Phaeton

Body Manual

Student Reference
Volkswagen of America, Inc.
Service Training
Printed in U.S.A.
Printed 08/2003

©2003 Volkswagen of America, Inc.

All rights reserved. All information contained

in this manual is based on the latest
information available at the time of printing
and is subject to the copyright and other
intellectual property rights of Volkswagen of
America, Inc., its affiliated companies and its
licensors. All rights are reserved to make
changes at any time without notice. No part
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the publisher.

All requests for permission to copy and

redistribute information should be referred
to Volkswagen of America, Inc.

Always check Technical Bulletins and the

Volkswagen Worldwide Repair Information
System for information that may supersede
any information included in this booklet.

Trademarks: All brand names and product

names used in this manual are trade names,
service marks, trademarks, or registered
trademarks; and are the property of their
respective owners.
 Table of Contents
Specifications ................................................................................................ 1

Front Bumper and Fenders .......................................................................... 2

Front Bumper Support ................................................................................. 3

Rear Bumper .................................................................................................. 4

Hood ............................................................................................................... 5

Front Doors .................................................................................................... 6

Rear Doors ..................................................................................................... 8

Luggage Compartment Lid ........................................................................ 10

Exterior Lights ............................................................................................. 14

Mirrors .......................................................................................................... 15

Glass ............................................................................................................. 16

Exterior Trim ................................................................................................ 18

Sunroof ........................................................................................................ 20

Instrument Panel ......................................................................................... 21

Console ........................................................................................................ 23

Interior Trim ................................................................................................. 26

Luggage Compartment Trim ...................................................................... 28

Front Seats .................................................................................................. 31

Rear Seats .................................................................................................... 32 New!

Vehicle Identification Number Plate .......................................................... 33

Bonded Joints ............................................................................................. 34

Body Insulation ........................................................................................... 35

Body Cavity Sealing .................................................................................... 39

Body Repair ................................................................................................. 40

Special Tools ................................................................................................ 45

Important/Note!
The Service Training Student Reference provides you
with information regarding designs and functions.
The Service Training Student Reference
is not a Repair Manual!
For maintenance and repair work, always refer to
the current technical literature

i
 Specifications
Specifications

57.09 in
(1450 mm)

64.09 in 63.46 in
(1628 mm) (1612 mm)
74.92 in
(1903 mm)

44.13 in 113.43 in 41.38 in

(1121 mm) (2881 mm) (1051 mm)
199.02 in
(5055 mm) SSP270/118

• Length • Rear track width

199.02 inches (5055 mm) 63.46 inches (1612 mm)
• Width • Permitted gross vehicle weight
74.92 inches (1903 mm) 5732 – 6592 pounds (2600 – 2990 kg)
(depending on the engine)
• Height
57.09 inches (1450 mm) • Curb weight
4398 – 5320 pounds (1995 – 2413 kg)
• Wheelbase
(depending on the engine)
113.43 inches (2881 mm)
• Luggage compartment space
• Turning circle
17.7 cubic feet (500 liters)
39.4 feet (12 m)
• Drag coefficient
• Fuel tank capacity
0.32 CD
23.8 gallons (90 liters)
• Front track width
64.09 inches (1628 mm)

1
Front Bumper and Fenders

The front bumper

components are plastic.

The spoilers and chrome

trim strips are attached
with clips and can be
replaced separately.

VOA889-003a

The front bumper and fenders

are attached with screws from
the inside.

The front fenders are plastic.

Special Fasteners

VOA889-003b

Front Fenders – Repair Group 50

2 Bumpers – Repair Group 63
 Front Bumper Support

VOA889-004a

The Right Distance

Regulation Sensor G259
is attached to the front
right bumper deformation
element on Phaetons
equipped with the Adaptive
Cruise Control feature.

VOA889-004b

The sensor cover must

only be painted with
millimeter-wave permeable
color. It must not be
recoated on the inside or
the outside, and must not
be covered.

An additional support is installed

between the longitudinal frame members
just behind the front bumper components.

Metal
Plastic

VOA889-004c

Bumpers – Repair Group 63

3
Rear Bumper

The rear bumper

components are plastic.

VOA889-010a

Trailer hitch options

may vary depending
upon marketing area.

The chrome trim covers for

the exhaust system are
attached to the rear bumper.

Metal
Plastic
VOA889-010b

Bumpers – Repair Group 63

4
 Hood

Hood height can be adjusted using

the stop screws at the hinges.

The hood is aluminum.

VOA889-005

Hood – Repair Group 55

5
Front Doors

Door seals are self-adhesive.

The door seals

cannot be removed
without damage. If
removed, they must
be replaced.

Newly developed
window guides ensure
smooth operation and
reduce wind noise.

The front doors are

aluminum. Laser-welded
aluminum die castings and
extruded sections provide
four times the rigidity of a
conventional design.

Metal
Rubber

VOA889-006

Front Doors – Repair Group 57

6
 Front Doors

Basic front door design is similar

to other Volkswagen models.

