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Volkswagen Golf V: Lock carrier Page 1 / 6

50 - 1

Lock carrier
Tools

Required special tools, workshop equipment, testing and


measuring equipment, and aids

„ Guide rod T 10093

„ Torque wrench 550 Nm V.A.G 1331

„ Torque wrench 40200 Nm V.A.G 1332

Lock carrier service position, assembly overview


Lock carrier Page 2 / 6

„ Lock carrier with attachments

„ Removing and installing


50-1, Lock carrier with
attachments, removing and
installing

„ Service position 50-1,


Service position

„ Screw

„ Qty 4

„ 8 Nm

„ Screw

„ Qty. 8

„ 60 Nm
Lock carrier Page 3 / 6

Service position

Performing service position

- Remove front bumper 63-1, Front


bumper cover, removing and installing

- Disengage hood release cable in


coupling 55-1, Hood release cable,
disconnecting

- In vehicles with charge air cooler,


disconnect pressure hoses 50-1,
Releasing pressure hoses .

- Remove signal horn - 4 - with bracket


from longmember at right side
Lock carrier Page 4 / 6

Repair Manual, Electrical Equipment,


Repair Group 96, Lights, lamps, interior
switch, signal horn, removing and
installing

- Unscrew bolts - 3 - at left and right


longmembers.

- Screw in guide rod T 10093 at left and


right longmembers.

- Remove bolts - 2 - at left and right on


top of lock carrier - 1 - .

- Lock carrier - 1 - can be pulled toward


front approx. 10 cm on guide rod T
10093 .

Resetting service position

Installation is performed in the reverse order of removal.

- Center lock carrier on side rails and between fenders

Repair Manual, Body Collision Repair, Repair Group 00,


Technical data; Body gap dimensions

Note:

„ Make sure that pressure hoses for charge air cooler


are re-engaged correctly.

„ Hoses and lines must not be pinched.

Releasing pressure hoses

- Disengage connector coupling - 1 - and disconnect


Lock carrier Page 5 / 6

pressure hose - 2 - in - direction of arrow - from


coupling.

- When re-connecting pressure hoses, make sure that


connector couplings engage audibly.

Lock carrier with attachments, removing and installing

Removing

- Perform service position of lock carrier


with attachments - 1 - 50-1,
Performing service position .

- Disconnect the electrical harness


connectors present.

- Drain coolant and disconnect coolant


lines
Lock carrier Page 6 / 6

Repair Manual, 2.0 Liter 4-Cyl. 4V


Turbo Engine Mechanical, Fuel Injection
Ignition, Engine Code(s): BPY, Repair
Group 19, Cooling system parts; draining
and filling coolant

- Disconnect condenser lines

Repair Manual, Heating Air


Conditioning, Repair Group 87, A/C
system; removing and installing
condenser

- With a second technician, unscrew


guide rod T 10093 on longmember on
left and right sides and lift out lock
carrier.

Warning!

If lines for A/C system and/or for coolant are


disconnected, the powertrain aggregate must no
longer be started.

Note:

„ Do not hang condenser and hydraulic oil cooler on


hoses.

„ Lines for condenser and hydraulics must not be


kinked.

Installing

Installation is performed in the reverse order of removal.

„ Make sure that all plug and hose connections are


corrected installed when re-assembling.

- Center lock carrier on side rails and between fenders

Repair Manual, Body Collision Repair, Repair Group 00,


Technical data; Body gap dimensions
Volkswagen Golf V: Fender Page 1 / 6

50 - 2

Fender
Tools

Special tools, testers and auxiliary items required

„ Torque wrench 210 Nm V.A.G 1783

„ Heat gun V.A.G 1416

Front fender, assembly overview

Note :

„ The illustration shows the left side. The right side is


similar and can be determined from this.
Fender Page 2 / 6

„ Fender

„ removing and installing


50-2, Fender, removing and
installing

„ Screw

„ Qty. 1, A-pillar

„ Qty. 2, side member

„ Qty. 2, wheel housing

„ Qty. 2, fender brace

„ Qty. 3, fender connecting


piece

„ 6 Nm
Fender Page 3 / 6

„ Foam piece

„ Loosely inserted between


fender and upper
longmember

„ Fender brace

„ Removing and installing


50-2, Fender brace,
removing and installing

„ Molded foam part

„ Placed on upper
longmember.

„ Secures at fender.

„ Hex nut

„ Qty. 1, at fender connecting


piece

„ 6 Nm

Fender, removing and installing

Note:

„ Removing and installing is described only for the left


fender. Removing and installing right fender is
derived accordingly from this.

