lksw
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Prote AG.

wage es n
Volks ot g
by ua
d ran
rise tee
tho
or
– Guide wires a-3-
u in door. ac
s
ce
le
– Remove assembly carrier -1- with door lock -2- from door in
un
pt
an
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pe
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147
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Prote AG.
2. Rear door (Variant)

wage es n
Volks ot g
by ua
d ran
rise tee
tho
u or
a ac
ss
ce
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nl
pt
du
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ab
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spec
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rrectness of i
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t.
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2.7.2 Installing
cted agen
Prote AG.

– Secure door window ⇒ page 310 .
– Specified torque for assembly carrier bolt -arrow-: 8 Nm

– Specified torque for door lock bolt -2-: 18 Nm
wage es n
Volks ot g
d by ua
ran
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tho
or
s au ac
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un
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t.
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Prote AG.

Note
1 - Door lock
⇒ page 155
2 - Cable
terior door handle.
3 - Cover
❑ Not supplied with door lkswage es n
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lock. byV ua
ed ran
ris tee
❑ Secured on door lock utho
or
with locking lugs ss
a ac
ce
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nl
4 - Bearing bracket
pt
du
an
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erm
ab
⇒ page 154
ility
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5 - Torx bolt
is n
h re
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❑ 4.5 Nm
spec
6 - Base
t to the co
rrectness of i
⇒ page 151
8 - Cover
cial p
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❑ For housing
mer
atio
❑ Secured on housing
m
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with locking lugs
n in
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9 - Housing
t
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um
for
⇒ page 151
en
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10 - Base t. rig
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11 - Door lock bracket
c Vo
by lksw
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Prote
❑ Not supplied with door lock.
AG.
❑ Pushed onto door lock and riveted.

12 - Bolt
❑ 18 Nm
13 - Cable
❑ To release lock from door exterior handle.

Note
Removal and installation sequence is only for right housing. Re‐

moval and installation of left housing is similar.
2.9.1 Removing
– Lever out caps in front of bolts -1-.
– Pull housing -3- out of door handle bearing bracket at right
angles to door.
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
2.9.2 Installing ss au ac
ce
e
nl
pt
– Fit housing -2- in door handle -1- bearing bracket at right an‐
du
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T10072- .
spec
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The door handle engages in housing again with an audible click.
t to the co
Note
rrectness of i
l purpos

nform
ercia

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t.
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Note
rig ht
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by lksw
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AG.

similar.

2.10.1 Removing
G. Volkswagen AG d
2.10.2 Installingolkswagen A oes
not
yV gu
db ara
– Guide assembly risetool -T10118- into door through opening ntein
tho
door outer panel. eo
s au r ac
s
ce
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nl
pt
ibility.
du
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-arrow B-.
h re
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spec
t to the co
rrectness of i
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mer
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rig ht
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by lksw
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Prote AG.

Note
Hooking the spring into the operating lever secures the lock. This prevents incorrect attachment of the Bowden
cable to the door handle later.
wage es n
Volks ot g
y ua
edb ran
ir s tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness of i
cial p
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co

in t
or
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ate
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pr
dle -1- -arrow-.

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♦ Press door handle -1- against door panel when assembling.
agen
Prote AG.
♦ Clip -2- must engage in door handle -1- with a clearly audible
click.


AG. Volkswagen AG d
agen oes
Golf Variant 2007 ➤ ,VJetta
olks 2005 ➤
w not
gu
by
ris
ed exterior - Edition 10.2009 ara
nte
ho eo
aut ra
2.11 Removing and installing bearing bracket ss c
ce
e
nl
pt
du
an
itte
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erm
ab
2.11.1 Removing
ility
ot p
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is n
h re
ole,
Note
spec
t to the co
is similar.
rrectness of i
cial p
nfo
– Remove door assembly carrier ⇒ page 145 .
mer
rmatio
m
– Remove bolt -3- from bearing plate -1-.

o
n in
or c
– Remove bearing plate -1- inwards in -direction of arrow- out of
thi
te
sd
a
door cut-out in door -2-.

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o
pr
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or
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.11.2 Installing
– Insert bearing plate -1- into door -2- in -direction of arrow-.
– Specified torque for bolt -3-: 4.5 Nm.

Note
2.12.1 Removing
– Remove door assembly carrier ⇒ page 145 .
– Turn assembly carrier around and pull connections -4- off door
lock -5-.
– Drive clip -2- out using a punch.
– Lever door lock -5- with retaining bracket -1- out of assembly
carrier using a screwdriver.
Note
The retaining bracket is not supplied with the door lock -5-. The
door lock is pushed onto the retaining bracket -1- and secured
with a pop rivet -6-.
– Unclip Bowden cable -1- from door lock.

– Turn cable nipple through 90° -arrow- and remove cable from
eye.
wage es n
Volks ot g
y ua
edb ran
ir s tee
tho
or
s au ac
s
ce
e
nl
2.12.2 Installing
pt
du
an
itte
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erm
ab
ility
ot p
wit
• Then always check function while door is still open, as an in‐
is n
h re
correctly fitted and adjusted Bowden cable cannot open the
ole,
door. spec
t to the co
2.13 Door inner seals
rrectness of i
Note
cial p
nform
mer
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tio
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p
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t.
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together before refitting. C py
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rig ht
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by lksw
cted agen
Prote
155
AG.
2. Rear door (Variant)

Note
The removal and installation sequence is only for the left door
inner seal. The removal and installation of the right door inner seal
is similar.
2.14.1 Removing
AG. Volkswagen AG d
agen oes
– Pull door inner seal -1-y Voff
olksbody flange.
w not
gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
atio
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n in
o
thi
te
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o
p
cum
for
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ng
i t.
py Co
t. Co py
rig
gh ht
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lksw
b
cted agen
Prote AG.
2.14.2 Installing
– Align door inner seal -1- so that vulcanised point -arrow b- is
at same height as lower hinge.


aperture.
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
are similar.
♦ Adhesive remover -D 002 000 10- must be used exclusively.
♦ The door outer seal must be bonded in place immediately after
cleaning.

2.15.1 Removing
– Pull door outer seal -1- off door -2-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
2.15.2 Installing
– Immediately before bonding outer seal for door, clean bonding
– The vulcanised point -arrow b- of door outer seal -1- must be
located in centre of sill.

– Pull off protective backing and start fitting seal in upper radius
-arrow a- of door. Do not pull door outer seal excessively to
avoid stretching seal.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
ion
co
around using roller -3356- .

in t
or
his
ate

do
priv

cum
or
f
en
ng
t.
i
py Co
Co
py
t. rig
gh ht
yri by
cop Vo
by lksw
cted
on butt joint well.
agen
Prote AG.
Note
again.

wage es n
Volks ot g
by ua
d ran
rise tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
iv
pr
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

General body
. Volkswage
repairs, exterior - Edition 10.2009
n AG n AG d
wage oes
Volks not
gu
by
60 – Sunroof
ara
ed nte
oris eo
th
au ra
c
ss
ce
e
1 Sliding/tilting sunroof with glass pan‐
nl
pt
du
an
itte
el (Meritor)
y li
erm
ab
ility
ot p
wit
is n
h re
1.1 Tools ole,
spec
t to the co
equipment required
rrectness of i
foil -3356-
♦ Front end hook -3370-
cial p
nform
mer
1783-
a
m
tio
r co
n in
o
thi
te
s
ir va
do
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.2 Function
All actions of the sliding/tilting sunroof with glass panel can be
performed with the ignition switched on.
After the ignition is switched off, actions can be performed until
either the driver or front passenger door is opened.
The opening of the glass panel in sliding or tilting positions can
be preselected using the rotary switch.
On the rotary switch there are marks for preset sliding and tilting
positions of the glass panel.
1. Sliding/tilting sunroof with glass panel (Meritor) 161

olkswagen AG
en AG. V
Golf Variant 2007 ➤ , Jettaol2005
ksw ➤
ag does
not
V
General body repairs,eexterior
d by - Edition 10.2009 gu
ara
ris nte
ho eo
ut
Opening sliding/tilting the so sunroof
ss
a to called comfort position, ra
c
prevents to a large extent wind noise while driving, which can oc‐
ce
e
nl
cur when sunroof is fully open.
pt
du
an
itte
y li
Pre-selector switch
erm
ab
ility
The sliding/tilting sunroof with glass panel is equipped with a force ot p
wit
is n
limitation (roll back) feature while closing. If the sunroof encoun‐
h re
ole,
ters an obstruction while closing from tilting or sliding position, it
spec
will open automatically.
t to the co
In addition, there is an emergency closure function. If problems
occur during closure, the sliding/tilting roof with glass panel can
be forced to shut by pressing the preselector switch when it is in
rrectness of i
the “close sliding/tilting roof” position.
The roll-back function is disabled when the emergency closure
function is active.
cial p
nf
The drive for the sliding/tilting sunroof with glass panel is protec‐
o
mer
rm
ted against overheating by a time limit. The protective mechanism
atio
m
activates when the sunroof is operated continuously for approx.

o
n in
c
2 minutes. It is functional again after a cooling-off phase.

or
thi
te
sd
a
In the event of power failure, the sliding/tilting sunroof with glass

iv
o
pr
cu
panel can be moved using a hexagon key directly on the drive.
or
m
f
en
ng
Hexagon key is located in vehicle tool kit. yi

t.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
162 Rep. Gr.60 - Sunroof

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

sunroof (single pane safety
glass)
⇒ page 166
2 - Panel seal
❑ Renewing ⇒ page 169
❑ Joint of seal centred at
rear
3 - Sliding headliner
⇒ page 170
AG. Volkswagen AG d
4 - Bolt agen oes
olksw not
V gu
by
❑ Bolts are microencap‐ ir se
d ara
nte
sulated and must al‐ utho eo
ra
ways be renewed after ss
a c
loosening.
ce
e
nl
pt
du
❑ Qty. 4
an
itte
y li
erm
❑ 1.8 Nm
ab
ility
ot p
5 - Spring slide
wit
is n
h re
❑ Screwed to sliding
ole,
spec
headliner
❑ Qty. 4
t to the co
❑ Can be renewed individ‐
ually.
rrectness of i
6 - Bellows
cial p
❑ To cover guide plate.
nform
mer
⇒ page 164
a
m
tion
co
7 - Water channel
in t
or
his
te

a
do
priv
cum
r
8 - Latch guide
fo
en
ng
t.
yi
❑ Is removed together with guide plate ⇒ page 178
Co
Cop py
ht. rig
9 - End piece upper part rig ht
py by
co Vo
lksw
❑ Clipped to end piece upper part.
by
cted agen
Prote AG.
10 - End piece lower part
❑ Can be renewed individually.
❑ To seal use butyl adhesive sealing cord -AKL 450 005 05- .
11 - Carrier unit
❑ If needed, guide channels may be greased only with special grease -G 000 450 02- , otherwise correct
operation cannot be guaranteed.
12 - Bolt
❑ Bolts are microencapsulated and must always be renewed after loosening.

❑ Qty. 3
❑ 3.5 Nm
13 - Crank for emergency operation
❑ Hexagon key is located in vehicle tool kit
14 - Electric drive
❑ Adjusting drive (0 position) ⇒ page 172 .
15 - Spring
❑ Qty. 2
❑ Pushes up wind deflector.
❑ Clipped onto wind deflector and can be renewed individually
16 - Wind deflector
17 - Wind deflector bearing
❑ Qty. 2
❑ Clipped onto wind deflector and can be renewed individually
18 - Front guide
❑ Can be pushed out of guide rail individually.
AG. Volkswagen AG d
agen oes
❑ Removing ⇒ page 178 olksw not
yV gu b ara
ed
19 - Lower rear guide ris nte
utho e or
❑ Is removed together
ss
a with guide plate ⇒ page 178 ac
ce
e
nl
20 - Torx bolt
pt
du
an
itte
❑ Qty. 3 on each side

y li
erm
ab
❑ 5 Nm
ility
ot p
wit
is n
21 - Guide plate
h re
ole,

spec
22 - Spacer
t to the co

rrectness of i
1.4 Removing and installing bellows

cial p
nform
mer
1.4.1 Removing
a
m
tion
co
– Slide sliding headlining to rear.

in t
or
his
ate
– Run sliding/tilting sunroof glass panel to tilted position.

do
iv
pr
cum
or
– Carefully unclip bellows -1- from lower part of guide plate -3-
f
en
ng
t.
using a removal wedge -3409- .
i
py Co
t. Co py
rig
– Pull bellows -1- off securing pins -4-.
gh ht
yri by
cop by
Vo
lksw
– Detach bellows -1- at top rear -2-. Prote
cted AG.
agen

– Remove bellows -1-.
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.4.2 Installing
– Slide sliding headlining to rear.
– Run sliding/tilting sunroof glass panel to tilted position.
– Fit bellows -1- first at top rear -2-.
– Clip bellows -1- in securing pins -4- in guide plate.

– Hook in bellows -1- at bottom front and clip in bellows in lower

part of guide plate -3-.
lkswage es n
o ot g
byV ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
i t.
py Co
Co py
1.5 Removing and installing sliding/tilting
t. rig
gh ht
yri by
op
sunroof glass panel
c Vo
by lksw
cted agen
Prote AG.
1.5.1 Removing
– Remove bellows ⇒ page 164 .

– Remove bolts -1- on left and right.

– Remove sliding/tilting sunroof glass panel -2- out upwards.
Caution
The guide plate must not moved to “Open” position when re‐
moved, because the water channel will not be compressed by
the glass panel and can become wedged together in the roof.
1.5.2 Installing
• Panel must be installed in the zero position (panel closed).
Zero position:
The mark -arrow- on the rear of the guide upper section -1- must,
on both sides, lie within the marks dimension -a- on the guide
plate -2-.
The guide plate -2- must be located in the guide rails (cannot be
moved by hand).
If this is not the case, adjust parallel running ⇒ page 173 .
wage es n
Volks ot g
by ua
d ran
rise tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
– Insert sliding/tilting sunroof glass panel -2- from above and fit
erm
ab
bolts -1-.
ility
ot p
wit
is n
– Lightly tighten bolts -1-.

h re
ole,
spec
– Adjust sliding/tilting sunroof glass panel (height adjustment)

⇒ page 167 .
t to the co
Note
rrectness of i
♦ After adjusting panel height, tighten securing screws (5 Nm).

♦ Install bellows after adjusting height of panel ⇒ page 164 .
cial p
nform
mer
a
m
1.6 Adjusting height of sliding/tilting sunroof

ion
co
in t
r
glass panel
o
his
ate
do
iv
pr
cum
or
f
en
ng
Note i t.
py Co
t. Co py
rig
gh
The glass panel height adjustment is performed after the glass
ht
yri by
op Vo
panel has been closed from tilt position. by c lksw
cted agen
Prote AG.
Sliding/tilting sunroof glass panel 0 (zero) position OK (checking

⇒ page 167 ).

– Remove bellows ⇒ page 164 .

– Loosen sliding/tilting sunroof glass panel -2- securing bolts
-1- on left and right (do not remove).
– Run sliding/tilting sunroof glass panel to “open” position.
– Run sliding/tilting sunroof glass panel to “closed” position.
– Carry out height adjustment of sliding/tilting sunroof glass pan‐
el at front and rear on both sides as follows:
wage es n
Volks ot g
y ua
edb ran
ir s tee
ho
Front panel adjustment:aut or
ac
ss
-a- = 0…1 mm lower than roof
ce
le
un
pt
an
d
itte
-Arrow- points forwards
y li
rm
ab
pe
ility
– Tighten foremost left and right bolts (5 Nm).
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Rear panel adjustment:

-b- = 0…1 mm higher than roof
n
ercia
fo
-Arrow- = Forwards
rm
m
atio
com
– First tighten middle and then rear bolts on left and right (5 Nm).
n in
r
te o
thi
sd
iva
Note
r
rp
cu
fo
m
en
ng
t.
yi
♦ To achieve the best possible optical appearance, ensure that
Co
op py
adjustments on left and right are as far as is possible uniform
. C rig
ht ht
rig
(symmetric). py by
co Vo
by lksw
cted agen
♦ The glass panel should not be higher than the roof at any point
Prote AG.
at the front or lower than the roof at any point at the rear.
– Install bellows ⇒ page 164 .
1.7 Adjusting panel seal

– Check that the pre-loading between panel seal -2- and body
is uniform all-round using a 0.3 mm thick strip of paper (a vis‐
iting card for example).
• It must be possible to pull the paper strip through tightly be‐
tween the panel seal and body.
If this is not the case:
– Removing glass panel for sunroof ⇒ page 166 .
– If the pressure is too little, roof seal -2- can be pushed apart
with removal wedge -3409- -1-.

– If the pressure is too great, roof seal -1- can be pushed to‐
gether all round by rolling with roller -3356- .
1.8 Renewing panel seal

– Pull seal -1- off sliding/tilting sunroof glass panel -2-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ir se nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Fit new seal -1- to rear edge of panel, start in middle and push
t to the co
onto sliding/tilting sunroof glass panel -2- from bottom to top.
rrectness of i
Note
♦ To ease fitting of seal, coat panel edge with a soapy solution.

cial p
♦ If the seal is not correctly installed, the surface will ripple.

nform
mer
♦ The panel seal must be shortened to suit the panel circumfer‐

a
m
ence.
io
r co
n in
o
thi
te
– Install sliding/tilting roof glass panel ⇒ page 166 .

s
a
do
ir v
p
cum
or
– Adjust panel seal ⇒ page 168 .

f
en
ng
t.
yi Co
op py
1.9 Removing and installing wind deflector
C
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
1.9.1 Removing
– Fully open sliding/tilting sunroof glass panel.
– Push wind deflector and height limit stop out of front of roof
aperture and set wind deflector vertical.