VOA889-007

Front Doors – Repair Group 57

7
Rear Doors

Door seals are self-adhesive.

The door seals

cannot be removed
without damage.
If removed, they
must be replaced.

Newly developed
window guides ensure
smooth operation and
reduce wind noise.

The rear doors are aluminum. Metal

Laser-welded aluminum die Rubber
castings and extruded sections
provide four times the rigidity
of a conventional design.

VOA889-008

Rear Doors – Repair Group 58

8
 Rear Doors

Basic rear door design is similar

to other Volkswagen models.

VOA889-009

Rear Doors – Repair Group 58

9
Luggage Compartment Lid

The standard luggage compartment lid is opened

and closed manually with an electrical assist.

Emergency opening is achieved mechanically

with the key inserted in the lock mechanism
in the VW emblem on the lid.

Lids – Repair Group 55

10
Luggage Compartment Lid

Metal

VOA889-024

Lids – Repair Group 55

11
Luggage Compartment Lid

To open the power-assisted luggage

compartment lid, operate either
the switch on the door panel, the
microswitch in the VW emblem on
the lid, or the radio remote control.
Emergency opening is achieved
mechanically with the key
inserted in the lock mechanism
in the VW emblem on the lid.

The Rear Lid Lock Button (in Luggage Compartment) E406

in the luggage compartment lid is used to close the lid.

Lids – Repair Group 55

12
Luggage Compartment Lid

The power-assisted
luggage compartment lid is
opened and closed by an
electro-hydraulic mechanism.

Metal
Aluminum

VOA889-025

Lids – Repair Group 55

13
Exterior Lights

All front lighting elements except

fog lights are integrated into the
front headlight housings.

Standard lighting includes xenon headlights

with gas discharge low-beam lamps and
HB 3 high-beam lamps.

Front fog lights are

mounted in the bumper.
They use H11 lamps
behind transparent lenses.

The rear seats

must be removed
to replace the center
high-mounted
brake light. Rear light elements
are LEDs, except for the
backup lights which use
a replaceable HPL bulb.

Rear light assemblies are

alignment adjustable.

VOA889-026

Exterior Lights – Repair Group 94

14
 Mirrors

The inside rearview mirror is attached to

a mounting plate on the windshield.

Special Fastener
Glass

The outside rearview mirrors feature

power adjustment, power fold, automatic
dimming, side turn signal lights, and
surround lighting.

The outside mirror housing,

turn signals, and surround
lighting components can all
be replaced separately.
VOA889-011

Exterior Mirrors – Repair Group 66

Interior Mirrors – Repair Group 68 15
Glass

The Phaeton windshield is not precoated.

New windshields must be pretreated in
accordance with Repair Manual instructions
before installation.
Rain/Light Recognition Sensor G397 is
installed at the top center of the windshield.

The rubber seal bonded

to the windshield can be
replaced separately.

Glass
Rubber

VOA889-012

Glass – Repair Group 64

16
 Glass

The rear window is not precoated.

New rear windows must be pretreated
in accordance with Repair Manual
instructions before installation.

Tungsten heating elements

and all antennas are integrated
into the rear window.

The rubber seals

bonded to the
rear window can
be replaced separately.

Glass
Rubber

VOA889-013

Glass – Repair Group 64

17
Exterior Trim

The plastic clips that retain

the roof trim strips are wedged
into the roof joint.

The metal roof rack mounts are fastened

to the roof joint channel with screws.

Plastic
Metal
Aluminum

VOA889-014

Exterior Trim – Repair Group 66

18
 Exterior Trim

The rain channel

moldings at the
A-pillars are attached
with riveted
retaining clips.

Metal
Glass
Rubber
Aluminum

VOA889-015

Exterior Trim – Repair Group 66

19
Sunroof

A tilt and slide sunroof is available

on the Phaeton.
The wind deflector is controlled
electro-mechanically to reduce
wind noise and drafts, depending
on the driving speed and the
amount the sunroof is open.
The sunshade moves at the
same time that the sunroof glass
is opened or closed, but it can
also be separately controlled
electrically regardless of the
position of the glass.

Plastic
Glass

VOA889-020

Sunroof – Repair Group 60

20
 Instrument Panel

The instrument panel top

covers and panels can be
replaced separately.

The front parking

aid displays in the
defroster panel are
a new feature.

Wood trim elements are

replaceable separately.

VOA889-016

Interior Trim – Repair Group 70

21
Instrument Panel

The multi-part instrument panel

is attached to an aluminum carrier Instrument panel
that also acts as an air duct. alignment to
door trim panels
is optimized by
the use of
special shims.

Special Parts

VOA889-017

Interior Trim – Repair Group 70

22
 Console

Four-seat Phaetons have

full-length center consoles.

Full-length center consoles include

front and rear seat center armrests,
cupholders, phone and miscellaneous
storage, rear air vents, rear seat
controls, and rear AC controls.