Removing
Fender Page 4 / 6

- Remove front bumper 63-1, Front


bumper cover, removing and installing

- Remove wheelhousing liners 66-1,


Front wheel housing liner, removing and
installing

- Unscrew guide profile Item - 10 -

- Loosen hex nut - 6 - and remove bolts


- 2- .

- Pull out foam piece - 3 - between


fender and longmember.

- Lightly heat fender - 1 - from outside in


area of molded foam element - arrow -
with hot air gun V.A.G 1416 .

- The adhesive on molded foam element


- 5 - loosens and fender - 1 - can be
removed.
Fender Page 5 / 6

Installing

Installation is performed in the reverse order of removal.

- Make sure gaps are parallel and pay attention to gap


dimensions

Repair Manual, Body Collision Repair, Repair Group 00,


Technical data; Body gap dimensions

Fender brace, removing and installing

Note:

„ Removing and installing is described only for the left


fender brace. Removing and installing right fender
brace is derived accordingly from this.

Removing

„ Fender is removed.

- Remove screws - 2 - and remove fender brace - 1 - .

Installing
Fender Page 6 / 6

- Assemble the fender brace - 1 - .

- Tightening torques: Bolts - 2 - 6 Nm.

- Fender brace is installed together with fender to hood


and bumper:

Repair Manual, Body Collision Repair, Repair Group 00,


Technical data; Body gap dimensions
Volkswagen Golf V: Noise insulation Page 1 / 3

50 - 3

Noise insulation
Tools

Special tools, testers and auxiliary items required

„ Torque wrench 210 Nm V.A.G 1783

Noise insulation panel, assembly overview

Note :

„ Slight changes may have to be made to removal and


installation procedures, depending upon engine
installed in vehicle.
Noise insulation Page 2 / 3

„ Noise insulation

„ - Arrow - points in direction


of travel.

„ Removing:

- Remove bolts - 2 - and -


3 - .

„ Screw

„ Qty. 8

„ 2 Nm

„ Screw

„ Qty. 3
Noise insulation Page 3 / 3

„ 6 Nm
Volkswagen Golf V: Underbody trim Page 1 / 3

50 - 4

Underbody trim
Tools

Special tools, testers and auxiliary items required

„ Torque wrench 210 Nm V.A.G 1783

Underbody trim, assembly overview

Note :

„ The illustration shows the left side. The right side is


similar and can be determined from this.
Underbody trim Page 2 / 3

„ Underbody cover

„ - Arrow - points in direction


of travel.

„ Removing:

- Remove hex nuts - 2 - .

„ Hex nut

„ Qty. 8

„ 1.5 Nm

„ Rear underbody cover

„ Only installed on the left


side.
Underbody trim Page 3 / 3

„ Removing:

- Remove hex head nuts -


4 - and screws - 5 - .

„ Hex nut

„ 1x

„ 1.5 Nm

„ Screw

„ Qty. 3

„ 2 Nm

„ Cover

„ Removing:

- Remove bolts - 7 - .

„ Screw

„ Qty. 2

„ 2 Nm
Volkswagen Golf V: Plenum chamber bulkhead Page 1 / 2

50 - 5

Plenum chamber bulkhead


Tools

Special tools, testers and auxiliary items required

„ Torque wrench 210 Nm V.A.G 1783

Plenum chamber bulkhead, assembly overview


Plenum chamber bulkhead Page 2 / 2

„ Plenum chamber bulkhead

„ Hex nut

„ 8 Nm

„ Seal for plenum chamber


bulkhead

„ Ensure seal is seated


correctly when installing
bulkhead.

„ Screw

„ 8 Nm
Volkswagen Golf V: Front hood Page 1 / 18

55 - 1

Front hood
Tools

Special tools, testers and auxiliary items required

„ Torque wrench 550 Nm V.A.G 1331

„ Pry lever - RMV outside mirror 80-200

Hood, assembly overview


Front hood Page 2 / 18

„ Hood

„ Removing and installing


55-1, Hood, removing and
installing

„ Adjusting 55-1, Hood,


adjusting

„ Adjustment buffer

„ Qty. 2

„ Adjusting 55-1, Hood,


adjusting

„ Stop buffer

„ Qty. 2
Front hood Page 3 / 18

„ Insulation

„ Removing and installing


55-1, Noise insulation,
removing and installing

„ Guide piece

„ Qty. 2

„ Hinge

„ Removing and installing


55-1, Hood hinge, removing
and installing

„ Adjusting 55-1, Hood,


adjusting

„ Gas strut

„ Removing 55-1,
Removing gas-filled strut

„ Venting gas 55-1, Gas-


filled strut, venting

„ Hood seal

„ Secured to interior hood with


17 clips.