– Insert front-end hook -3370- between edge of roof and wind

deflector bearing -arrow-.
– Pull wind deflector bearings out of detents on left and right, in
direction of -arrow-, using front-end hook -3370- .
– Remove wind deflector upwards out of guide rails.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
1.9.2 Installing ris nte
tho eo
au ra
ss c
– Place wind deflector in guide rails and slide wind deflector with
ce
e
nl
height limit stop under front of roof aperture on both sides.
pt
du
an
itte
y li
– Using light pressure press wind deflector bearings into guide
erm
ab
rails.
ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
Wind deflector bearings must audibly engage in the guide rails.
1.10 Removing and installing sliding headlin‐
rrectness of i
er
cial p
nform
1.10.1 Removing
mer
a
m
tion

co
in t
or
his
e
– Move sliding headliner backwards slightly.

at
do
priv
– Remove front bolts -arrow- on left and right.

um
or
f
en
ng
i t.
– Push spring slide forwards past the stop -1-. py Co
t. Co py
rig
– Move sliding headliner forwards and lift sliding headliner
gh ht
yri by
cop
slightly above roof aperture.
Vo
by lksw
cted agen
Prote AG.
– Remove rear bolt -arrow- on left and right.

– Push spring slide to rear and remove sliding headliner -1- out
upwards.

1.10.2 Installing
Finally carry out a functional check.

sunroof glass panel drive
1.11.1 Removing
– Removing lights and front operating unit ⇒ Electrical system;
Rep. Gr. 96 ; Lights and switches in roof trim .
Motor change - preselction switch recognition:
Note
♦ To interrupt the authorization signal and therefore to activate

the switch recognition, the requirements described below must
be fulfilled.
♦ If this is not the case, it can lead to, that the driven does
AG. Vonot
lkswagen A
correctly recognise the preselection switcholkand swa does not run
ge G do
es n
ot g
to the selected positions. This can be seen by V if the sunroof stops ua
ed ran
approx. 10 cm before the fully closed ris position when the switch tee
ho
is in the closed position. au
t or
ac
ss
ce
e
nl
pt
du
an
Caution
itte
y li
erm
ab
ility
ot p
Remove or install drive for tilting/sliding sunroof glass panel
wit
is n
only when sunroof is closed (0 position ).
h re
ole,
The requirements for removing and installing drive are: engine
spec
not running and ignition off, key not in ignition and door open.
t to the co
– Switch off engine and ignition, withdraw key and open door.
This condition must remain until drive has been installed. rrectness of i
– Remove screws -arrows- and pull off sliding/tilting sunroof
cial p
drive.
nform
mer
– Separate connector for sliding/tilting sunroof drive.

a
m
tion
co
in t
or
his
te
iva
do
pr
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.11.2 Installing
The screws for the sliding/tilting sunroof drive are microencapsu‐
lated and must always be renewed (3.5 Nm).
After installation is complete, key can be inserted into lock cylin‐
der of ignition/starter switch again.

– Finally carry out a functional check.
1.12 Adjusting drive for sliding/tilting sunroof

AG. Volkswagen AG d
agen
glass panel (0 position)
by
Volksw
oes
not
gu
ara
ed nte
There may be a requirement to adjusttho
ris the zero (0) position if the e or
drive was removed when not ins theau zero position or the sliding/ ac
tilting sunroof glass panel was sopened or closed using the emer‐
ce
e
nl
gency key.
pt
du
an
itte
y li
• Drive removed but still connected electrically.
erm
ab
ility
ot p
– Select “open sunroof” using preselection control rotary switch.
wit
is n
h re
– Select “close sunroof” using preselection control rotary switch.
ole,
spec
– Select “tilt sunroof” using preselection control rotary switch.
t to the co
– Select “close sunroof” using preselection control rotary switch.
– Install drive in this position (zero position) with sunroof closed.
rrectness of i
The sliding/tilting sunroof glass panel drive is in zero (0) position,
if a white dot can be seen in the drive aperture -arrow-.
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
ir va
o
p
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
sunroof glass panel automatic preselec‐

tion switch
– Removing preselector for sliding/tilting sunroof roof glass pan‐
el ⇒ Electrical system; Rep. Gr. 96 ; Lights and switches in
roof trim .
1.14 Checking parallel running


plate -2-.
olkswagen AG
en AG. V
• The guide plate -2- must be located in the guide orails
lksw (cannot
ag does
not
be moved by hand). ed
byV gu
ara
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
1.15 Adjusting parallel running
spec
t to the co
Note
rrectness of i
The parallel running adjustment can only be made when the drive
and glass panel are removed ("0" position).
cial p
nform
– Remove sliding/tilting sunroof glass panel drive ⇒ page 171 .
mer
a
m
tion
co
in t
r
plate -2-.
o
his
ate
do
iv
• The guide plate -2- must be located in the guide rails (cannot
pr
cum
r
be moved by hand).
fo
en
ng
i t.
py Co
– Push guide upper part -1- both sides centrally between the . Co py
marks.
t rig
gh ht
yri by
cop Vo
– Install drive in this position (zero position) ⇒ page 171 .
by lksw
cted agen
Prote AG.
– Then check zero position ⇒ page 172 .

1.16 Assembly overview - carrier unit
1 - Carrier unit
⇒ page 174
2 - Bolt
❑ Qty. 12
❑ 8 Nm
3 - Connector . Volkswagen AG
gen AG does
swa
4 - Sliding/tilting sunroof glassby
Vol
k not
gu
ara
panel drive ris
ed
nte
ho eo
❑ Removing and aut installing ra
c
⇒ page 171ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
1.17 Removing and installing carrier unit
Caution
Remove or install drive for tilting/sliding sunroof glass panel

only when sunroof is closed (0 position ).
The requirements for removing and installing drive are: engine
not running and ignition off, key not in ignition and door open.
1.17.1 Removing
Caution
Carry out following sequences using extreme care so as not to

damage the moulded headliner.
– Lower moulded headliner (moulded headliner is not removed

from the vehicle, the front seats and front passenger door are

not removed) ⇒ General body repairs, interior; Rep. Gr. 70 ;

Roof trims .
– Pull water drain hoses -arrows- off carrier unit -1-.
. Volkswage n AG n AG d
wage oe
– Separate connector -3-y Von
olkssliding/tilting sunroof glass panel
s no
t gu
drive -4-. ised b ara
n r te
tho eo
– Remove boltss-2-au and remove carrier unit -1- from vehicle with r ac
the help of a second mechanic.
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
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1.17.2 Installing
Caution
Carry out following sequences using extreme care so as not to

damage the moulded headliner.
– Fit carrier unit -1- into roof aperture with the help of a second
mechanic.
– During installation align carrier unit -1- in roof using two cylin‐
drical pins (shank end of drill) 12 mm front right and 10 mm
rear left.

Carrier unit must not contact roof frame.

– Check routing of wiring and connectors of electrical consum‐
ers in roof and correct as necessary.
– Tighten screws (8 Nm) for carrier unit -1-, starting at sunroof
drive -4- and moving rearward, alternating between left and
right sides.
– Install water drain hoses -arrows-.
– Attach connector -3- on sliding/tilting sunroof glass panel drive
-4-.
– Install moulded headliner ⇒ General body repairs, interior;
Rep. Gr. 70 ; Roof trims .
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1.18 Operating without current

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In the event of powerut failure, the sliding/tilting sunroof with glass e or
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panel can be movedss using a hexagon key directly on the drive.
a ac
Hexagon key is located in vehicle tool kit.
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– Guide hexagon key into bolt on drive.
h re
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spec
– Press key upwards -arrow- to release the drive.
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The bolt will be pressed a few millimetres inwards -a-. Sliding/
tilting sunroof glass panel can only be moved in this position.
rrectness of i
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1.19 Removing and installing guide plate

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– Removing glass panel for sunroof ⇒ page 166 . cop Vo
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– Using a screwdriver, unclip spacer -2- from guide plate -1- at
front and rear -arrows-.
– Pull spacer -2- in -direction of arrow- out of guide plate -1-.
– Lift guide plate up -1- in -direction of arrow-.

– Slide front guide -2- forwards and pull guide plate -1- in
-direction of arrow- out of front guide -2-.
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1.20 Removing and installing guide plate
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1.20.1 Removing
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Note
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Always renew guides with cables as a pair.
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– Remove sliding/tilting sunroof glass panel drive ⇒ page 171 .

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– Remove carrier unit ⇒ page 174 . Co py
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– Remove guide plate ⇒ page 177 . y cop Vo
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– Detach water channels -1- carefully using a screwdriver at
AG.
both sides on guide locating hook -2- in -direction of arrow-

and remove water channels.
– Release end piece upper part -1- fastening -arrows- from end
piece lower part -2- and pull off upwards.

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

rail -3-, until the locating hook guide locking mechanism -2- is
released.
– Pull out rear guide lower part -1- and locking hook guide -2-
together in -direction of arrow- from
agen
guide
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1.21 Cleaning water drain hoses
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Note
l purpos
For cleaning, a locally manufactured tool made from a speedom‐
nform
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eter inner cable, approx. 2300 mm long is recommended.

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1.21.1 Front water drain hoses

The front water drain hoses run through the A-pillars and end at
the bulkhead cross member. Cleaning is done from the sunroof
panel aperture.
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1.21.2 Rear water drain hoses
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The rear
ss water drain hoses run through the C-pillars and end
a ac in
the rear wheel housings. Cleaning is done from the wheel hous‐
ce
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ing. The wheel housing liner must be removed ⇒ page 323 .
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2 Panorama sliding sunroof (Arvin-

Meritor)
2.1 Tools
♦ Roller for door insulation foil -3356-
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♦ Adhesive strip remover -VAS 6349-
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2.2 Function
All actions of the panorama sliding roof can be performed with
ignition switched on.
After the ignition is switched off, actions can be performed until
either the driver or front passenger door is opened.

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Opening of front glass panel can be preselected
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Opening glass panel to the southcalled
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vents to a large extent windssnoise
a while driving, which can occur ac
when roof is fully open.
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The panorama sliding roof is equipped with a roll-back function.
es, in part or in w
If the glass panel encounters an obstruction while closing from
t to the co
tilting or sliding position, it will open automatically.
In addition, there is an emergency closure function. If problems
rrectness of i
occur during closure, panorama sliding roof can be forced to close
by pulling rear end of rotary switch. Rotary switch must thus be in
l purpos
“Sliding sunroof closed” position.

The roll-back function is disabled when the emergency closure
nform
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function is active.
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The sliding sunroof motor is equipped with an overheating pro‐
io
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tection, whose activation depends on various parameters. The
o
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sliding sunroof motor is functional again after a cooling-off phase.
te
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In the event of power failure, front glass panel and sun blind can
or
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be moved manually ⇒ page 217 .
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2.3 Establishing reference points of panor‐
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Note
♦ After renewal of glass panel, motor, tilting mechanism or sun

blind, establish reference points of panorama sliding roof for
respective drive.
♦ Roll-back function is switched off when establishing reference
points.
Establishing reference points of sliding sunroof motor

Ignition is switched on.
Rotary switch must be in “Sliding sunroof closed” position.
– Pull rotary switch -1- downwards and hold during whole proc‐
ess to establish reference points (approx. 20 s) in this position.
– When establishing reference points, glass panel first closes
and then moves approx. 200 mm towards the rear.
– After glass panel is closed again, establishment of reference
points is finished and rotary switch must be released.
Establishing reference points for sun blind motor
Ignition is switched on.
2. Panorama sliding sunroof (Arvin-Meritor) 183

– Press sun blind closing button -3- and hold during whole
standardization run (approx. 20 s) in this position.
– When establishing reference points, sun blind first closes and
then moves approx. 200 mm towards the rear.
– After sun blind is closed completely again, establishment of
reference points is finished and button must be released.
2.4 Assembly overview - panorama sliding roof
1 - Exterior seal
2 - Rear glass panel
⇒ page 187
3 - Front glass panel
⇒ page 185
4 - Assembly frame
⇒ page 203
⇒ page 207
5 - Sun blind agen
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⇒ page 199 rised
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6 - Sun blind motor
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⇒ page 198
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⇒ page 183
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⇒ page 196
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❑ Standardization
⇒ page 183
rrectness of i
8 - Tilting mechanism
⇒ page 215
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9 - Wind deflector
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Rep. Gr.60 - Sunroof Prote AG.

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auth General body repairs, exterior
eo
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ss c
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2.5 Removing and installing front glass pan‐
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– Open glass panel -1- until trim -2- is accessible.

– Unclip locking lugs -3- by pressing together in direction of
-arrow A- on back.
– First pull off trim panel -2- downwards at rear and then inwards
in direction of -arrow B- and remove it from bolt -4-.
– Push trim panel in direction of -arrow C- forwards and remove.

– Remove bolts -2- from glass panel -1- on left and right.
Note
To remove bolts, use a magnetic tool so that bolts do not fall into
mechanism of panorama sliding roof.
– Remove glass panel upwards.
Caution
To avoid damaging wind deflector, do not move tilting mecha‐

nism when glass panel is removed.
2.5.2 Installing
Note
♦ Always use new bolts when installing or removing glass panel.

♦ To screw in bolts, use a magnetic tool so that bolts do not fall
into mechanism of panorama sliding roof.
– Set glass panel -1- from top and screw bolts -2- without tight‐
ening them.
– Adjust front glass panel ⇒ page 188 .
– Tighten bolts -2- (5 Nm).
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– Fit front trim panel -2- into glass panel -1- and slide in direction
erm
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– Push trim panel in direction of -arrow B- onto bolt -4- and clip h re
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locking lugs -4- on back. spec

– On completion of work, establish reference points of sliding

t to the co
sunroof motor ⇒ page 183 .

rrectness of i
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2.6 Removing and installing rear glass pan‐

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nl
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mechanism of panorama sliding roof.
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– Open front glass panel completely by pressing rotary switch
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beyond comfort position.
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– Remove bolts -3- of rear glass panel -1-.
spec
– Remove spacer -2- under bolting point.
t to the co
– Move front glass panel into “tilted” position.
rrectness of i
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– Pull inner seal -3- inwards slightly at point -arrow- and remove
bolts -2-.
– Remove rear glass panel upwards -1-.
2.6.2 Installing
Note
♦ Always use new bolts when installing or removing glass panel.

♦ To screw in bolts, use a magnetic tool so that bolts do not fall
into mechanism of panorama sliding roof.

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– Fit glass panel -1- from top into roof. ir se ran
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– Install spacer -2- and tighten bolt -3- (5 Nm). ss
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– Pull inner seal -3- slightly backwards at -arrow- positions and
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screw bolts -2- without tightening them.
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– Adjust rear glass panel ⇒ page 188 .

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– After adjusting rear glass panel, tighten bolts (5 Nm). C py
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sunroof motor ⇒ page 183 . Prote
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agen
2.7 Adjusting height of front and rear glass

panel
Note
♦ Front glass panel must only be adjusted on front edge and rear
glass panel on rear edge.
♦ To achieve the best possible optical appearance, ensure that
adjustments on left and right are as far as is possible uniform
(symmetric).

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AG. Volkswagen AG,dJetta 2005 ➤
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General by body repairs, exterior - Edition t10.2009
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Checking height adjustment auth
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– Check adjustment of front glass panel -1- and rear glass panel
ce
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-2- with a depth gauge.
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♦ Dimension -a- = 1.5 ± 1 mm
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♦ Dimension -b- = 1 ± 1 mm
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♦ Dimension -c- = 1 ± 1 mm
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es, in part or in w
If measured values differ from specifications, respective glass
t to the co
panel must be adjusted.
♦ Adjusting front glass panel ⇒ page 189
rrectness of i
♦ Adjusting rear glass panel ⇒ page 189
l purpos
Adjusting front glass panel
n
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Note m
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The glass panel height adjustment is performed after the glass
r
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panel has been closed from slide open position.
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– Close glass panel.
AG.
– Adjust glass panel -1- as shown in illustration.

♦ Dimension -a- = 1.5 ± 1 mm
♦ Dimension -b- = 1 ± 1 mm
– Tighten left and right bolts (5 Nm).
– Install trim ⇒ page 186 .
Adjusting rear glass panel

– Pull inner seal -3- slightly backwards at -arrow- positions and

remove bolts -2- of rear glass panel -1-.
– Adjust rear glass panel -2- as shown aingeillustration.

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♦ Dimension -b- = 1 ± 1 mm utho eo
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2.8 Renewing seals for rear glass panel
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– Remove rear glass panel ⇒ page 187 .
l purpos
Renew front and inner seals

– Pull respective seal -1- off rear glass panel.
nform
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♦ 2 Front seal
m
at
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♦ 3 Inner seal
n in t
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– Remove existing adhesive residue using adhesive strip re‐

at
d
v
mover -VAS 6349- .

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– Bonding surface on glass panel must be free of dust and

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– Clean bonding surface completely using cleaning solution -D py by
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Note
To guarantee a good bonding of seal, do not bond at a tempera‐

ture below 20°C.
– Remove protective backing from adhesive tape of new seal

and press on seal at both ends.
– Sprain any seal excess length evenly.
– Press in seal evenly using roller for door insulation foil -3356- .
– Install rear glass panel ⇒ page 187 .
Removing side seal

– Remove side seal -2- from profile of rear glass panel -1-.
mover -VAS 6349- .
– Bonding surface on glass panel must be free of dust and
grease.
– Clean bonding surface completely using cleaning solution -D agen
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♦ New seal is supplied in excess length. Cut new seal to appro‐
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priate length. It is recommended to leave new seal 1-2 mm
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longer and to sprain any excess length.
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perature below 20°C.
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spec
– Pull off protective backing from adhesive tape of new seal.
t to the co
– Set new seal -2- with fastener -3- on glass panel -1-.
rrectness of i
– Press seal on both ends.
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– Press seal -2- onto profile of glass panel -1- and sprain any yri
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– Press in seal evenly using roller for door insulation foil -3356- .
2.9 Renewing outer seal

– Remove front glass panel ⇒ page 185 .