VOA889-030

Interior Trim – Repair Group 70

23
Console

VOA889-031

Interior Trim – Repair Group 70

24
 Console

Five-seat Phaetons have

short center consoles.

Short center consoles

include front seat center
armrests, cupholders,
phone and miscellaneous
storage, and rear air vents.

VOA889-032

Interior Trim – Repair Group 70

25
Interior Trim

The interior trim panels are

fastened with a combination
of clips and screws.

The sides of the rear shelf

trim panel are connected
to the bottom edges of the
C-pillar trim panels.

Plastic

VOA889-018

Interior Trim – Repair Group 70

26
 Interior Trim

The roof insulation and

reinforcements are bonded.
The headliner is held in place
by the pillar trim panels.

The carpeting provides noise insulation and

is comprised of three separate sections.
The insulation panel forward of the
instrument panel is installed flush with the
bottom of the windshield.

If this insulation panel is

damaged during windshield
replacement, it must also
be replaced.

Plastic
Metal

VOA889-019

Interior Trim – Repair Group 70

27
Luggage Compartment Trim

The luggage compartment

trim panels are fastened
with a combination of clips
and screws.

Plastic
Metal

VOA889-021

Interior Trim – Repair Group 70

28
Luggage Compartment Trim

VOA889-022

Interior Trim – Repair Group 70

29
Luggage Compartment Trim

Several control modules are

installed on the insulation panel
under the rear shelf.

There is an additional trim panel

Plastic in the luggage compartment
behind the rear seatback.
VOA889-023

Interior Trim – Repair Group 70

30
 Front Seats

Front seats are new

designs and are available
in 12-way and 18-way
adjustable versions.

Different front seat variants have different

comfort features depending upon their
configuration and optional equipment.

The optional automatic lap belt

must be separated from the
18-position front seats in order
to remove these seats.

All front seats on the Phaeton

are equipped with an active
headrest system.

VOA889-028

Seat Frames – Repair Group 72

Seat Upholstery, Covers – Repair Group 74 31
Rear Seats

The Phaeton is available with a

standard or premium full-width rear
bench seat, or 10-position individual
rear seats with a center console
between them.
Different rear seat variants
have different comfort features
depending upon their configuration
and optional equipment.

VOA889-029

Seat Frames – Repair Group 72

32 Seat Upholstery, Covers – Repair Group 74
 Vehicle Identification Number Plate

In addition to the VIN located on the front left

edge of the instrument panel that is visible
through the windshield, the vehicle identification
number is stamped in the upper support for
the right front fender.
The model designation is 3D.
D
3

Special Parts

PR lables are attached to the body in the

luggage compartment just forward of the
spare wheel recess.

VOA889-027

General – Repair Group 00

33
Bonded Joints

In addition to welding, high-stress areas of

the body are reinforced with an epoxy resin
bond to ensure rigidity.

Epoxy Adhesive

VOA889-037

34
 Body Insulation

Body insulation is used to reduce

noise levels in the Phaeton.

Some body insulation is installed

during body shell assembly

Special Parts

VOA889-033

35
Body Insulation

Special Parts

VOA889-034

36
 Body Insulation

Some body insulation is applied during

final body assembly stages.

Special Parts

VOA889-035

37
Body Insulation

Special Parts

VOA889-036

38
 Body Cavity Sealing

Special Body Cavity Sealing Areas

VOA889-038

39
Body Repair

The Phaeton main body

structure consists of high-grade
and super high-strength steels
and is completely galvanized
for corrosion protection.

VOA889-039

Body Front Section – Repair Group 50

40
 Body Repair

VOA889-040

Body Center Section – Repair Group 51

41
Body Repair

VOA889-041

Body Center Section – Repair Group 51

42
 Body Repair

Plastic

VOA889-042

Body Rear Section – Repair Group 53

43
Body Repair

VOA889-043

Body Rear Section – Repair Group 53

44
 Special Tools

After the body shell has been assembled, the

attachment points for the steering gear (at alignment
fixture reference points 15) are gauged in reference
to the suspension strut tower attachment points
(at alignment fixtures 8 and 9).
Adjustments are made using welded shims to
achieve the tolerances required by the steering gear.

These shims are available

as replacement parts.

VAS 6130

VOA889-044b

VAS 6130

VOA889-044d

45
Special Tools

The headlight mounts

must be aligned using portal
gauge VAS 5007 with
alignment fixtures 44 and 45
before welding them into
position or the panel joints
will be misaligned.

Alignment fixtures 42, 43,

44, and 45 are supplied with
portal gauge VAS 5007/14.

Airbag sensor mounts must be

welded in place using VAS 5007
with alignment fixtures 42 and 43.

They should be installed

after completing other
body repairs to minimize VAS 5007/14
variations caused
by welding.

VOA889-045a

46
Special Tools

VAS 5007/14

VOA889-045b

47
Notes

48
Notes

49
Volkswagen of America, Inc.
3800 Hamlin Road
Auburn Hills, MI 48326
Printed in U.S.A.
August 2003