Hood, removing and installing

Removing
Front hood Page 4 / 18

- Remove left and right spray nozzles - 6


-

Repair Manual, Electrical Equipment,


Repair Group 92, Windshield washer and
wiper system; Windshield washer
system; Windshield washer system spray
nozzles, removing and installing

- Unclip line - 2 - from hinge - 3 - and


hood - 5 - .

- Remove line - 2 - from opening of


hood - 5 - .

- Loosen hex nuts - 1 - at left and right


(do not unscrew completely).

A second technician is required for the


rest of the removal procedure.
Front hood Page 5 / 18

- Remove gas-filled strut - 4 - at hood -


5- 55-1, Removing gas-filled strut

- Remove hex nuts - 1 - and lift hood - 5


- from hinges - 3 - .

Installing

Installation is performed in the reverse order of removal.

- Tightening torques: Hood hex head nut, 22 Nm

- Adjust hood - 1 - 55-1, Hood, adjusting

- Route line - 2 - as shown - arrow - . If line is installed


twisted, the line is kinked.

Removing gas-filled strut

- Open hood and support hood.

- Reach under spring clips - 2 - using a small


screwdriver.

- Lift spring clips - 2 - only far enough so that the spring


clips can be slid over ball socket in - direction of arrow -
.

- Remove gas-filled strut - 1 - from ball studs - 3 - and - 4


- .

After removing gas-filled strut - 1 - , immediately slide


back spring clips - 2 - again.

Warning!
Front hood Page 6 / 18

Proceed carefully when re-using gas-filled strut.


Spring clips must not be pried completely out of ball
socket, otherwise spring clips will be damaged. Gas-
filled strut springs out of mount and leads to damage
and injury to the operator.

- Tightening torques of ball studs - 3 - and - 4 - : 22 Nm.

- Gas-filled strut, venting 55-1, Gas-filled strut, venting

Gas-filled strut, venting

- Clamp gas-filled strut in vice area - x - . Dimension of -


x - = 50 mm (2 in.).

Warning!

Clamping the gas-filled strut must only be done in this


area - x - , otherwise there is a risk of an accident.

- Using saw, cut into cylindrical part of strut at point within


first third of cylinders length (measured from cover edge at
piston rod end of cylinder).

Note:

„ Always wear eye protection when performing this


procedure.

„ Cover the area of the separated portion with a clean


rag.

„ Dispose of fluid and cleaning rag in a proper


manner.

Hood hinge, removing and installing

Note:
Front hood Page 7 / 18

„ Removing and installing is described only for the left


hood hinge. Removing and installing right hood
hinge is derived accordingly from this.

Removing

- Hood, removing 55-1, Removing

- Remove screws - 2 - and remove hood hinge - 1 - .

Installing

- Assemble the hood hinge - 1 - .

- Tightening torque for bolts - 2 - : 22 Nm


Front hood Page 8 / 18

- Hood, installing 55-1, Installing

Noise insulation, removing and installing

Removing

- Using pry lever 80-200 , pry out


retaining clips - 1 - (qty. 10) from noise
insulation - 2 - .

- Pull noise insulation - 2 - out of


longitudinal holes.

Installing
Front hood Page 9 / 18

- Slide noise insulation - 2 - under gas-


filled strut and insert mounting tabs into
longitudinal holes.

- Engage all retaining clips - 1 - (qty. 10)


in noise insulation - 2 - .

„ When installing noise insulation - 2


- , make sure that retaining clips -
1 - are inserted with wide side
facing outside.

Locking and unlocking components of hood, assembly


overview
Front hood Page 10 / 18

„ Catch

„ Removing:

- Unscrew bolts - 2 - and


remove catch.

„ Adjusting:

- Catch can be adjusted


toward the left or right in its
longitudinal holes.

„ Screw

„ Qty. 3

„ 10 Nm

„ Spreader nut
Front hood Page 11 / 18

„ Qty. 2

„ Mounting bracket

„ Hood release cable

„ Clipped into mounting


bracket.

„ Screw

„ Qty. 2

„ 1.5 Nm

„ Release lever

„ Removing and installing


55-1, Release lever,
removing and installing

„ Hood release cable

„ Clipped in on wheelhousing
and lock carrier.

„ Hood release cable coupling

„ Disconnecting 55-1, Hood


release cable,
disconnecting

„ Hood lock

„ Removing and installing


55-1, Hood lock, removing
and installing

„ Adjusting 55-1, Hood lock,


adjusting

Hood lock, removing and installing

Removing
Front hood Page 12 / 18

- Open hood.