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– Pull out outer seal u-1-
th in bonding
o area -3- from roof -2-. or
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– Cut off all round profile of outer seal -1- in -arrow- area, flush
sd
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with edge of roof -4-.
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– Remaining part -3- stays between roof -4- and assembly frame
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– Remove existing adhesive residue using adhesive strip re‐ copy Vo
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– Entire bonding surface on roof cut-out must be free of dust and

grease.
– Clean bonding surface completely using cleaning solution -D
009 401 04- .
Note
♦ New seal is supplied in excess length. Cut new seal to appro‐

priate length. It is recommended to leave new seal 1-2 mm
longer and to sprain any excess length.
♦ To guarantee a good bonding of seal, do not bond at a tem‐
perature below 20°C.
♦ After bonding outer seal, wait at least 30 min before fitting
glass panel to assure seal does not unstick.

AG. Volkswagen AG d
agen GolfoeVariant 2007 ➤ , Jetta 2005 ➤
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ara - Edition 10.2009
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– Centre new outer seal -1- with
ss
aubutt -arrow- on rear centre of ra
c
roof cut-out.
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– Pull protective backing from adhesive tape -3- of new outer
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seal -1- and press seal on roof -2-.
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– The seal must not pull into the radii, otherwise the seal will
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stretch and compress.
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– Press in outer seal evenly and all round twice using roller for
door insulation foil -3356- .
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– Install front glass panel ⇒ page 185 .
rrectness of i
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2.10 Renewing inner seal
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or
m
f
en
ng
t.
yi
Co
Cop py
ht. rig
– Remove rear glass panel ⇒ page 187 . rig ht
py by
co Vo
by lksw
– Pull inner seal -2- off assembly frame -1-. cted agen
Prote AG.

mover -VAS 6349- .
– Bonding surface must be free of dust and grease.
– Clean bonding surface completely using cleaning solution -D
009 401 04- .
Note
To guarantee a good bonding of seal, do not bond at a tempera‐

ture below 20°C.
– Place inner seal -2- with butt positioned on rear centre of roof
cut-out, onto bonding surface of assembly frame -1-.
– Pull protective backing from adhesive tape of new inner seal
section by section and press it on.
– The seal must not pull into the radii, otherwise the seal will
stretch and compress.
– Press inner seal in evenly and all round twice using roller
-3356- .
2.11.1 Removing
– Open front glass panel completely.

– Using a screwdriver, unclip nsecuring

AG. Volkswclip
agen-3- over mounting
AG do
bracket -2- of wind deflector
olks
wage -1-. es n
o
yV t gu
db ara
rise nte
tho eo
au ra
c
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e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
– Using a screwdriver, unclip mounting bracket -2- of wind de‐
a
m
flector -1- from assembly frame -3-.
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
– Remove bolts -2- from wind deflector -1-.

– Remove wind deflector -1- upwards.
2.11.2 Installing
Specified torque
Wind deflector bolts 2 Nm

Note
♦ Wind deflector mounting bracket must engage audibly.

♦ Securing clip of mounting bracket must always be renewed
after removal.

bracket
2.12.1 Removing
– Remove wind deflector ⇒ page 193 .
– Using a drift -1-, drive dowel pin -3- out of upper net strip G
-2-.
. Volkswage nA n AG d
wage oes
Volks not
gu
by ara
ed nte
oris eo
th
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c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Pull wind deflector bracket -1- out of net strip -5- in direction
of -arrow-.
rrectness of i
– Pull tensioning wire -2- out of lower net strip -4- and net -3-.
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
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o
p
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or
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ng
t.
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2.12.2 Installing Cop py
ht. rig
ht
rig by
py
– Carefully push tensioning wire -2- through net -3- into lower
co Vo
by lksw
cted
net strip -4-.
agen
Prote AG.

Use a new dowel pin to secure wind deflector bracket.
– Install wind deflector ⇒ page 193 .

2.13 Removing and installing preselector for

glass panel and sun blind
– Removing preselector for panorama sliding roof glass panel
⇒ Electrical system; Rep. Gr. 96 ; Lights and switches in roof
trim .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
2.14 Removing and installing sliding sunroof
au ra
ss c
motor
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
2.14.1 Removing
wit
is n
h re
ole,
spec
t to the co
WARNING
rrectness of i
On some models, a ribbon cable is bonded to the light cut-out
web. Before removing sliding sunroof motor, carefully detach
ribbon cable from web and push it to side. Ensure that ribbon
cable is not damaged when doing this.
cial p
nform
mer
a
m
tio
o
n in
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te o
thi
s
a
do
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p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.

lkswage es n
o ot g
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ed ran
oris tee
uth or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.
– Carefully detach ribbon cable -3- (if fitted) from web -1- and
pull it to side -arrow-.
To access right bolt -4- of sliding sunroof motor -2- with tool, drill
a 10 mm ∅ hole in web -1-.
Dimension -a- = 10 mm
Dimension -b- = 2 mm
Caution
Ensure when drilling hole that sliding roof motor underneath is

not damaged. If necessary, use a drill with depth-control stop
and set drilling depth to 3 mm.

– Slightly lower sliding sunroof motor and tilt it out forwards.
– Separate connector.

2.14.2 Installing
With front glass panel removed:
– Pull tilting mechanism fully forwards on both sides until it is
completely lowered.
– Push tilting mechanism on -arrow- areas of slider -2- not on
guide plate -3-.
Specified torque for sliding sunroof motor bolts: 3.5 Nm
sunroof motor ⇒ page 183 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ir se nte
2.15 Removing and installing sun blind motor autho eo
ra
ss c
ce
e
nl
pt
du
an
2.15.1 Removing
itte
y li
erm
ab
ility
– Remove moulded headliner ⇒ General body repairs, interior;
ot p
wit
is n
h re
ole,
– Disconnect connector -1- on sun blind motor -2-.
spec
– Remove bolts -arrow- from sun blind motor -2-.
t to the co
– Remove sun blind motor -2-.
rrectness of i
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

2.15.2 Installing
– Before installing motor, adjust sun blind by ensuring parallel
distance -a- between sun blind cross strut -1- and sun blind
housing -2-.
Specified torque
Bolts 3.5 Nm wage es n
Volks ot g
by ua
– On completion of work, establish
rise reference points of sun blind
d ran
tee
motor ⇒ page 183 . autho
or
ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.16 Removing and installing sun blind
rrectness of i
l purpos
2.16.1 Removing
n
ercia
for
– Run sun blind to fully open position.
m
m
atio
com
n in
r
te o
thi
Note
sd
iva
o
r
rp
cu
In the event of power failure, sun blind can be moved by turning
fo
m
en
ng
sun blind motor with a commercially available hexagon key to re‐

t.
yi Co
op
moval position (fully open). ⇒ page 217 C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove bolt -3- from cap -2-.
– Using a screwdriver, unclip fastener -arrow- of cover cap -2-
from rear part -4- and tilt cover cap -2- upwards.
Inner seal -1- must not be removed for this.

– Carefully lift sun blind cross strut -3- with sun blind slide -1-.
Note
Ensure that sun blind fabric -2- is not damaged.
– Pull sun blind slide -1- in direction of -arrow- on side of sun

blind cross strut -3-.
– Remove bolts -1- of sun blind housing -2-.

– Pull sun blind housing -2- in direction of -arrow- slightly down‐
wards to get past sun blind motor -3-.
AG. Volkswagen AG d
agen oes
o lksw not
V gu
d by a
– Pull sun blind housing
orise -2- with sun blind steel strap -4- inrandi‐
tee
rection of -arrow-
aut
h out of sun blind rail -1-. or
ac
ss
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
ility

ot p
wit
, is n
h re
Sun blind cross strut can be renewed when sun blind is removed.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.

– Carefully pull sun blind cross strut -1- in direction of -arrow-

out of beading -3- of sun blind fabric -2-.
– Carefully slide sun blind cross strut -1- on beading -3-.
Note

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Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.16.2 Installing
rrectness of i
Note
l purpos
♦ Sun blind cross strut must be fitted before installation of sun

blind housing.
n
ercia
form
♦ Do not grease sun blind slide and sun blind cables.
m
atio
com
n in
r
te o
– Push sun blind housing -2- with sun blind steel strap -4- in
thi
sd
direction of -arrow- into sun blind rail -1-.
iva
o
r
rp
cu
fo
m
en
ng
t.
yi
Note
Co
Cop py
ht. rig
rig ht
py by
Ensure that sun blind fabric -3- is not damaged. co Vo
by lksw
cted agen
Prote AG.

Lug -3- of sun blind housing -2- must be inserted under sun blind
rail -1-.
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Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
iv
pr
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Push sun blind slide -1- in direction of -arrow- into sun blind
cross strut -4-.
Note
Ensure that sun blind slide -1- engages into cut-out of sun blind steel strip -5- and into follower of sun blind
cable -2-.

Specified torques
Sun blind housing bolt 3.5 Nm
Cover cap bolt 2 Nm
Note
AG. Volkswagen AG d
After installation, sun blind synchronism and ease ofooperation
lksw
agen oes
not
should be checked. To do this, move by hand sun byblind drive on
V gu
ara
ed
motor using a commercially available hexagon oriskey and avoid nte
eo
wrinkling and deformation of sun blind fabric.
au
th ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
– On completion of work, establish reference points of sun blind
h re
motor ⇒ page 183 .
hole
spec
es, in part or in w
2.17 Assembly overview - assembly frame
t to the co
1 - Sun blind rail
rrectness of i
❑ Cannot be renewed in‐
l purpos
dividually
2 - Guide rail
n
ercia
fo
rm
m
atio
dividually
com
n in
❑ Attached to front part
r
te o
thi
sd
iva
3 - Bolt
o
r
rp
cu
❑ 2 Nm
fo
m
en
ng
t.
yi Co
4 - Rear part . Cop py
rig
ht
❑ Removing and installing rig ht
py by
⇒ page 209
co Vo
by lksw
cted agen
Prote AG.
5 - Rear motor plate
⇒ page 204
6 - Front motor plate
⇒ page 215
7 - Front part
dividually
❑ Attached to guide rail
8 - Inner seal

2.18 Installing and removing motor plate and

sun blind cable
2.18.1 Removing
– Remove sun blind motor ⇒ page 198 .
– Remove sun blind ⇒ page 199 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
– Remove bolts -arrows- of cable covers -1- and -2-.

– Remove cable covers -1- and -2-.
Motor plate -3- remains on rear part -4-.

wage es n
Volks ot g
by ua
d ran
rise tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
ir va
o
p
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Pull sun blind cables -3- out of discharge tubes -1- and motor
plate -4-.
– Using an appropriate screwdriver -5-, lever motor plate -5- out
of rear part -6-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
– Lever guide tube -1- out of cable support bracket -4- of rear
mer
part -3-.
a
m
tion
– Remove cable -2- from sun blind rail -5-.

co
in t
or
his
e
2.18.2 Installing
at
do
priv
cum
or

f
en
ng
i t.
py Co
Specified torques Co py
t. rig
gh ht
yri
Bolt for cable cover: 2 Nm
by
cop by
Vo
lksw
cted agen
Prote AG.
Note
Do not grease motor plate and sun blind cables.
– Install sun blind ⇒ page 201 .

– Install sun blind motor ⇒ page 199 .
– On completion of work, establish reference points of all drives
for panorama sliding roof ⇒ page 183 .

2.19 Removing and installing assembly

frame en AG. V
olkswagen AG
wag does
olks not
byV gu
ara
ed nte
ris
2.19.1 Removing au
tho eo
ra
ss c
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
pe
A second mechanic is required for removing and installing as‐
ility
ot
sembly frame.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Vehicles with net partition:
– Remove net partition mounting ⇒ General body repairs, inte‐
rrectness of i
rior; Rep. Gr. 68 ; Net partition .
l purpos
All vehicles:
– Remove grab handle mounting (roof) ⇒ General body repairs,
n
ercia
fo
interior; Rep. Gr. 68 ; Grab handles .
rm
m
atio
com
n in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Pull off water drain hoses from connections -arrows- of as‐

sembly frame -1-.
– Disconnect connector to wiring harness of sliding sunroof mo‐
tor -8-.
– Unscrew bolts -3- and -4- of on console -5- and remove left
and right consoles.
– Unscrew bolts -2- on assembly frame -1- and remove assem‐
bly frame from vehicle with the help of at least one mechanic.
2.19.2 Installing
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
riv
– Lift assembly frame -1- into vehicle with the help of at least a
p
cum
r
second mechanic.
fo
en
ng
t.
yi Co
– When screwing, align assembly frame using 2 cylindrical pins Cop py
(shank end of drill ∅ 10mm) in elongated holes -6- and -7-. ht. rig
rig ht
py by
co Vo
– Screw bolts -2- in, but do not tighten.
by lksw
cted agen
Prote AG.
– Tighten bolts -3-, specified torque: 8 Nm.
– Tighten bolts -4-, specified torque: 4.5 Nm.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ir se nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
– First tighten letter marked bolts -2- in alphabetic order to 8 Nm.

ab
ility
ot p
– Tighten then remaining bolts -2- of assembly frame -1- to

wit
is n
8 Nm.
h re
ole,
spec

t to the co
Vehicles with net partition:

– Install net partition mounting ⇒ General body repairs, interior;
rrectness of i
Rep. Gr. 68 ; Net partition .

All vehicles:
– Install grab handle mounting (roof) ⇒ General body repairs,
cial p
nform
interior; Rep. Gr. 68 ; Grab handles .

mer
atio

m
r co

n in
o
thi
e
2.20 Removing and installing rear part

t
sd
ir va
o
p
cum
for
en
ng
t.
yi Co
2.20.1 Removing Cop py
ht. rig
ht
rig by
py
– Remove assembly frame from vehicle ⇒ page 207 .
co Vo
by lksw
cted agen
Prote AG.

– Pull inner seal -2- off assembly frame -1-.

– Remove sun blind ⇒ page 199 .
– Loosen wiring harness from rear part.
wage es n
Volks ot g
y ua
edb ran
ir s
– Remove bolts
tho -2- from guide rail -1-. tee
or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
– Mark position -arrow- of rear part -3- for further assembly.

– Separate adhesive bonding -2- between guide rail -1- and rear
cial p
part -3- using a knife.

nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
– Pull entire rear part -1- with discharge tubes -2- in direction of
AG.
-arrow- out of guide rail -3-.

n AG. Volkswagen AGolf
G do Variant 2007 ➤ , Jetta 2005 ➤
lkswage es n
o ot g
d by V General body repairs, uexterior
ara - Edition 10.2009
e nte
oris e
th or
2.20.2 Installing ss
au ac
ce
le
un
pt
an
d
mover -VAS 6349- .
itte
y li
rm
ab
pe
– Clean bonding surfaces on rear part and guide rails with clean‐
ility
ot
er -D 009 401 04- .
wit
, is n
h re
– Press a ∅ 3.5 mm butyl sealing cord -AKD 497 010 04 R10-
hole
spec
-2- as shown in illustration into adhesive canal on rear part
-1-. es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
form
m
atio
com
n in
r
te o
thi
sd
iva
– Push entire rear part -1- with discharge tubes -2- in direction
o
r
rp
cu
of -arrow- onto guide rail -3-.
fo
m
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.
– Tighten bolts -2- on guide rail -1- to 2 Nm.
Note
Before installation, it is recommended to check leak tightness of

assembly frame.
– Seal water drain hoses -1-.

– Fill marked area -3- between rear part -2- and guide rail -4-
with water.
– Wait for at least 5 minutes before checking leak tightness.
– Seal any leaks with butyl sealing cord -AKD 497 010 04 R10- .
– Install sun blind ⇒ page 199 .
– Install sun blind motor ⇒ page 198 .
– Install a new inner seal ⇒ page 193 .
– Install assembly frame ⇒ page 208 .

2.21 Removing and installing front motor

plate
2.21.1 Removing
– Remove sliding sunroof motor ⇒ page 196 .
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Remove bolts -arrows-.

– Remove cable covers -1 and 2-.
Front motor plate -3- remains on front part -4-.

lkswage es n
o ot g
byV ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
– Pull ends of cable -1- out of motor plate -2-.

du
an
itte
y li
– Using appropriate screwdriver -4-, lever motor plate -2- out of

erm
ab
ility
front part -3-.

ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

2.21.2 Installing
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
Note
s
a
do
ir v
p
cum
♦ Insert motor plate -2- into front part -3-.

for
en
ng
t.
yi Co
♦ Do not grease motor plate and cables -1-. ht. Cop py
rig
rig ht
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Specified torques
Bolt for cable cover: 2 Nm
– Install sliding sunroof motor ⇒ page 196 .
– Install assembly frame ⇒ page 208 .
– On completion of work, establish reference points of sun blind
motor ⇒ page 183 .

2.22 Removing and installing tilting mecha‐

nism and front glass panel cable
2.22.1 Removing
– Remove sliding sunroof motor ⇒ page 196 .
– Remove rear part of assembly frame ⇒ page 209 .
After removal of rear part, tilting mechanism can be slid out back‐
wards.
To do this, proceed as follows:
Caution
Observe position of cables agbefore

en AG. Vremoval to avoid
olkswagen AG
does any error
ksw
when installing. b y Vol not
gu
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Do not pull or tpush
ho
ri tilting mechanism guide plate. e or
au ac
ss
ce
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nl
– Push glass panel tilting mechanism only on areas -arrow- of pt

du
an
itte
slider -2-, not on guide plate -3-. y li

erm
ab
ility
Tilting mechanism tilts when moving.
ot p
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is n
– Using appropriate screwdriver, push tilting mechanism back‐

h re
ole,
wards to end of guide rail -1-.

spec
t to the co
rrectness of i
cial p
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mer
a
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– Unhook cable -2- out of slider -1- -arrow A-. py Co
t. Co py
rig
– Pull slider -1- out of guide rail -3- -arrow B-.
gh ht
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– Pull cable -2- out of guide rail -3-. cted agen
Prote AG.

2.22.2 Installing
Note
♦ Guide rails must only be cleaned if heavily soiled.

♦ To do this, use cleaner -D 009 401 04- .
♦ Then grease guide rail in guide areas with lithium grease -G
052 147 A2- ⇒ page 217 .
♦ Do not grease cables.
– Slide tilting mechanism -3- into guide rail -1-.

– Ensure that slides -2- face towards rear when slid into guide
rail -1-.
– Push cable -2- into guide rail -3- -arrow B-.

– Hook cable -2- into slider -1- -arrow A-.
Note
Do not pull or push tilting mechanism guide plate. n AG. Volkswagen AG do

lkswage es n
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nl
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– Push tilting mechanism on -arrow- areas of slider -2- not on
erm
ab
guide plate -3-.
ility
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– Pull tilting mechanism fully forwards on both sides until it is

h re
ole,
completely lowered.
spec
– Install rear part on assembly frame ⇒ page 211 .

t to the co
– Install sliding sunroof motor ⇒ page 198 .

– Install assembly frame into vehicle ⇒ page 208 .
rrectness of i

cial p
nform

mer

atio
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thi
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n AG. Volkswagen AG do Golf Variant 2007 ➤ , Jetta 2005 ➤
wage
Volks General
es n
ot gbody repairs, exterior - Edition 10.2009
by ua
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2.23 Maintenance and care tho
or
s au ac
s
No regular maintenance is usually required for the panorama
ce
e
nl
pt
du
sliding roof.
an
itte
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ab
If cleaning is necessary because it is heavily soiled, use cleaner
ility
-D 009 401 04- . ot p
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Guide areas -3- of guide rail -2- must then be greased again with
hole
lithium grease -G 052 147 A2- .
spec
es, in part or in w
Inner seal -1- and outer seal -4- have a solid film lubricant coating
t to the co
and must not be greased.
Do not grease cables and motor plate.
rrectness of i
l purpos
nform
mercia
at
m
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o
his
te
2.24 Operating without current

a
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2.24.1 Glass panel
C py
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rig ht
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by lksw
cted agen
Prote AG.
Note
♦ In the event of power failure, front glass panel near to sliding

sunroof motor can be moved by hand using a commercially
available hexagon key.
♦ Front glass panel must only be moved until its front edge is
flush with front edge of rear glass panel. If glass panel is
moved further backwards, mechanism cables may hook off.

WARNING
On some models, a ribbon cable is bonded to the light cut-out

web. For the emergency key, carefully detach ribbon cable
from web and push it to side. Ensure that ribbon cable is not
damaged when doing this.

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es, in part or in w
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format
m
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Cop py
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by lksw
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Prote AG.
– Carefully detach ribbon cable -5- (if fitted) from web -1-.
– Pull ribbon cable to side -arrow- using a commercially availa‐
ble hexagon key -4- until access is made possible through hole
in web -1-.
– Guide hexagon key -4- through hole in web -1- into bolt -3- of
sliding sunroof motor -2-.
When turning by hand, greater force is necessary since motor is
not uncoupled from drive.
2.24.2 Sun blind
Note
In the event of power failure, sun blind can be moved by hand on

sun blind motor using a commercially available hexagon key.


– Insert hexagon key -2- into bolt of sun blind motor -1-.
When turning by hand, greater force is necessary since motor is
not uncoupled from drive.
2.25 Cleaning water drain hoses
Note
For cleaning, a locally manufactured tool made from a speedom‐

eter inner cable, approx. 2300 mm long is recommended.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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au ra
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nl
pt
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ab
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spec
t to the co
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or
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ate
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2.25.1 Front water drain hoses
lkswage es n
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th or
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nl
pt
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ab
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spec
The front water drain hoses run through the A-pillars and end at
t to the co
the bulkhead cross member. Cleaning is done from panorama

sliding roof cut-out.
rrectness of i
cial p
nform
mer
a
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tion
co
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2.25.2 Rear water drain hoses
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nl
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ab
ility
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spec
The rear water drain hoses run through the D-pillars and end in
the rear wheel housings. Cleaning is done from the wheel hous‐
t to the co
ing. The wheel housing liner must be removed.
rrectness of i
cial p
nform
mer
atio
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63 – Bumpers
1 Front bumper
1.1 Tools
Special tools and workshop equipment required AG. Volkswagen AG d
agen oes
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♦ Torque wrench -V.A.G 1783- byV
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spec
t to the co
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1.2 Repairing bumper cover

by lksw
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Note
If bumper cover is damaged, determine whether plastic can be

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

Body Repairs ; Plastic repair procedures
222 Rep. Gr.63 - Bumpers

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1.3 Assembly overview - bumper cover
ir se
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V ua
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th or
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1 - Bolts
ce
le
un
pt
❑ 2 Nm
an
d
itte
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rm
2 - Bolt
ab
pe
ility
❑ 3.5 Nm
ot
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3 - Cover
hole
spec
❑ Material PP/EPDM
es, in part or in w
t to the co
⇒ page 223
4 - Bolt
rrectness of i
l purpos
❑ 2 Nm
n
ercia
5 - Bolt
format
❑ Qty. 8
m
com
ion
❑ 2 Nm
in
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Prote AG.
1.4 Removing and installing front bumper

cover
Note
The removal and installation procedures may have to be modified

slightly depending on variations in equipment.
1.4.1 Removing
– Vehicles with headlight washer system, pull washer jet with
cover cap up out of bumper cover onto stop and unclip cover
cap.
– Remove bolts -5- from below.
1. Front bumper 223

– Remove bolts -4- and -1- (point upwards) on left and right in
area of wheel housing liner.
Further dismantling requires the assistance of a second mechan‐
ic.
– Pull bumper cover -3- parallel out of guide profiles with help of
a second mechanic.
– Disconnect all electrical connections from electrical compo‐
nents and separate hoses.
AG. Volkswagen AG d
agen oes
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tho eo
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pt
du
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ab
ility
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spec
t to the co
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ate
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1.4.2 Installing

1.5 Front bumper cover add-on parts
1 - Bumper cover
⇒ page 223
2 - Left bumper strip
❑ Different versions for
vehicles with headlight
washer system.
❑ Engaged in bumper
cover
❑ Can be levered out of
latches carefully from
outside using a plastic
wedge and removed
3 - Left air intake grille
❑ Different versions for
vehicles with fog lights.
⇒ page 226 AG. Volkswagen AG d
agen oes
lksw not
4 - Bolt d byV
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❑ 1.5 Nm horis
eo
aut ra
5 - Spoiler ss c
ce
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nl
❑ Material PC/ABS
pt
du
an
itte
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❑ Engages in cover.
erm
ab
❑ Only remove when

ility
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bumper cover is re‐

wit
, is n
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moved
hole
spec
6 - Centre air intake grille

es, in part or in w
t to the co
❑ Pull forward out of fas‐

tenings in
-direction of arrow-.
rrectness of i
7 - Bolt
l purpos
❑ 1.5 Nm
8 - Right air intake grille
nform
ercia
❑ Different versions for vehicles with fog lights.

m
at
m

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n in t
o
9 - Right bumper strip

his
ate
d
v
i
o
pr
cu
or
❑ Different versions for vehicles with headlight washer system.

f
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❑ Engaged in bumper cover t. Co py
rig
gh
❑ Can be levered out of latches carefully from outside using a plastic wedge and removed.
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1. Front bumper 225

1.5.1 Removing and installing air intake grille

Removing
Note
The removal and installation sequence is only for the left side.
Removal and installation of the right side is similar.

– Carefully swing air intake grille in direction of -arrow- so that
the outer side lug -2- does not break off.
Note
Grasp inner side of air intake grille and pull grille

AG. Voout
lkswaof
gebumper
n AG d
agen
then swing air intake grille outwardsVol
and
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oes
not
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Installing tho eo
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c
Install in reverse order ofs removal.
ce
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nl
pt
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
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o
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ate
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1.6 Front bumper cover substructure parts
1 - Right guide
❑ Bolted to bumper carrier
⇒ Item 9 (page 227) .
2 - Expanding nut
3 - Bolt
❑ 2 Nm
4 - Guide bracket
❑ Left and right
❑ To remove, unbolt bolts n AG. Volkswagen AG do
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⇒ Item 3 (page 227) Volks
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5 - Bolt ir se tee
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or
❑ Qty. 2 s au ac
s
❑ 2 Nm
ce
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nl
pt
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itte
6 - Left guide
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ab
ility
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⇒ Item 5 (page 227) .
ole,
spec
7 - Left air duct
t to the co
❑ Fastened to lock carrier.
8 - Right air duct
rrectness of i
9 - Bolt
❑ Qty. 2
cial p
nform
❑ 2 Nm
mer
a
m
tio
o
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s
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1. Front bumper 227

1.7 Assembly overview - bumper carrier
1 - Bumper carrier
2 - Bolt
❑ 60 Nm
3 - Bolt
❑ Qty. 6
❑ 8 Nm
4 - Foam element
❑ Self-adhesive AG. Volkswagen AG d
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spec
t to the co
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1.8 Installing small registration plate carrier pyri by
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– Mark the four points -5- on the grille which require drilling.
AG.
Note
The correct position of the registration plate carrier -2- is estab‐

lished by inserting the registration plate carrier guide -3- into the
recess -4- on the grille.
– Drill out the four points -5-.

Diameter of hole: 7.7 +0.2 mm
– Install registration plate carrier using the four plastic spreader
rivets -1-.

2 Front bumper, Cup Edition
2.1 Front bumper cover
2.1.1 Tools
AG. Volkswagen AG d
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2.1.2 Repairing front bumper cover cum

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2. Front bumper, Cup Edition 229

2.1.3 Assembly overview - front bumper cover
1 - Front bumper cover

❑ Material PUR/MF 17
❑ Installing ⇒ page 232
2 - Bolt
❑ Left and right
❑ Points upwards agen
AG. Volkswagen AG d
oes
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❑ Specified torque: 2 Nm d byV gu
ara
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3 - Bolt ut
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❑ Qty. 4 on each side ss
ce
e
❑ Specified torque: 2 Nm nl
pt
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4 - Bolt
erm
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ility
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❑ Left and right
wit
is n
❑ Specified torque:
h re
ole,
3.5 Nm
spec
5 - Bolt
t to the co
❑ Qty. 6.
❑ Specified torque: 2 Nm
rrectness of i
6 - Bolt
❑ Qty. 2.
cial p
❑ Specified torque:
nform
3.5 Nm
mer
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2.1.4 Removing
AG. Volkswagen AG d
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au ra
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nl
pt
du
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erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
m
io
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n in t
o
– Remove left and right side marker lights -5- ⇒ Electrical sys‐
his
ate
tem; Rep. Gr. 92 ; Removing and installing side marker lights

d
iv
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in from bumper .
p
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– Remove bolts -6- from above. rig ht
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by lksw
– Remove bolts -2- (pointing upwards) on left and right of wheel Prote
cted AG.
agen
housing.
– Unscrew bolts -3- from left and right wheel housing.
– Unscrew bolts -4- and -5- from underneath.
Further dismantling requires the help of a second mechanic.
– With help of a second mechanic pull front bumper cover -1-
parallel off vehicle.
– Disconnect electrical connectors from all electrical compo‐
nents (if fitted).

2.1.5 Installing
wage es n
Volks ot g
d by ua
ran
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tho
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s
ce
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nl
pt
du
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ab
ility
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spec
t to the co
rrectness of i
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tion
co
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his
ate
do
riv
– With help of a second mechanic, install front bumper cover

p
cum
or
-1- on lock carrier ensuring it remains parallel with vehicle

f
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When positioning front bumper cover -1-, ensure it is parallel to wing.
– Ensure joints are parallel and shut lines are equal ⇒ Body Re‐
pairs; Rep. Gr. 00; Karosseriespaltmaße; Karosserie vorn
– Start bolts -2, 3, 4, 5 and 6- and tighten these to the relevant
torque settings ⇒ page 230

2.1.6 Front bumper cover add-on parts

❑ Material PUR/MF 17
2 - End plate
❑ Left
❑ Clipped on the inside
with 4 panel clips.
bumper cover -1- is re‐
moved
. Volkswagen AG
3 - Air intake grille kswagen AG does
not
ol
❑ Left yV gu
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ris nte
❑ Secured ut
ho with four bolts eo
ra
from
ss the outside.
a c
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nl
pt
du
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itte
4 - Centre air intake grille
y li
erm
ab
❑ Clipped on the inside
ility
ot p
with 19 panel clips.
wit
is n
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spec
moved
t to the co
5 - Spoiler attachment
rrectness of i

moved
6 - Air intake grille
cial p
nform
❑ Right
mer
❑ Secured with four bolts

a
m
tion
from the outside.

co
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ate
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7 - Towing eye cap

p
cum
or
f
❑ Engaged in front bumper cover -1-

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Co py
8 - End plate t. rig
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❑ Clipped on the inside with 4 panel clips. Prote AG.
❑ Only remove when bumper cover -1- is removed

9 - Adapter
❑ Secured to the middle of the front bumper -1- with four bolts from above and four blind rivets from below.
❑ Specified torque for the 4 bolts (2 Nm).

2.1.7 Front bumper cover substructure parts
1 - Right guide
⇒ Item 9 (page 234) .
2 - Expanding nut
3 - Bolt
AG. Volkswagen AG d
❑ Specified torque: 2 Nm lksw
agen oes
not
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by
4 - Guide bracket ir se
d ara
nte
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❑ Left and right auth
ra
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nl
pt
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5 - Bolt
erm
ab
ility
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❑ Qty. 2.
wit
is n
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ole,
spec
6 - Left guide
t to the co
⇒ Item 5 (page 234) .
rrectness of i
7 - Left air duct
cial p
8 - Right air duct

nform
mer

a
m
tio
9 - Bolt
o
n in
r c
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❑ Qty. 2.
s
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Prote AG.

2.1.8 Assembly overview - front bumper carrier
1 - Front bumper carrier

2 - Bolt . Volkswagen AG
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Note



1 - Bolt
❑ Bolted from luggage
compartment (to re‐
move, remove luggage
compartment side cov‐
ers ⇒ General body re‐
pairs, interior; Rep. Gr.
70 ; Luggage and load
compartment trim )
❑ 8 Nm
2 - Bolt
❑ 5 Nm
3 - Spreader rivet
4 - Bolt
❑ Qty. 3
❑ Only on right side
❑ 2 Nm
5 - Bolt
❑ Qty. 3
❑ 5 Nm
6 - Bumper cover
⇒ page 237 n AG. Volkswagen AG do
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3.4.1 Removing
l purpos
– Remove tail lights in left and right side panels ⇒ Electrical

nform
ercia
system; Rep. Gr. 94 ; Tail lights .

m
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liner.
in t
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a
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3. Rear bumper (saloon) 237

– From luggage compartment, remove bolt -1- on left and right

(remove luggage compartment side covers ⇒ Generalgbody AG. Volkswagen AG d
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3.4.2 Installing

3.5 Rear bumper cover with add-on parts
1 - Bumper cover
⇒ page 237
2 - Spoiler
❑ Material PC/ABS
cover
❑ Can only be removed
when bumper cover is
removed
3 - Towing eye cap
cover
4 - Bumper strip
❑ Engaged in spoiler
when spoiler is removed
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3.6 Rear bumper cover substructure parts
1 - Securing strip
2 - Hexagon nut
❑ Qty. 4
❑ 2 Nm
3 - Guide
❑ Left and right
4 - Hexagon nut
❑ 2 Nm
5 - Bolt
❑ 2 Nm
6 - Bolt
❑ 2 Nm
7 - Guide bracket
❑ Left and right
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1 - Bumper carrier
2 - Bolt
❑ 20 Nm
3 - Foam element agen
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4.1 Rear bumper cover, saloon
hole
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4.1.1 Tools
rrectness of i
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♦ Pop rivet pliers -VAS 5072-
4.1.2 Repairing rear bumper cover
Note



4.1.3 Assembly overview - rear bumper cover
1 - Bolt
❑ Left and right
2 - Bolt
3 - Spreader rivet
❑ Left and right
4 - Bolt
❑ Qty. 3.
❑ Only on right side
5 - Bolt
❑ Qty. 3.
6 - Rear bumper cover
7 - Bolt
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4. Rear bumper, saloon, Cup Edition 243

4.1.4 Removing
AG. Volkswagen AG d
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– Remove luggage compartment side trim ⇒ General body re‐

rrectness of i
pairs, interior; Rep. Gr. 70 ; Trims; Luggage and load com‐

partment .
cial p

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mer
– Release quick-release screw -9- and remove diffuser -8- from

a
spoiler.
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t. rig
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– Remove bolts -2- on left and right from above.
c by lksw
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– Remove bolt -1- on left and right in luggage compartment.
Further dismantling requires the assistance of a second person.
– With the help of a second mechanic, pull rear bumper cover
-6- parallel out of guide profiles.

4.1.5 Installing
AG. Volkswagen AG d
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– With the help of a second mechanic, guide rear bumper cover

parallel into left and right guides.
Note
Ensure when fitting the rear bumper cover that it runs parallel along the left and right guide profiles.
– Install left and right spreader rivets -3-.