- Remove radiator grille 66-3, Radiator grille, removing


and installing

- Disconnecting hood release cable 55-1, Hood release


cable, disconnecting

- Disconnect harness connector - 5 - for Front Hood


Switch F 266 .

Harness connector is secured over right headlight.

- Remove bolts - 4 - (three pieces) on lock carrier - 3 -


and remove hood lock - 1 - upward.

- To unclip hood release cable - 2 - , press together tabs


on hood release cable - arrows - .

- The locking mechanism is released and hood release


cable - 2 - can be removed from hood lock - 1 - .

Installing
Front hood Page 13 / 18

- Clip hood release cable - 2 - into hood lock - 1 - .

- Install hood lock - 1 - in lock carrier - 3 -

- Tightening torque for bolts - 4 - : 12 Nm.

- Connect harness connector - 5 - for Front Hood Switch F


266 .

- Install hood release cable - 2 - 55-1, Hood release


cable, disconnecting .

- Adjust hood lock 55-1, Hood lock, adjusting

„ Before the hood is closed, a function test of the


release lever and hood release cable must be
performed.

Hood release cable, disconnecting

- Open hood.
Front hood Page 14 / 18

- Unclip hood release cable coupling - 1 - over headlight


on drivers side of lock carrier - 2 - .

- Open hood release cable coupling - 1 - and remove


hood release cable - 3 - in - direction of arrow - from
hood release cable coupling.

Note:

„ When installing, make sure that hood release cable


sleeve is inserted correctly and coupling is locked.

„ Before the hood is closed, a function test of the


operating lever and hood release cable must be
performed.

Hood, adjusting

- For Basic Setting of hood - 1 - , vehicle


must stand on the ground and catches
Front hood Page 15 / 18

must be removed.

- Remove catches - 9 - Item - 1 - .

- Remove gas-filled strut - 2 - at hood -


1- 55-1, Removing gas-filled strut

- By loosening hex nuts - 5 - and bolt -


3 - at left and right on hood hinge - 4 -
(do not unscrew completely), hood - 1 -
can be aligned between fenders.

- In rear area, height of hood - 1 - can


be adjusted to fenders with adjusting
screw - 6 - on left and right sides.

- Stop buffers - 7 - (qty. 2) do not serve


to adjust. Their function is to stabilize and
to cushion the hood - 1 - .

- Hood - 1 - can be adjusted in height


relative to fenders in the front area using
the stops - 8 - (qty. two).

- Ensure gap dimensions are even

Repair Manual, Body Collision Repair,


Repair Group 00, Technical data; Body
gap dimensions

- After installing or adjusting perform


corrosion protection measures on hinges
- 4 - , hex head nuts - 5 - screws - 3 -
.

- After hood - 1 - has been adjusted,


catches can be reinstalled and adjusted:
Item - 1 -

Hood lock, adjusting


Front hood Page 16 / 18

- If after closing hood the gap dimensions are no longer as


they had been adjusted, adjustment can be corrected
slightly by the hood lock and catches.

- Remove radiator grille 66-3, Radiator grille, removing


and installing

- If the bolts - 1 - are loosened now, hood gap dimensions


can be corrected or adjusted

Repair Manual, Body Collision Repair, Repair Group 00,


Technical data; Body gap dimensions

- Tightening torques: Bolts - 1 - 12 Nm

- Adjust catches Item - 1 - .

Release lever, removing and installing

Removing
Front hood Page 17 / 18

- Engage the release lever - 1 - and release hood.

- Insert a small screwdriver into gap between release lever


- 1 - and clip - 2 - .

- Remove clip - 2 - from release lever - 1 - and pull


release lever off.

Installing

- Slide clip - 2 - completely into release lever - 1 - .

- Then push release lever - 1 - onto mount in mounting


bracket and lock the release lever.

„ Before the hood is closed, a function test of the


Front hood Page 18 / 18

release lever and hood release cable must be


performed.
Volkswagen Golf V: Rear lid Page 1 / 19

55 - 2

Rear lid
Tools

Special tools, testers and auxiliary items required

„ Torque wrench 550 Nm V.A.G 1331

Rear lid, assembly overview


Rear lid Page 2 / 19

„ Rear lid

„ Removing and installing


55-2, Rear lid, removing and
installing

„ Adjusting 55-2, Rear lid,


adjusting

„ Rear lid lock

„ Removing and installing


55-2, Rear lid lock, removing
and installing

„ Adjustment buffer

„ Left and right

„ Adjusting 55-2,
Adjustment buffer, adjusting
Rear lid Page 3 / 19

„ Gas strut

„ Removing 55-2,
Removing gas-filled strut

„ Venting gas 55-2, Gas-


filled strut, venting

„ Hinge

„ Removing and installing


55-2, Rear lid hinge,
removing and installing

„ Striker pin

„ Removing and installing


55-2, Latch bracket,
removing and installing

„ Adjusting 55-2, Adjusting


latch bracket

„ Cap

„ Left and right

„ Adjustment buffer stop.