Ensure that joints are parallel and specified dimensions are main‐
tained ⇒ Body Repairs; Rep. Gr. 00 ; Body panel gaps/shut lines;
Body - rear
– Start bolts -1, 2, 4, 5 and 7- and tighten these to the relevant
torque settings ⇒ page 243
– Install diffuser -8- and lock quick-release screws -9-.

4.1.6 Rear bumper cover add-on parts

2 - Spoiler
❑ Engaged in rear bumper
cover -1-
when rear bumper cover
is removed
3 - Reflector
❑ Left and right
❑ Engaged in spoiler
4 - Diffuser
5 - Quick-release screw
❑ Qty. 4.
6 - Left diffuser
7 - Heat shield
8 - Pop rivet
❑ Qty. 3.
❑ Insert with pop rivet pli‐
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9 - Clip byV ua
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Volks ot g
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tee ➤
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s
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pt
4.1.7 Rear bumper cover substructure parts
du
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wit
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2 - Hexagon nut
spec
❑ Qty. 4.
t to the co
3 - Guide
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❑ Left and right
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ate
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❑ Left and right

4.1.8 Assembly overview - rear bumper carrier
1 - Rear bumper carrier

2 - Bolt
❑ Qty. 3 on each side agen
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5 Rear bumper (Variant)
5.1 Tools
AG. Volkswagen AG d
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Note
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spec


t to the co

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cial p
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5. Rear bumper (Variant) 249

1 - Bolt
❑ Qty. 7
❑ 5 Nm
2 - Spreader rivet
3 - Bumper cover
⇒ page 250
4 - Bolt
❑ 2 Nm
5 - Bolt
❑ Qty. 2
❑ 2 Nm
AG. Volkswagen AG d
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5.4 Removing and installing bumper cover

erm
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t to the co

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5.4.1 Removing
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mer
liner.
a
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or
driver.
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ate
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250
cted agen
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Rep. Gr.63 - Bumpers

Further dismantling requires the assistance of a second mechan‐

ic.
a second mechanic.
AG. Volkswagen AG d
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5.4.2 Installing
n in
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Tightening torques: gh ht
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Bolt -1-: 5 Nm Prote
cted AG.
agen
Bolt -4-: 2 Nm
Bolt -5-: 2 Nm

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5.5 Rear bumper cover with add-on parts

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1 - Bumper cover olks
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⇒ page 250
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2 - Reflector
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3 - Towing eye cap
h re
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spec
cover
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4 - Spoiler
❑ Material PC/ABS
rrectness of i
cover
l purpos

when bumper cover is
n
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fo
removed
rm
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5 - Spring clip
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6 - Cover en
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❑ Qty. 2
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8 - Retaining disc
❑ Qty. 2

5.6 Rear bumper cover substructure parts
1 - Securing strip
2 - Nut
❑ Qty. 4
❑ 2 Nm
AG. Volkswagen AG d
3 - Nut agen oes
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❑ Qty. 1 on each side rised ara
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❑ 2 Nm
ility
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5 - Guide bracket
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❑ Left and right ole,
spec
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1 - Bumper carrier
2 - Bolt
❑ Qty. 5
❑ 20 Nm
3 - Foam element
❑ USA versions only
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Volks ot g
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pt
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5.8 Assembly overview - towing bracket
1 - Bolt
❑ Sealing plugs
❑ Qty. 3
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The bolts -1- function
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plugs and seal aut the pas‐ or
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2 - Towing bracket
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spec
❑ Illustration shows tow‐
ing bracket with remov‐
t to the co
able ball head -2-
3 - Ball coupling
rrectness of i
❑ Removable ball hitch is
housed in fold-out lug‐
gage compartment floor
cial p
4 - Bolt
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mer
❑ Qty. 2 on each side a

m
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WARNING
um
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en
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t.
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Bolts -4- must always be
Co
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. C rig
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moved. py by
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5.9 Removing and installing towing bracket
5.9.1 Removing
Note
♦ The specified torques refer only to factory-installed towing brackets.

♦ Request torque specifications for other towing brackets from the manufacturers.
♦ Information on electrics can be found in ⇒ Electrical system; Rep. Gr. 94 .
– Remove rear bumper cover ⇒ page 250 .

– Remove rear silencer ⇒ Exhaust system; Rep. Gr. 26 ; Si‐
lencer with mountings .
– Remove heat shield.

wage es n
Volks ot g
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tho
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pt
du
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5.9.2 Installing
rrectness of i
DANGER!
cial p
The bolts -1- function as plugs and seal the passenger com‐
nform
partment against exhaust fumes, and must without exception

mer
be installed.
atio
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WARNING
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Bolts -4- must always be renewed after being removed.
Co
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ht
Contact surfaces between towing bracket and body must be
rig by
opy Vo
free of grease and cavity sealant.
by c lksw
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Prote AG.
Specified torques
Bolt -1-: 20 Nm

Bolt -4-: 50 Nm + turn 90° + 30° further
AG. Volkswagen AG d
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t to the co
rrectness of i
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mer
atio
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o
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en
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Cop py
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Prote AG.

64 – Glazing
1 Flush bonded windows
1.1 Tools

equipment required
♦ Removal kit for flush bon‐
ded windows -
V.A.G 1474 A-
♦ Suction lifter -V.A.G 1344- wage es n
Volks ot g
by ua
♦ Cutting tool -V.A.G 1351- rise
d ran
tee
tho
u or
♦ Windscreen removal kit - ss
a ac
V.A.G 1755-
ce
e
nl
pt
du
an
♦ Cartridge gun -V.A.G 1628-
itte
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erm
ab
♦ Cartridge heater -
ility
ot p
V.A.G 1939 A-
wit
is n
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spec
t to the co
rrectness of i
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mer
a
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Cop py
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rig ht
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by lksw
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Prote AG.
1. Flush bonded windows 259

♦ Electric cutter -
V.A.G 1561 A- AG. Volkswagen AG d
agen oes
lksw not
♦ Cutting blade - by
Vo gu
ara
V.A.G 1561/2- rised
nte
tho eo
u
♦ Scraping blade - ss
a ra
c
V.A.G 1561/8-
ce
e
nl
pt
du
an
♦ Cutter (offset) -
itte
y li
V.A.G 1561/10- erm
ab
ility
ot p
♦ Cutting blade -
wit
is n
V.A.G 1561/19-
h re
ole,
spec
♦ Double cartridge gun -
VAS 5237-
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
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ate
do
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or
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t.
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Cop py
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Vo
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by
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Prote AG.

♦ Removal wedge -T10039/1-
1.2 Materials
♦ 2K glass adhesive -DA 004 600 A2- 7) 8)
♦ 1K glass adhesive -DH 009 100 03- 9) 10)
♦ Activator -D 181 801 A1- 11)
260 Rep. Gr.64 - Glazing

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise Golf Variant 2007 ➤ , Jetta 2005
nte ➤
eo
h
a General body repairs, exterior - Edition 10.2009
ut ra
ss c
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♦ Adhesive remover -D 002 000 10- 11)
h re
hole
spec
♦ Cutting cord -357 853 999-
es, in part or in w
t to the co
rrectness of i
8) Double cartridge gun -VAS 5237- must be used to apply these materials
9) Small cartridge, 110 ml, for sealing and/or when a 400 ml cartridge alone is not
l purpos
sufficient.
n
ercia
1939 A- .
form
m
atio
com
n in
1.3 Assembly overview - windscreen r
te o
thi
sd
iva
o
r
rp
cu
fo
m
1 - Windscreen
en
ng py
i t.
Co
❑ Removing and installing Co py
⇒ page 264
t. rig
gh ht
yri by
cop Vo
2 - Windscreen adjuster
by lksw
cted agen
Prote AG.
❑ -443 845 631 A-
3 - Plenum chamber cover
❑ Only pull out of wind‐
screen seal by hand
⇒ page 262
4 - Windscreen seal
❑ Part of windscreen
5 - Spacing lip
6 - PUR adhesive sealant
❑ Cross section of bead:
width = 6.5 mm, height =
10 mm (including resid‐
ual material on window
glass and window
flange)
❑ Minimum curing period
⇒ page 276

lkswage es n
o ot g
yV
Golf Variant ed2007 ➤ , Jetta 2005 ➤
b ua
ran
ris tee
General ut body repairs, exterior - Edition 10.2009
ho
or
a ac
ss
ce
1.4
le
Assembly overview - plenum chamber cover
un
pt
an
d
itte
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rm
ab
pe
ility
1 - Plenum chamber cover
ot
wit
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❑ Only pull out of wind‐
h re
screen seal by hand
hole
spec
es, in part or in w
t to the co
⇒ page 262
rrectness of i
⇒ page 15
l purpos
3 - Windscreen
n
ercia
fo
⇒ page 264
rm
m
atio
com
4 - Plenum chamber seal
n in
r
te o
thi
5 - Windscreen seal
sd
iva
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rp
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m
en
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i t.
py Co
t. Co py
rig
gh ht
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y cop Vo
lksw
b
cted agen
Prote AG.
1.5 Removing and installing plenum cham‐

ber cover
1.5.1 Removing plenum chamber cover

– Unbolt wiper arms ⇒ Electrical system; Rep. Gr. 92 ; Wiper
system .
Caution
The plenum chamber cover must not be levered off with a tool
(wedge). The windscreen will be damaged and may subse‐
quently crack.
– Pull plenum chamber seal -4- off over entire length of plenum
chamber bulkhead -2-.

– Beginning on right, carefully pull plenum chamber cover -1-

upwards out of windscreen seal -5-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
se nte
ori eo
th
au ra
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
1.5.2 Installing plenum chamber cover

h re
ole,
spec
t to the co
Caution
Striking the plenum chamber cover can cause cracks in the

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

cial p
nform
num chamber cover -1- is easier to press on.

mer
– Position plenum chamber cover -1- on windscreen seal -5- and

a
m
tio
clip it into windscreen seal -5- using light pressure beginning

r co
n in
in the middle.
o
thi
te
sd
va
– Install plenum chamber seal -4- and windscreen wiper ⇒

i
o
pr
cu
r
Electrical system; Rep. Gr. 92 ; Wiper system .

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

Note
An insert is installed in windscreen seal of new windscreens. Remove this insert before installing plenum
chamber cover.
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
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o
n in
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thi
s
a
do
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p
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for
en
1.6 Removing and installing windscreen

ng
t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
1.6.1 Removing windscreen
by lksw
cted agen
Prote AG.
– Remove plenum chamber cover ⇒ page 262 .

– Remove A-pillar trim ⇒ General body repairs, interior; Rep.
Gr. 70 ; Pillar and side panel trim .
– Remove sun visor ⇒ General body repairs, interior; Rep. Gr.
68 ; Compartments, covers and trims .
– Remove interior mirror ⇒ General body repairs, interior; Rep.
Gr. 68 ; Interior mirror

agen
AG. Volkswagen AG d
oes Golf Variant 2007 ➤ , Jetta 2005 ➤
ksw
y Vol General body
not
guarepairs, exterior - Edition 10.2009
db ran
rise tee
o
– Slide cover -V.A.G 1474/8-
auth between windscreen -1- and dash or
ac
panel. ss
ce
e
nl
pt
– Thrust awl -V.A.G 1474/2- -2- through adhesive bead.
du
an
itte
y li
– Pull cutting cord -3- through adhesive sealing material into in‐
erm
ab
ility
side of vehicle using awl -V.A.G 1474/2- -2-.
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
– Secure inside end of cutting cord against falling out using pull
handle -V.A.G 1351/1- -3-.
cial p
nform
– Place cutting cord -2- using small tube -1- in upper area of
mer
window.
a
m
tion
o
– Lay cutting cord -2- around window and guide second end of
c
in t
r
cord inwards into interior.

o
his
te
iva
do
Ensure that cutting cord -2- lies under window in corners.
pr
cum
for
en
ng
– Secure other end of cord to reel device -V.A.G 1654- . i t.

py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
– Position reel device -V.A.G 1654- in “position I”.
– Reposition reel device -V.A.G 1654- as necessary and cut
window free.
– Use wedge -V.A.G 1474/5- to press cutting cord against win‐
dow glass while cutting in order to avoid damaging dash panel
and to create clearance at window flange.
1.6.2 Installing windscreen

Preparing used undamaged window for glazing ⇒ page 274
Preparing new window for glazing ⇒ page 274
Preparing body flange for glazing ⇒ page 275
Installation instructions ⇒ page 276 .
Minimum curing period ⇒ page 276

1.7 Assembly overview - rear window (saloon)
1 - Rear window
⇒ page 266
2 - Rear lid
glass and window
flange).
⇒ page 276
4 - Windscreen adjuster
5 - C-pillar trim
❑ Removing ⇒ General
body repairs, interior;
Rep. Gr. 70 ; Pillars and
side panel trim .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
1.8 Removing and installing rear window

rrectness of i
(saloon)
cial p
1.8.1 Removing undamaged rear window

nform
mer
– Remove C-pillar trims ⇒ General body repairs, interior; Rep.

a
m
tion
Gr. 70 ; Pillars and side trims .

co
in t
or
his
te
– Remove roof end strip ⇒ General body repairs, interior; Rep.

iva
do
Gr. 70 ; Roof trims .

pr
cum
for
en
– Remove rear shelf ⇒ General body repairs, interior; Rep. Gr.

ng
i t.
py Co
70 ; Luggage/load compartment trim . t. Co py
rig
gh ht
– Remove high-level brake light ⇒ Electrical system; Rep. Gr.
yri by
cop Vo
94 ; Additional brake lights .
by lksw
cted agen
Prote AG.
– Disconnect connections for heated rear window and window
aerial.
– Insert cutting cord into window flange using tube.

– Pull cutting cord through adhesive sealing material into inside

AG. Volkswagen AG d
of vehicle using awl -V.A.G 1474/2-
ksw
agen . oes
n
Vol ot g
d by ua
ran
e
ris tee
tho or
au ac
ss
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un
pt
an
d
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ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Pull the other end of the cord through into the interior and
counterhold using handle -V.A.G 1351/1- .
rrectness of i
– Secure inner end of cord on reel device -V.A.G 1654- .
l purpos
– Position reel device -V.A.G 1654- .

– Carefully slide cover -V.A.G 1474/8- -1- between rear window
n
ercia
and moulded headliner, remove moulded headliner securing
form
screws for this.
m
atio
com
n in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
t.
yi Co
– Position reel device -V.A.G 1654- in “position I”. . Cop py
rig
ht ht
– Move reel device according to position required and cut win‐
rig by
opy Vo
dow free. by c lksw
cted agen
Prote AG.
– Press cutting thread against window glass with plastic wedge
during cutting process, in order to have clearance at window
flange.
– Instead of reel device -V.A.G 1654- , reel device -V.A.G 1654

A- can be used.
– One suction cup can be removed from the reel device as
shown in illustration. This ensures that the reel device roller
can be guided closer to the window flange.
1.8.2 Removing broken rear window

– Protect body and interior from glass splinters.
– Remove pieces of glass up to adhesive sealing material.
– Remove C-pillar trims ⇒ General body repairs, interior; Rep.
Gr. 70 ; Pillars and side trims .

– Remove roof end strip ⇒ General body repairs, interior; Rep.

Gr. 70 ; Roof trims .
– Remove rear shelf ⇒ General body repairs, interior; Rep. Gr.
70 ; Luggage/load compartment trim .
– Remove high-level brake light ⇒ Electrical system; Rep. Gr.
94 ; Additional brake lights .
– Pull off connectors for rear window heating and aerial.
– Cover flange -2- all round with textile-reinforced adhesive
tape.
– Cut through adhesive sealing material (with remains of win‐
dow) in window aperture using electric cutter -V.A.G 1561 A-
and blade -V.A.G 1561/10- (with stop roller).
WARNING
Always wear safety goggles and leather gloves.
1.8.3 Installing rear window

Preparing new window for glazing o⇒lkspage
wage 274 es n
ot g
V
by ua
Preparing body flange for glazingir se
d ⇒ page 275 ran
tee
tho
or
Installation instructionsss⇒au page 276 . ac
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
ir va
o
p
cu
or
m
f
en
ng
t.
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Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

1.9 Assembly overview - rear window (Variant)
1 - Rear window
⇒ page 269
2 - Rear lid
glass and window
flange).
⇒ page 276
4 - Rear lid trim AG. Volkswagen AG d
agen oes
❑ Removing ⇒ General olksw not
V gu
by
body repairs, interior; rised ara
nte
Rep. Gr. 70 ; Rear lid utho eo
ra
trim ss
a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
1.10 Removing and installing rear window

do
priv
cum
or
(Variant)
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
1.10.1 Removing undamaged rear window
cop by
Vo
lksw
cted agen
Prote AG.
– Remove window frame trim ⇒ General body repairs, interior;
Rep. Gr. 70 ; Trim, insulation .
– Remove rear window wiper ⇒ Electrical system; Rep. Gr. 92 ;
Window wash/wipe system .

– Pull off connector -1- for heated rear window -arrow- and press
connecting tabs onto window.
– Pull cutting cord -1- through adhesive sealing material at lower

radius of rear window and into inside of vehicle using awl -
V.A.G 1474/2- from removal kit for flush bonded windows -
V.A.G 1474 A- .
– Lay cutting cord -1- around rear window and pull second end
of cord inwards into interior.
– Secure one end of cord to pull handle -V.A.G 1351/1- -2- toolkswage es n
ot g
counterhold. db
yV ua
ran
e
ris tee
– Secure other end of cord to reel device -1-. au
tho or
ac
ss
– Reposition reel device -1- as necessary and cut window free.
ce
le
un
pt
an
d
– Use plastic wedge to press cutting cord against window glass

itte
while cutting in order to have clearance at window flange. y li

rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.10.2 Removing broken rear window

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

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

n
ercia

form

m
atio
com
– Remove window frame trim ⇒ General body repairs, interior;

n in
r
te o
Rep. Gr. 70 ; Trim, insulation .

thi
sd
iva
– Remove rear window wiper ⇒ Electrical system; Rep. Gr. 92 ;

r
rp
cu
fo
Window wash/wipe system .

en
ng
t.
yi Co
op
– Disconnect connections for heated rear window. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Cover flange -2- all round with textile-reinforced adhesive

tape.
– Cut through adhesive sealing material (with remains of win‐
dow) in window aperture using electric cutter -V.A.G 1561 A-
and blade -V.A.G 1561/10- (with stop roller).
WARNING
Always wear safety goggles and leather gloves.
1.10.3 Installing rear window

Installation instructions ⇒ page 276 .
wage es n
Minimum curing period ⇒ page 276y Volks ot g
ua
b
ed ran
1.11 Assembly overview - side window (Variant) thoris tee
or
au ac
ss
ce
e
nl
pt
1 - Side window
du
an
itte
y li
❑ Removing side window
erm
ab
⇒ page 272
ility
ot p
wit
❑ Installing side window
is n
h re
⇒ page 273
ole,
spec
2 - Trim strip
t to the co
❑ Integral part of side win‐
dow.
3 - Seal rrectness of i
dow.
cial p
4 - Side panel
nform
mer

a
m
tion
o

c
in t
or

his
te
iva
10 mm (including pre‐
do
r
coating, residual materi‐

p
cum
or
al on window glass and

f
en
ng
t.
yi
window flange)
Co
Cop py
ht. rig
❑ Minimum curing period rig ht
py by
⇒ page 276 co Vo
by lksw
cted agen
Prote AG.
6 - Retaining clip
dow.

1.12 Removing undamaged side window

(Variant)
Note
The removal and installation sequence is only for the right side
window. The removal and installation of the left side window is
similar.
– Remove C and D-pillar trim: ⇒ General body repairs, interior;

Rep. Gr. 70 ; Trims, insulation; Pillars and side trims .
– Depending on equipment, disconnect connector from impe‐
dance converter -1-.
Vehicles with side window trim
– Carefully insert wedge -T10039/1- in direction of -arrow- under AG. Volkswagen AG d

agen
trim strip -1-. Volksw
oes
not
y gu
db ara
– Remove trim strip -1-. rise nte
tho eo
All vehicles au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Pull cutting cord -1- through adhesive sealing material at point

marked on illustration and into inside of vehicle using awl -
rrectness of i
V.A.G 1474/2- from removal kit for flush bonded windows -

V.A.G 1474 A- .
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Insert cutting cord -3- behind seal in window flange with aid of
tube -1-.
– Secure one end of cord -2- to pull handle -V.A.G 1351/1- -2-
to counterhold.
– Pull other end of cord into vehicle interior.
– Secure other end of cord to reel device -V.A.G 1654 A- -1-.
– Reposition reel device -V.A.G 1654 A- -1- as necessary and
cut window free.
– Use plastic wedge to press cutting cord against window glass
while cutting in order to have clearance at window flange.
– Instead of reel device -V.A.G 1654- , reel device -V.A.G 1654

A- can be used.
– One suction cup can be removed from the reel device -V.A.G en AG. V
olkswagen AG
1654- as shown in figure. This ensures that the reel device o- lkswag does
not
V.A.G 1654 A- roller can be guided closer to the window ed by
V gu
ara
flange. ho
ris nte
e t or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
1.13 Removing broken side window (Variant)
t to the co
Removing a broken side window is performed in the same man‐
ner as removing a broken rear window ⇒ page 270 .
rrectness of i
1.14 Installing side window (Variant)
Preparing old undamaged window for glazing ⇒ page 274
cial p

nform
mer

a
m
tio
r co
n in
Installation instructions ⇒ page 276

o
thi
e

t
sd
ir va
o
p
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.

1.15 Preparing old undamaged window for olkswagen AG.

Volkswagen AG
does
not
glazing ise
db
yV gu
ara
nte
r
ho eo
aut ra
ss c
Note
ce
e
nl
pt
du
an
itte
y li
♦ If installing an undamaged window, cut back residual adhesive
erm
ab
seal to 1...2 mm, being careful not to damage primer and ce‐
ility
ot p
ramic coating.
wit
is n
h re
♦ Remaining material serves as adhesion base for newly ap‐
ole,
spec
plied adhesive sealing compound.
t to the co
Caution
rrectness of i
Do not prime bonding surface and do not treat with a cleaning
solution. Keep bonding surface free of dirt and grease.
cial p
nform
mer
Exception: If bonding is not performed immediately after cutting
atio
back, the remaining residual material must be activated with ac‐
m
r co
tivator -D 181 801 A1- .
n in
o
thi
te
sd
ir va
1.16 Preparing new window for glazing
o
p
cum
for
en
ng
Only the applied ceramic layer and injection moulded sealing lip
i t.
py Co
with spacer rib are found on all new windows. t. Co py
rig
gh ht
yri by
Exception: rear window does not have a sealing lip or spacing lip. cop Vo
by lksw
cted agen
Prote
1 - Sealing lip
AG.
2 - Spacing lip
3 - Window
Note
The area on which the adhesive bead is applied is not precoated

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

– Then rub edge of window dry using a lint free cloth.
WARNING
Ceramic coating on window is not primer! It must be primed

before application of adhesive sealing compound! Use only
primer -D 009 200 02- !

– Now apply primer -4- evenly in one motion using applicator -

D 009 500 25- -3- to the previously cleaned area -1- of window.
Ensure that glass adhesive is applied to primed area at a distance
of approx. 2 mm from sealing lip -2-.
Drying time approx. 10 minutes
wage es n
Volks ot g
y ua
edb ran
ris tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
1.17 Touching up paint damage
t to the co
If paintwork is damaged, paint structure must be restored accord‐
ing to specifications in “Paint” workshop manual.
rrectness of i
1.18 Preparing body flange for glazing
– Cut back remaining material on body flange with electric cutter
cial p
-V.A.G 1561 A- and scraping blade -V.A.G 1561/8- , but do not
nform
remove completely.
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back, the remaining residual material must be activated with ac‐ Prote AG.
tivator -D 181 801 A1- .
Caution
Activator must not have contact with paint or the paintwork will
be damaged.
If the window flange has been repaired or partially renewed, the

area concerned must be cleaned and primed again after painting.

1.19 Installation instructions

– Apply adhesive material to primed area -1- or to trimmed seal‐
ant bead, holding double cartridge gun -VAS 5237- at right
angle to window.
WARNING
Window must be installed within 10 minutes, or adhesive prop‐

erties of glass adhesive will be impaired.
♦ Using two suction lifters -V.A.G 1344- , install glass pane in

window aperture, align to centre and press in onto spacing lip.
♦ Secure windscreen during curing period with window adjust‐
ers.
♦ It is absolutely necessary to install the plenum chamber cover
as described ⇒ page 263 .
♦ Replace stickers (e.g. for airbag) which may be installed.
♦ The activator must not come into contact with the window
heater bus bar.
♦ If the adhesive bead is too thick and the adhesive expands
onto the area of the window heating, excess adhesive must
be removed.
1.20 Minimum curing period n AG. V olkswagen AG

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three hours for all windows.

Minimum curing period is the time from bonding the window until
vehicle may be used. During this time, the vehicle must stand on
rrectness of i
a level surface at room temperature (at least 15 °C).

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Painting over twice (wet-on-wet) with glass/paint primer -D
009 200 02- - flash-off time = at least 10 minutes.


material
– Use of adhesive remover -D 002 000 10- as a cleaning solution
is recommended. Observe the appropriate safety precautions
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2 Front door windows
2.1 Tools
♦ Roller -T10314-
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2.2 Assembly overview- front door window ris
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1 - Door window
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⇒ page 279
2 - Window channel
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⇒ page 287
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3 - Mounting
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❑ Accessible from interior,
AG.
remove by turning
clockwise (to remove:
remove front door trim
Trims, insulation; Door
trims )
❑ Qty. 2
❑ 8 Nm
5 - Window regulator
⇒ page 291
6 - Cover
❑ Qty. 2
⇒ page 284
2.3 Removing and installing door window
Note
Removal and installation is described only for the right door win‐
dow. Removal and installation of the left door window is done in
the same manner.
2. Front door windows 279

2.3.1 Removing
Note
The bolt -3- is accessible from interior and exterior. From exterior the bolt has a right-hand thread. This means:
from exterior the bolt is removed by turning it to left, from interior the bolt is removed by turning it to right.
– Removing front door trim ⇒ General body repairs, interior;

Rep. Gr. 70 ; Door trim .
– Lower door window -1- until clamping bolts -3- for mounting
-2- are accessible.
Note
If the work step cannot be carried out because there is a fault with the electric window motor, remove motor to
slide window down.
Caution
Remove bolt -3- from interior by turning it clockwise.
AG. Volkswagen AG d
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Rep. Gr.64 - Glazing

– Loosen bolts -3- (do not remove) from inside by turning to right
and press clamping jaws apart.
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– Lift rear of door window -1- and swivel out of door forwards, in
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2.3.2 Installing
– Insert door window -1- in door in -direction of arrow-.
Ensure that door window -1- is properly located in window chan‐
nels.
– The bolt can now be tightened by turning to left.
Specified torque for bolt: 8 Nm.
Then test for proper function.
2.4 Adjusting door window

– Lower door window -1- until clamping bolts -3- for mounting
-2- are accessible.
Caution
Remove bolt -3- from interior by turning it clockwise.
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– Loosen bolts -3- (do not remove) from inside by turning to right
and press clamping jaws apart.
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– Applying light pressure press door window -1- in clamping

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– Tighten clamping jaws by turning bolts anti-clockwise from in‐
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Specified torque for bolt: 8 Nm.
Then test for proper function.

2.5 Assembly overview - window regulator motor
Note

⇒ page 284
2 - Bolt
❑ Qty. 3
❑ 3.5 Nm
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2.6 Removing and installing window regula‐

tor motor
rrectness of i
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Note
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♦ The removal and installation sequence is only for the right

m
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left window regulator motor is similar.

in t
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♦ The window regulator motor can also be removed with mount‐

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ing plate when door outer panel is removed.

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2.6.1 Removing
– Secure door window against sliding down with adhesive tape.
– Release connectors -arrows- using a screwdriver in
– Remove the three bolts -2-.
– Remove window regulator motor with control unit -1- from
mounting plate.
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2.6.2 Installing
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– Push window regulator motor -1- into place and reconnect

mer
connector -arrows-.
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– Move door window lightly up and down so that the splines be‐
in t
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his
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– Tighten bolts -2- window regulator motor.

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Specified torque: 3.5 Nm
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285
AG.
2. Front door windows

– Run window regulator twice in each direction to upper and

lower stops. This initiates and readies the window regulator
motor and activates the roll-back function.
AG. Volkswagen AG d
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2.7 Assembly overview - window channel
Note

♦ For a better representation the illustration is drawn without door outer panel.
1 - Window channel
2 - Trim
3 - Bolt
❑ Qty. 2
❑ 2 Nm
4 - Window frame on door inner
part
5 - Trim strip fasteners
❑ Spreader rivet or screw
6 - Window channel trim strip
❑ Depends on equipment
⇒ page 289 swagen AG. Volkswagen AG does
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2.8 Removing and installing window chan‐

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♦ Removal and installation is described only for the right window
Prote AG.
channel. The removal and installation of the left window chan‐
nel is similar.
♦ For a better representation the removal and installation is
drawn without door outer panel.

2.8.1 Removing
– Remove exterior mirror ⇒ page 331 .
– Removing door window ⇒ page 279 .
Vehicles with window channel trim strip
– Remove window channel trim strip -6- ⇒ page 289 .
All vehicles
– Pull window channel -1- out of mounting.
– Remove bolts -3- (Qty. 2) and pull trim plate -2- off in direction
of B-pillar -direction of arrow-.
– Pull window channel -1- off all around window frame -4- and
. Volkswagen AG
remove upwards out of window swa
slot.
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2.8.2 Installing

Note
To prevent wind noise, ensure window channel seats evenly

when installing.

nel trim strip
2.9.1 Removing
– Push window channel -1- in top rear area slightly to side.
– Remove spreader rivet -6- for window channel -1-.
– Pull trim strip -5- out of window channel -1- in direction of
-arrow-.
Trim -2- must not be removed.
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2.9.2 Installing
AG.
– Spray window channel with soapy water.

– Press trim strip -1- evenly in direction of -arrow- into window

channel -2- by hand.
– Then press window channel -2- fully into mounting of trim strip
-1- with roller -T 10314- .
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2.10 Assembly overview - window regulator
Note
⇒ page 291
2 - Bolt
❑ Qty. 4
❑ 8 Nm
3 - Bolt
❑ Qty. 5 agen
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4 - Drive utho eo
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5 - Mounting plate
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tor
Note
The removal and installation sequence is only for the right window
regulator. The removal and installation of the left window regulator
is similar.
2.11.1 Removing
– Remove side impact protection ⇒ page 92 .


– Remove bolts -2- from mounting plate -5-.
– Remove bolts -3- for window regulator.
– Remove window regulator -1- with drive -4- and mounting
plate -5- for window regulator motor from inner part of door.
– Disconnect connections for window regulator motor
⇒ page 285 .
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2.11.2 Installing
Carry out functional check before installing door outer panel.

3 Rear door window (saloon)
3.1 Tools

equipment required
♦ Release tool -T10236-
♦ Roller -T10314-
1783-
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3. Rear door window (saloon) 293

3.2 Assembly overview - rear door window
Note
1 - Door window
⇒ page 294
2 - Window channel
❑ Component part of fixed
door window
⇒ page 297
3 - Fixed door window
❑ Part of widow channel.
⇒ page 297
4 - Window regulator guide
5 - Spreader plug
❑ Always renew when
working on door window
6 - Spreader pin
7 - Cover
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❑ Removing and installing lksw
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⇒ page 302
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Note
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The removal and installation sequence is only for the rear right
door window. The removal and installation of the rear left door
nform
ercia
window is similar.
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294
AG.
Rep. Gr.64 - Glazing

3.3.1 Removing
Note
When door outer panel has been removed the spreader pin and
spreader plug to remove door window are accessible from exte‐
rior.
– Remove rear door trim ⇒ General body repairs, interior; Rep.

Gr. 70 ; Door trim .
– Lower door window until spreader pin -3- and spreader plug
-4- in cut-out of window regulator is accessible.
Note
AG. Volkswagen AG d
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Note
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out of door window.
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mer
– Remove window regulator motor ⇒ page 302 .

a
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– Lower door window fully.
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♦ When installing door window, always renew spreader plug and

spreader pin.
♦ Before inserting spreader plug and spreader pin check washer
for damage.
– With door window -1- removed insert spreader plug -3- in mid‐
dle - centralised.
– Press spreader pin -2- flush into spreader plug -3-.
– Remove window slot seal ( ⇒ Item 1 (page 123) ).
– Guide door window -1- into door and insert door window into
mounting of window regulator guide -4-.
– With light pressure from above -arrow-, engage window -1- in
– Install window slot seal ( ⇒ Item 1 (page 123) ) again.
Carry out functional test function before installing door trim.

3.4 Assembly overview - door with fixed window with window channel
Note
1 - Window channel
door window
⇒ page 297
❑ Part of widow channel.
⇒ page 297
part
⇒ page 300
5 - Spreader rivet
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3.5 Removing and installing door with fixed

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nform
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Note
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p
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or
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t.
tion of the left door fixed window with window channel is
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3.5.1 Removing
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– Pull window channel -4- out of middle frame -1- and guide
h re
window channel inwards.
hole
spec
es, in part or in w
– Remove bolts -2- and -3- and slide middle frame -1- down‐
t to the co
wards -arrow A-.
– Pull middle frame -4- off fixed door window seal -arrow B-.
rrectness of i
l purpos
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– Release window channel -1- with fixed door window -2- on in‐
AG.
side and outside from window frame -4-.

– Using release tool -T10236- release locking lugs on guide pin
-3- in window frame -4-.

Remove window channel trim strip -4- ⇒ page 300 .
All vehicles
– Pull complete window channel -1- with fixed door window -2-
off window frame -3- in -direction of arrow-.

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3.5.2 Installing
erm
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Specified torque for bolts -2- on middle frame: 5.5 Nm spec

Specified torque for bolts -3- on middle frame: 4.5 Nm

t to the co
Note
rrectness of i
When installing fixed door window with window channel ensure it

is seated uniformly (wind noise).
cial p
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– Push window channel -1- in top front area slightly to side.
– Remove spreader rivet -5-.
rrectness of i
– Pull trim strip -4- out of window channel -1- in direction of
l purpos
-arrow-.
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3.6.2 Installing

– Press trim strip -1- evenly -arrow- into window channel -2- by
hand.
with roller -T 10314- .
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3.7 Assembly overview - window regulator motor
Note
1 - Connector
2 - Bolt
❑ Qty. 3
❑ 3.5 Nm
⇒ page 302
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regulator motor. The removal and installation of the left window
AG.
regulator motor is similar.
3.8.1 Removing
– Removing door trim ⇒ General body repairs, interior; Rep. Gr.
70 ; Door trim .


– Remove window regulator motor with control unit -3- from
mounting plate.
AG. Volkswagen AG d
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3.8.2 Installing
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– Push window regulator motor -3- into place and reconnect

connector -1-.
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– Tighten bolts -2- window regulator motor.

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3.9 Assembly overview - window regulator
Note
⇒ page 305
2 - Bolt
❑ Qty. 4
❑ 8 Nm
3 - Mounting plate
4 - Drive
5 - Bolt
❑ Qty. 2
❑ 8 Nm
AG. Volkswagen AG d
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i
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3.10.1 Removing
– Remove bolts -2- from mounting plate -3-.
– Remove bolts -5- for window regulator.
– Remove window regulator -1- with drive -4- and mounting
plate -3- for window regulator motor from inner part of door.
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Carry out functional check before installing door outer panel.

4 Rear door window (Variant)
4.1 Tools
♦ Roller -T10314-
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4. Rear door window (Variant) 307

4.2 Assembly overview - rear door window
Note
1 - Door window
⇒ page 308
2 - Window channel
door window
⇒ page 312
❑ Removing and installing wage
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⇒ page 312 y Volks ot g
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❑ Part of assembly carrier
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⇒ page 317
n
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10 - Bolt
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❑ Qty. 8
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Note
♦ The removal and installation sequence is only for the rear right
door window. The removal and installation of the rear left door
window is similar.
♦ Outer window slot seal need not be removed.

4.3.1 Removing
– Remove rear door trim ⇒ General body repairs, interior; Rep.
Gr. 70 ; Door trim .
– Lower door window completely.
– Remove screws -2- and pull trim -1- towards B-pillar
– Lever out cap -5-.

– Lift door window until spreader pin -3- and spreader plug -4-
in cut-out of window regulator is accessible.
Note
If the procedure cannot be carried out because there is a fault with

the electric window regulator, remove electric window motor to
slide window down.
– Screw a 5 mm bolt (approx. 70 mm long) into spreader pin

-3-.
– Screw an 8 mm bolt (approx. 80n Amm
G. Volong)
lkswaginto spreader plug
en AG
-4-. wage does
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– Pull window slot inner seal -6- off door inner panel.
t to the co
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4. Rear door window (Variant)

– Pull door window upwards -arrow- out of window slot.
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4.3.2 Installing
d ran
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♦ When installing door window, always renew spreader plug and
pe
ility
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hole
spec
for damage.
es, in part or in w
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dle - centralised.
rrectness of i
– Press spreader pin -2- flush into spreader plug -3-.
l purpos
– Guide door window -1- into door and insert door window into
n
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f
– With light pressure from above -arrow-, engage window -1- in
mounting of window regulator guide -4-. orm
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Carry out functional test function before installing door trim.

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4.4 Removing and installing window slot

outer seal
4.4.1 Removing
– Remove door window ⇒ page 309 .

– Lever spreader clip -4- out of clip -3- using a small screwdriver.
– Pull the four clips -3- out of the window slot seal -2-.
– Pull window slot seal -2- upwards off door outer panel -1-.
4.4.2 Installing
4.5 Assembly overview - door

agen
AGwith
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nel trim strip
hole
spec
es, in part or in w
t to the co
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⇒ page 316
l purpos
3 - Window channel
⇒ page 312
nform
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4 - Clip
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⇒ page 312
8 - Bolt
❑ Qty. 2
❑ 5.5 Nm
part

4.6 Removing and installing door with fixed

window with window channel
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The removal and installation sequence is only for thethright
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4.6.1 Removing
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– Remove door window ⇒ page 309 .
wit
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– Remove window slot outer seal ⇒ page 310 . hole
spec
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– Lever out both caps -3-.
t to the co
– Remove both bolts -2- from middle frame -1-.
rrectness of i
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– Pull window channel rubber -3- off trim -2- in direction of

-arrow A-.
– Remove bolts -1- and pull off trim -2- in direction of
-arrow B-.

AG. Volkswagen AG d
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General body repairs, exterior ra
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ss
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– Remove spreader rivet -5- for window channel trim strip -1-.
erm
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– Release window channel -2- with fixed door window -3- on in‐
ole,
spec
side and outside from window frame -4-.
t to the co
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n
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– Pull middle frame -3- out of clips -2- and window channel -1-.
– Take fixed door window -5- out of window channel -1-.

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Spray window channel with soapy water when installing.

t to the co

Use a new clip when installing middle frame.
rrectness of i
Note
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When installing fixed door window with window channel ensure it

nform
is seated uniformly (wind noise).

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nel trim strip
4.7.1 Removing
– Remove spreader rivet -5- for window channel trim strip -1-.
– Pull trim strip -1- out of window channel -2-.
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4.7.2 Installing
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– Press trim strip -1- evenly -arrow- into window channel -2- by
mer
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at
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AG. Volkswagen AG d
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4.8 Assembly
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Vol
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❑ 3.5 Nm
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l purpos
⇒ page 317
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tor motor
4.9.1 Removing
Note
The removal and installation sequence is only for the right window regulator motor. The removal and installation
of the left window regulator motor is similar.
– Removing door trim ⇒ General body repairs, interior; Rep. Gr.

70 ; Door trim .


– Pull connector -1- in direction of -arrow- off window regulator
motor with control unit -3-.
– Remove window regulator motor with control unit -3- from as‐
sembly carrier.
AG. Volkswagen AG d
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4.9.2 Installing
in t
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ate
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v
– Install window regulator motor with control unit -3-.

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– Reconnect connector -1- to window regulator motor with con‐
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trol unit -3- (in opposite direction of -arrow-).

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rig
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cop by
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Prote AG.

66 – Exterior equipment
1 Wheel housing liner
1.1 Tools
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
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form
m
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Prote AG.
320 Rep. Gr.66 - Exterior equipment

1.2 Assembly overview - front wheel housing liner
Note
♦ Only the left side is shown. The right side is similar.

♦ The removal and installation procedures may have to be modified slightly depending on variations in equip‐
ment.
♦ The wheel housing liner consists of a front and a rear part.
1 - Wheel housing liner rear

part
❑ Material: PP/EPDM
2 - Bolt
❑ Qty. 7
❑ 2 Nm
3 - Wheel housing liner front
part
4 - Bolt
❑ Qty. 11
❑ 2 Nm
5 - Expanding nut
AG. Volkswagen AG d
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t to the co
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cial p
1.3 Removing and installing front wheel

nform
mer
housing liner
a
m
tion
co
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Note
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The removal and installation sequence is only for the left wheel
en
ng
i t.
py Co
housing liner. Removal and installation of the right wheel housing Co py
liner are similar.
t. rig
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Prote AG.
1. Wheel housing liner 321

1.3.1 Removing
Wheel housing liner rear part
– Remove wheel ⇒ Running gear, axles, steering; Rep. Gr. 44 ;
Specified torques for wheel bolts .
– Remove bolts -4- (Qty. 3) at transition of front and rear parts
of wheel housing liner
– Remove bolts -2- (Qty 7).
– Pull off rear part of wheel housing liner -1-.
Wheel housing liner front part
– Pull off front part of wheel housing liner -3-.
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ercia
1.3.2 Installing
m
at
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n in t

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322
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Rep. Gr.66 - Exterior equipment
Prote AG.

1.4 Assembly overview - rear wheel housing liner
Note
1 - Wheel housing liner

2 - Bolt
❑ Qty. 9
❑ 2 Nm
3 - Expanding nut
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spec
1.5 Removing and installing rear wheel

es, in part or in w
t to the co
housing liner
rrectness of i
Note
l purpos
The removal and installation sequence is only for the left wheel
housing liner. Removal and installation of the right wheel housing
nform
ercia
liner are similar.

m
a
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tio
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n in
1.5.1 Removing
o
thi
te
sd
va
– Remove wheel ⇒ Running gear, axles, steering; Rep. Gr. 44 ;

i
o
pr
cu
Specified torques for wheel bolts .

or
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323
co Vo
by lksw
Prote
cted AG.
agen 1. Wheel housing liner


– Pull off wheel housing liner -1-.
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es, in part or in w
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rrectness of i
l purpos
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1.5.2 Installing
iva
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Co py
1.6 Installing protective cover for wheel
t. rig
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housing y cop Vo
lksw
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Prote AG.
1.6.1 Installing
– Clean contact surfaces of bumper cover and wheel housing
liner so that they are free of dust and grease. We recommend
isopropyl alcohol.
– Remove protective backing -1- from protective cover -2-.

– Stick protective cover -2- on approx. 28.7 mm from -A-, where

the highest point of the protective cover -2- and the upper edge
of the bumper cover -3- are used as reference points.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
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au ra
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es, in part or in w
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n
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form
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rig
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Prote AG.
1. Wheel housing liner 325

2 Exterior mirror
2.1 Tools
♦ Removal lever -80-200-
AG. Volkswagen AG d
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ate
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Prote AG.

2.2 Assembly overview - exterior mirror
Note
1 - Mirror housing
❑ Material: ABS.
⇒ page 328
2 - Mirror mounting
⇒ page 331
3 - Bolt n AG. Volkswagen AG do
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❑ Qty. 3 d by V ua
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❑ 8 Nm uthor tee
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4 - Bolt ss
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nl
pt
❑ Qty. 2
du
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❑ 1 Nm
erm
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5 - Assembly part
wit
is n
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ole,
⇒ page 330
spec
6 - Bolt
t to the co
❑ Qty. 2
❑ 1 Nm
rrectness of i
7 - Side turn signal repeater
⇒ page 330
cial p
nform
8 - Trim
mer
a
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t
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⇒ page 329 n in
o
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9 - Bolt
o
p
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❑ Qty. 1
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t.
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❑ 1 Nm
Co
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10 - Ambient light rig ht
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Prote AG.
11 - Adjuster unit with motor for exterior mirror
12 - Mirror glass
2. Exterior mirror 327

2.3 Removing and installing mirror glass
Note
The removal and installation sequence is only for the left mirror
glass. The removal and installation of the right mirror glass is
similar.
2.3.1 Removing
WARNING
When doing this repair work, always wear safety goggles and
leather gloves!
– Protect edge of housing -1- against damage to paintwork with

e.g. fabric-reinforced adhesive tape.
– Press bottom of mirror glass -2- into mirror housing -1-.
– Using removal lever -80-200- , lever -arrow 6- mirror glass
-2- off adjuster unit with mirror -5-.
. Volkswagen AG
gen AG d
– Swivel mirror glass -2- to side -arrow
olks 4- and detach connectors
wa oes
not
-3- for electric dip and mirror yV
bheating on rear of mirror glass gu
ara
ed
nte
-2-. thoris
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nl
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2.3.2 Installing
rrectness of i
– Push connectors onto mirror glass.

– Press mirror glass centrally onto adjuster unit with motor in
cial p
nform
housing.
mer
– Mirror glass engages audibly.

m
tion
co
in t

or
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ate
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2.4 Removing and installing mirror housing

pr
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Note
C
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by lksw
The removal and installation sequence is only for the left mirror cted agen
Prote AG.
housing. The removal and installation of the right mirror housing
is similar.

2.4.1 Removing
– Remove mirror glass ⇒ page 328 .
– For ease of assembly, fold exterior mirror forwards.
– Using a screwdriver underneath the locking hooks -2- press
mirror housing out of fastening.
– Pull mirror housing slightly forward off mirror base carrier at
front.
– Then pull mirror housing -1- upwards off mirror base carrier.
2.4.2 Installing
olkswagen AG
en AG. V
– Place mirror housing -1- on mirror base carrier and pressksw mir‐
ag does
not
Vol
ror housing down until the locking hooks -2- engage
ed
b audibly.
y gu
ara
ris nte
– Install mirror glass again ⇒ page 328 . utho eo
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t to the co
2.5 Removing and installing trim
rrectness of i
Note
cial p
nform
The removal and installation sequence is only for the left trim
mer
plate. The removal and installation of the right trim plate is similar.
a
m
tio
o
n in
r c
te o
2.5.1 Removing
thi
s
a
do
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p
c
um
for
en
ng
t.
– Remove mirror housing ⇒ page 328 .
yi Co
Cop py
t. rig
– Using a screwdriver lever locking hooks -2- out of mirror base
gh ht
pyri by
carrier.
co Vo
by lksw
cted agen
Prote AG.
– Pull trim plate -1- off in -direction of arrow-.
2.5.2 Installing

2.6 Removing and installing side turn signal

repeaters
Note
♦ The removal and installation sequence is only for the left side
mounted turn signal. The removal and installation of the right
side turn signal repeater is similar.
♦ The side turn signal repeaters are fitted with long-life light-
emitting diodes (LEDs) instead of conventional bulbs.
♦ Therefore, changing bulbs is not necessary. In case of dam‐
age, the entire turn signal must be renewed.
2.6.1 Removing
wage es n
– Remove mirror glass ⇒ page 328 yV .
o lks ot g
ua
d b ran
e
– Remove mirror housing ⇒thopage
ris 328 . tee
u or
a ac
– Remove trim ⇒ page 329
ss .
ce
e
nl
pt
– Remove bolts -4- and remove assembly part -1- downwards.
du
an
itte
y li
– Detach connector -5- from turn signal -3-.
erm
ab
ility
ot p
– Remove bolts -2- and take turn signal -3- off assembly part
wit
is n
-1-.
h re
ole,
spec
t to the co
rrectness of i
2.6.2 Installing
cial p
nform

mer
a
m

ion
co
in t
or
2.7 Removing and installing entry light

his
ate
do
priv
cum
or
f
en
ng
t.
Note
i
py Co
t. Co py
rig
gh ht
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The removal and installation sequence is only for the left entry
by
cop Vo
light. The removal and installation of the right entry light is similar.
by lksw
cted agen
Prote AG.
2.7.1 Removing
– Remove mirror housing ⇒ page 328 .
– Remove trim ⇒ page 329 .

– Remove assembly part with turn signal repeater ⇒ page 330 .

– Swing entry light -2- out downwards and pull bulb out of entry
light housing.
AG. Volkswagen AG d
agen
2.7.2 Installing Volksw
oes
not
gu
d by ara
e
Install in reverse order of removal. thoris nte
eo
au ra
Specified torque for entry light bolt: 1 Nm
ss c
ce
e
nl
pt
du
an
itte
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erm
2.8 Removing and installing adjustment unit
ab
ility
ot p
with motor for exterior mirror
wit
is n
h re
ole,
spec
Note
t to the co
The removal and installation sequence is only for the left adjust‐
ment unit with motor. The removal and installation of the left
rrectness of i
adjustment unit with motor is similar.
2.8.1 Removing
cial p
nform
mer
a
m
tion
co
in t
or
– Remove adjustment unit with motor -2- and disconnect con‐
his
ate
nector.
do
iv
pr
cum
or
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
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cop by
Vo
lksw
cted agen
Prote AG.
2.8.2 Installing
Specified torque for adjustment unit with motor: 1 Nm
2.9 Removing and installing exterior mirror
Note
The removal and installation sequence is only for the left exterior
mirror. The removal and installation of the rear view mirror is sim‐
ilar.

2.9.1 Removing
– Removing front door trim on driver's side ⇒ General body re‐
pairs, interior; Rep. Gr. 70 ; Door trim .
– Release cable retainer -2- and detach connector -1- for exte‐
rior mirror.
– Lever cap -3- out of door and remove bolts -2-.

– Remove exterior mirror -1- and guide wire through aperture in
door.
2.9.2 Installing
AG. Volkswagen AG d
Specified torque for exterior mirror bolts: 8 Nm agen oes
olksw not
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by ara
Test function before installing door trim. rised
nte
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ility
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hole
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es, in part or in w
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rrectness of i
l purpos
n
ercia
form
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atio
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n in
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Cop py
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co
332
by lksw
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Rep. Gr.66 - Exterior equipment Prote AG.

3 Roof railing
3.1 Tools
♦ Torque wrench 5…50 Nm -V.A.G 1331-
AG. Volkswagen AG d
agen oes
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♦ Plastic wedge -T10039/1-
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
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n in
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thi
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s
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p
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t. Co py
rig
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Prote AG.
3. Roof railing 333

3.2 Assembly overview - roof railing
1 - Roof railing
⇒ page 334
2 - Bolt
❑ 20 Nm
3 - Roof railing rear cover
4 - Roof railing middle cover
5 - Roof railing front cover
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ility
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ole,
spec
t to the co
rrectness of i
3.3 Removing and installing roof railing

cial p
nform
3.3.1 Removing
mer
a
m
– Using wedge -T10039/1- , lever out front and rear roof railing
ion
co
covers -1- in direction of -arrow-.

in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Lever front and rear covers of roof railing -1- in direction of

-arrow A- and press them in direction of -arrow B-.
– Pull out cover for roof railing -1-.
– Remove bolt -3- from front and rear roof railing mounting -2-
(20 Nm).
– Pull middle cover -1- off roof railing -3- in direction of -arrow-.
– Remove bolt -2- from middle roof railing mounting -3- (20 Nm).
wage es n
Volks ot g
by ua
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ility
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hole
spec
es, in part or in w
t to the co
3.3.2 Installing
rrectness of i
l purpos
Check roof railing covers for damage and replace as necessary.
n
ercia
form
m
atio
com
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te o
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Cop py
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by lksw
cted agen
Prote AG.
3. Roof railing 335

4 Radiator grille
4.1 Tools
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
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th
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du
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erm
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ility
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wit
is n
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ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
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rig
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cop by
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cted agen
Prote AG.

4.2 Radiator grille
4.2.1 Assembly overview - radiator grille
1 - Radiator grille
2 - Bolt
❑ Qty. 4
3 - VW emblem
❑ Clipped into radiator
grille
❑ Removing: release lock‐
ing hooks on rear of
company emblem and
remove by turning it in
opposite direction to
-arrow c-.
❑ Installing: guide VW em‐
blem with locking hooks
into recesses in radiator wage es n
olks
grille -arrow b-, then d by turn
V ot g
ua
slightly in direction
o
ir se of
ran
tee
-arrow c- until
au VW em‐
th or
ac
blem engages
ss in radia‐
tor grille
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
fo
4.2.2 Removing
rm
m
atio
com
n in

r
te o
thi
– Release clips -arrows- from lock carrier using a small screw‐

sd
iva
o
r
driver.
rp
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fo
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en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Radiator grille 337

– Tilt radiator grille -1- forwards slightly and pull it upwards out
of bumper cover.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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nl
pt
du
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erm
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ility
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4.2.3 Installing
wit
is n
h re
ole,
– Insert radiator grille -1- into bumper cover mounting from

spec
above and tilted forwards slightly.

t to the co
– Tilt radiator grille -1- towards lock carrier and locate clips
-arrows- in lock carrier.
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
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o
p
cu
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f
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t. Co py
rig
gh ht
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cop by
Vo
lksw
cted agen
Prote AG.

– Install bolts -2- (2 Nm).
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
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ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
form
m
atio
com
n in
r
te o
thi
sd
iva
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rp
cu
fo
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en
ng
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rig
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cop by
Vo
lksw
cted agen
Prote AG.

4.3 Radiator grille, Cup Edition
4.3.1 Assembly overview - radiator grille
1 - Radiator grille
2 - Bolt
❑ Qty. 2.
3 - Locking lug
❑ Qty. 6.
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
te
iva
do
pr
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4.3.2 Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ir se nte
tho eo
au ra
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un
pt
an
d
itte
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rm
ab
pe
ility
ot

wit
, is n
h re
– Release clips -arrows- from lock carrier using a small screw‐

hole
spec
driver.
es, in part or in w
t to the co
– Tilt radiator grille -1- backwards slightly and pull locking hooks
-3- upwards out of front bumper cover.
rrectness of i
l purpos
n
ercia
format
m
com
ion
in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

4.3.3 Installing
wage es n
Volks ot g
y ua
edb ran
ir s tee
tho
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– With radiator grille -1- tilted forward slightly place locking

wit
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hooks -3- in front bumper cover.
ole,
spec
– Tilt radiator grille -1- towards lock carrier and locate clips t to the co
-arrows- in lock carrier.
rrectness of i
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4.3.4 Removing and installing emblem

Removing
– Release locking hooks -arrows- on rear of emblem -2- with
radiator grille removed -1-.
– Turn emblem -2- in -direction of arrow- slightly and pull em‐
blem forwards out of radiator grille -1-.
Installing
– Guide emblem -2- with locking hooks in recesses of radiator

. Volkswagen AG
grille -1-. swa
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– Turn emblem
se
db -2- in -direction of arrow- until emblem
ua
ran -2- en‐
gages oriwith radiator grille -1-. tee
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Golf Variant 2007 ➤ , Jetta 2005 ➤ d by
V ot g
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General body repairs, exterior - Edition 10.2009 horise
tee
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5 Mouldings and trims
un
pt
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5.1 Tools
wit
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hole
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♦ Double cartridge gun -VAS 5237- Cop
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♦ Hot air blower -V.A.G 1416-

5.2 Removing and installing side panel trim

strips on GLI vehicles
5.2.1 Removing
– Remove bolts -1- (Torx T25) from body.
– Remove side panel trim strip -2- in direction of -arrow-.
As necessary
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– Slide retainer -2- forwards and aurelease it as described ac
ss
-arrow-.
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– Remove damaged bolts -1-.
an
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Note
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spec
The part number for bolts -1- deviates from the production num‐
ber. Refer to parts department.
t to the co
rrectness of i
5.2.2 Installing
cial p
nform
– Clean side panel and retainer to remove adhesive remains,
mer
we recommend isopropyl alcohol.

a
m
tio
As necessary
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– Install bolts -1-. Specified torque: 1.2 ±0.1 Nm

s
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– Install retainer -2-, by checking that all bolts fit in their respec‐
um
for
en
tive holes then slide retainer forwards.

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Continuation for all cases
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5. Mouldings and trims 345

– Starting at rear of retainer, position side panel trim strip -2-

over retainer -4-.
– Secure front of side panel trim strip -2- using a bolt -1-. Speci‐
fied torque: 2 ±0.5 Nm.
– Remove protective backing -3- from double-sided tape of side
panel trim strip -2- using a wedge.
– Secure side panel trim strip -2- by pressing it onto body.
– Install remaining bolts -1- (Qty. 3). Specified torque: 2 ±0.5
gen AG
. VolkNm
swagen AG
wa does
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5.3 Side member extension, Jetta Cup Edi‐
ce
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tion
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Note
, is n
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hole
spec
The removal and installation sequence is for the left side member
es, in part or in w
(sill) extension. The removal and installation of the right side
t to the co
member (sill) extension is similar.
rrectness of i
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n
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5.3.1 Assembly overview
1 - Side member extension

❑ Lower adhesive surface
❑ Bead cross section:
width = 8 mm; height = 8
mm
3 - Bolt
❑ Specified torque: 2 ±0.5
Nm
❑ Upper adhesive surface
❑ Bead cross section: gen AG
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width = 8 mm; height = 8 y V olk not
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❑ Minimum curing aperiod
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5 - Spacer
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❑ At front and rear.
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6 - Bolt
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❑ Qty. 2 per spacer
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5.3.2 Removing
Note
The side member extension cannot be removed without being damaged.
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es, in part or in w
t to the co
rrectness of i
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WARNING
n
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fo
Clean all surrounding parts before beginning work and mask

rm
them with tape.

m
atio
com
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Do not use cutting wire to remove side member extension

r
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-1-.
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– From below, remove bolts -6- from front and rear spacers py
rig by
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– Before removing, heat side member extension -1- in bonding
AG.
surface areas -2- and -4- with hot air blower -V.A.G 1416- .

– Lift a corner of side member extension -1- using wedge

-3409- .
– Firmly holding corner, forcefully pull side member extension
-1- from side panel.
Note
Cut bonding using suitable equipment, if required.
5.3.3 Installing
wage es n
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t to the co
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– Installation instructions ⇒ page 353 . rig ht
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– Preparing body component for bonding ⇒ page 352 cted agen
Prote AG.
– Preparing new add-on part for bonding ⇒ page 353

– Apply 2K glass adhesive -DA 004 600 A2- to sealing surfaces
-3- and -4- evenly along the complete length of the side mem‐
ber extension -1- using double cartridge gun -VAS 5237- .
– Apply 2K glass adhesive -DA 004 600 A2- to front and rear
spacers -5-.

– Install side member extension -1- on side member, start at rear

wheel housing and use assistance of a second mechanic. en AG. Volkswagen AG
wag does
– Then tighten bolt -2-. olks not
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– Press side member extension -1- on firmly uand
tho secure it with eo
textile adhesive tape. ss
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– Loosen bolts -6- on front and rear spacers -5-.
nl
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– Move front and rear spacers -5- so that they are in full contact
erm
ab
with side member.
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– Then tighten bolts -6- on spacer -5-.
h re
hole
spec
es, in part or in w
Note
t to the co
The side member extension -1- must lie evenly on the side member over the complete length, otherwise a
perfect bond cannot be guaranteed.
rrectness of i
l purpos
• Minimum curing period ⇒ page 354
nform
mercia
at
m
io
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n in t
o
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6 Special add-on parts
6.1 Safety requirements
Caution
When removing special add-on parts, use suitable gloves and

protective eyewear.
Special add-on parts must cure at least 3 hours after being
bonded before work on the vehicle is continued.
Note
♦ The following special add-on parts have been developed to

fulfil the technical requirements of the respective models.
These special add-on parts should always be replaced with
the corresponding genuine parts.
♦ Without these special add-on parts, the vehicle will not comply
with the traffic regulations.
6.2 Fitting notes for extensions
Note
♦ The side member extension are applied with adhesive at the

factory. agen
AG. Volkswagen AG d
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♦ The side member
ed by
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extensions are supplied primed
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♦ Ensure
ss the side member extension adhesive surfaces remain c
free of paint and paint mist when painting extensions.
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6.3 Materials
ab
ility
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♦ 2K glass adhesive -DA 004 600 A2-

h re
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spec
♦ Static mixer with tapered noz‐ -D 002 001-

zle
t to the co
♦ Primer -D 009 200 02-

rrectness of i
♦ Cleaning solution -D 009 401 04-
♦ Primer applicator -D 009 500 25-

cial p
nfo
♦ Adhesive remover -D 002 000 10-

mer
rmatio
m
♦ Activator -D 181 801 A1-

o
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Observe instructions for use on the information sheet provided by
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the manufacturer.
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6. Special add-on parts 351

Heat 1-K glass adhesive according to manufacturer's instructions,

using cartridge heater -V.A.G 1939A- .
6.4 Special add-on parts, Jetta Cup Edition
1 - Radiator grille
❑ Installing ⇒ page 232 AG. Volkswagen AG d
agen oes
olksw not
3 - Scuff protection film d by
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❑ Renewing ⇒ page 355 tho
ri
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4 - Side member extension ss
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6.5 Preparing body kit component for bond‐

ing
Note
Remaining material serves as adhesion base for newly applied

adhesive sealing compound. Keep dirt and grease off of bonding
surfaces.
Exception: If bonding is not performed immediately after cutting

back, the remaining residual material must be activated with ac‐
tivator -D 181 801 A1- .

WARNING
Activator must not have contact with paint or the paintwork will
be damaged.
Note
If the body kit part has been repaired or partially renewed, the
area concerned must be cleaned and primed again after painting.
6.6 Preparing new add-on part for bonding
WARNING
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Mask off primed and bonding surfaces properly db
y before paint‐
V ua
ran
ing. orise
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– Immediately before bonding add-on parts, clean bonding sur‐

nl
pt
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face thoroughly with adhesive remover -D 002 000 10- .
itte
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– Now apply plastic primer -D 009 600- using applicator -D 009
hole
spec
500 25- equally in one stroke.
es, in part or in w
t to the co
• Drying time approx. 10 minutes
• The body component must be prepared for bonding.
rrectness of i
– A thin coat of 2K glass adhesive -DA 004 600 A2- must be
applied evenly to the primed surfaces of the add-on parts with
l purpos
the double cartridge gun -VAS 5237- .
nform
ercia
6.7 Installation instructions

m
at
The surfaces to be primed for the body kit parts should be com‐
m
io
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n
pletely clean.
in t
o
his
te
– Remove adhesive residue using adhesive remover -D 002 000

a
d
iv
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10- .
p
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– Soak cloth in silicon remover -LSE 020 100 A3- .

t.
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– Clean area of application for adhesive bead twice thoroughly
ht ht
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using cloth soaked with solution and allow to dry. co Vo
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– Now apply glass/paint primer using applicator -D 009 500 25-
AG.
evenly in one stroke.

♦ Drying time approx. 10 minutes
– Adhesive sealant must be applied to the primed areas of the
add-on parts.
WARNING
Body kit parts should be installed within 10 minutes, or bonding

properties of adhesive will be impaired.
♦ Gap dimensions should be kept to an absolute minimum, up

to approx. 1 mm.
6. Special add-on parts 353

♦ Use adhesive tape to secure add-on parts in position during

minimum curing time.

The minimum curing period for newly bonded attaching parts is 3
hours.
The minimum curing time is the time from bonding the add-on
parts until the vehicle may be used. During this time, the vehicle
must stand on a level surface at room temperature (at least 15 °
C). n AG. Volkswagen A
age G do
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WARNING ris
ed ran
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Vehicle is safe to use only after the curing
ss period is completed.
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Paint structure must be restored according to specifications in the
, is n
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“Paint” workshop manual.
hole
spec
es, in part or in w
t to the co
material
– Use adhesive remover -D 002 000 10- as a cleaning solution.
rrectness of i
Observe the appropriate safety precautions when performing
this work.
l purpos
– First clean painted surface as well as possible using a dry
nform
ercia
cloth. Remove residue using adhesive remover -D 002 000

10- .
m
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Golf
genVariant
AG. Volks2007
wagen➤
AG,dJetta 2005 ➤
swa oes
Generaly Vbody repairs, exterior - Edition
olk not10.2009
gu
db ara
rise nte
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ut ra
7 Protective backing ss
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7.1 Scuff protection film
ab
pe
ility
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7.1.1 Tools
spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
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7.1.2 Fitting notes
by
cop by
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Prote AG.
Note
♦ Before removal, heat the scuff protection film with a hot air
blower -V.A.G 1416- .
♦ If the scuff protection film is installed for the first time on a new
vehicle and newly painted surfaces, the procedure in ⇒ Work‐
shop manual "Paint"; ⇒Paintwork repairs; ⇒Paint finish;
⇒Mouldings & Film should be observed.
♦ If the scuff protection film is removed and reinstalled, only use
adhesive remover -D 002 000 10- to remove the adhesive re‐
mains.
♦ Ensure that the adhesive surfaces are free of dust and grease.
♦ Bond scuff protection film immediately after cleaning.
♦ Pull protective backing off only directly prior to installation.
♦ The working temperature is approx. 21 °C.
♦ The scuff protection film cannot be removed without damage.
7. Protective backing 355

7.1.3 Renewing scuff protection film
Note
Renewing scuff protection films is described only for the left side. The right side is similar.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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t to the co
rrectness of i
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Prote AG.
Removing
– Remove inner seal for front door in area of side member
⇒ page 93 .
– Heat front scuff protection film -1- using a hot air blower -V.A.G
1416- and pull scuff protection film -1- from sill.
Installing
– Clean installation area with adhesive remover -D 002 00 10- .
– Pull off protective backing -2-.
– Position front scuff protection film -1- on the references points
-a- = 155 mm and press it smooth using a plastic blade wrap‐
ped in a soft paper towel.

AG. Volkswagen AG d
agen oes Golf Variant 2007 ➤ , Jetta 2005 ➤
olksw not
V
ed by General body
gu
ara repairs, exterior - Edition 10.2009
ris nte
utho eo
ra
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ss
8 Lettering
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8.1 Tools
ility
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8.2 Installation instructions for lettering and
f
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emblems Cop py
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Note
AG.
♦ Before removal, heat lettering or emblem with a hot air blower

-V.A.G 1416- .
♦ If the lettering or emblem is installed for the first time on a new
vehicle and newly painted surfaces, the procedure in ⇒ Work‐
shop manual "Paint"; ⇒Paintwork repairs; ⇒Paint finish;
⇒Mouldings & Film should be observed.
♦ If the lettering or emblem is removed and reinstalled, only use
adhesive remover -D 002 000 10- to remove the adhesive re‐
mains.
♦ Ensure that bonding surfaces are free of dust and grease.
♦ Bond lettering or emblem immediately after cleaning.
♦ Pull protective backing off only directly prior to installation.
♦ The working temperature is approx. 21 °C.
8. Lettering 357
8.3 Rear lettering dimensions (saloon)
1 - Dimension -a- = 25 mm
❑ From outer edge of rear
lid to lettering
2 - Dimension -b- = 15 mm
❑ From lower edge of tail
light aperture in rear lid
to upper edge of letter‐
ing
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Volks ot g
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t to the co
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ate
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Prote AG.

8.4 Rear lettering dimensions (Variant)
8.4.1 Lettering (Golf Variant)
❑ Lower edge of lettering
to height of lower edge
of rear light -1-
❑ Transfer -dimension a-
from outer edge of rear
lid to lettering.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ab
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t to the co
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8. Lettering 359
8.4.2 Lettering (Jetta Variant)
❑ Transfer -dimension a-
from outer edge of rear
lid to lettering.
❑ Lower edge of lettering
to height of upper edge
of rear light -1-
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Prote AG.

8.5 Side lettering dimensions - Individual
8.5.1 Dimensions for emblem on left wing

❑ Transfer -dimension a -
from lower edge of wing
to wing.
❑ Transfer -dimension b-
from end point of dimen‐
sion a to corner of em‐
blem.
3 - Dimension -c- = 70 mm n AG. Volkswagen AG do
wage es n
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❑ Use -dimension c- to edb
y V ua
ran
check distance from up‐ ho
ir s tee
per edge of emblem to aut or
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edge of wing. ss
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4 - Dimension -d- = 92 mm
an
itte
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❑ Use -dimension d- to
erm
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check distance from
ility
ot p
lower edge of emblem to
wit
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edge of wing.
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t to the co
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8.5.2 Dimensions for emblem on right wing

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Service: Golf Variant 2007 Jetta 2005

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Service: Golf Variant 2007 Jetta 2005

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Service olksw

Service Department. Technical Information

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1.2 Assembly overview - bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.3 Removing and installing bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.4 Removing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.5 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.6 Removing and installing lid hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.7 Removing and installing insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.8 Assembly overview - bonnet latch and release components . . . . . . . . . . . . . . . . . . . . . . . . 23

1.10 Disconnecting Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2 Rear lid (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.2 Assembly overview - rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.3 Removing and installing rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.4 Removing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.5 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.6 Removing and installing lid hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.2 Removing and installing tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5 Fuel tank flap unit (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.1 Assembly overview - tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

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1.3 Assembly overview - door assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

1 Sliding/tilting sunroof with glass panel (Meritor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

1.3 Assembly overview - sliding/tilting sunroof with glass panel . . . . . . . . . . . . . . . . . . . . . . . . 163

1.4 Removing and installing bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

1.7 Adjusting panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

1.8 Renewing panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

1.10 Removing and installing sliding headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1.14 Checking parallel running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

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1.17 Removing and installing carrier unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

1 Front bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

1.2 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

1.3 Assembly overview - bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

1.4 Removing and installing front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

1.7 Assembly overview - bumper carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

2 Front bumper, Cup Edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

2.1 Front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

3 Rear bumper (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

3.2 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

3.3 Assembly overview - bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

3.4 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

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5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

1.4 Assembly overview - plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

1.5 Removing and installing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

1.7 Assembly overview - rear window (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

1.13 Removing broken side window (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nform 273

1.15 Preparing old undamaged window for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

1.16 Preparing new window for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

1.17 Touching up paint damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

1.18 Preparing body flange for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

1.19 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

3.10 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

4.7 Removing and installing window channel trim strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316