Rear lid, removing and installing

Removing
Rear lid Page 4 / 19

- Open rear lid - 1 - .

- Remove rear lid trim

Repair Manual, Body Interior, Repair


Group 70, Trim panels, insulation; rear lid
trim

- Disconnect connectors on electrical


components present and remove rear
window washer system hose.

- Guide lines and hose through opening.

- Loosen bolts - 3 - at left and right lid


hinges - 4 - (do not unscrew
completely).

A second technician is required for the


rest of the removal procedure.
Rear lid Page 5 / 19

- Remove left and right gas struts - 2 - at


rear lid - 1 - 55-2, Removing gas-filled
strut

- Remove screws - 3 - and remove rear


lid - 1 - .

Installing

Installation is performed in the reverse order of removal.

- Rear lid screw torque specification: 10 Nm.

- Rear lid, adjusting 55-2, Rear lid, adjusting

„ Before the rear lid is closed, a function test of the


unlocking components must be performed.

Removing gas-filled strut

- Open rear lid and support rear lid.

- Reach under spring clips - 2 - using a small


screwdriver.

- Lift spring clips - 2 - only far enough so that the spring


clips can be slid over ball socket in - direction of arrow -
.

- Remove gas-filled strut - 1 - from ball studs - 3 - and - 4


- .

After removing gas-filled strut - 1 - , immediately slide


Rear lid Page 6 / 19

back spring clips - 2 - again.

Warning!

Proceed carefully when re-using gas-filled strut.


Spring clips must not be pried completely out of ball
socket, otherwise spring clips will be damaged. Gas-
filled strut springs out of mount and leads to damage
and injury to the operator.

- Tightening torques of ball studs - 3 - and - 4 - : 21 Nm.

- Gas-filled strut, venting 55-2, Gas-filled strut, venting

Gas-filled strut, venting

- Clamp gas-filled strut in vice area - x - . Dimension of -


x - = 50 mm (2 in.).

Warning!

Clamping the gas-filled strut must only be done in this


area - x - , otherwise there is a risk of an accident.

- Using saw, cut into cylindrical part of strut at point within


first third of cylinders length (measured from cover edge at
piston rod end of cylinder).

Note:

„ Always wear eye protection when performing this


procedure.

„ Cover the area of the sawn portion with a clean rag.

„ Dispose of fluid and cleaning rag in a proper


manner.

Rear lid hinge, removing and installing


Rear lid Page 7 / 19

Note:

„ Removal and installation is described for right rear


lid hinge. Removal and installation for the left-hand
rear lid hinge is performed in the same manner.

Removing

- Remove rear lid - 1 - 55-2,


Removing

- Lower rear molded headliner

Repair Manual, Body Interior, Repair


Group 70, Trim, noise insulation; roof
trim; removing and installing molded
headliner

- Remove hex head nut - 3 - and rear lid


Rear lid Page 8 / 19

hinge - 2 - from roof side member.

Installing

Note :

„ After installing rear lid - 1 - , retighten hex head nut


- 3 - for rear lid hinge - 2 - to 24 Nm.

- Install rear lid hinge - 2 - and tighten


hex head nut - 3 - to 24 Nm.

- Install rear lid - 1 - 55-2, Installing

- At end of installation, retighten hex


head nut - 3 - to 24 Nm.

- Install molded headliner


Rear lid Page 9 / 19

Repair Manual, Body Interior, Repair


Group 70, Trim, noise insulation; roof
trim; removing and installing molded
headliner

Latch bracket, removing and installing

Removing

- Remove lock carrier cover

Repair Manual, Body Interior, Repair Group 70,


Luggage compartment trim; removing and installing lock
carrier cover

- Remove screws - 1 - and striker pin.

Installing

- Assemble the latch bracket - 2 - .

- Tightening torque for bolts - 1 - : 23 Nm.


Rear lid Page 10 / 19

- Adjust latch bracket 55-2, Adjusting latch bracket

Further installation is in reverse order of removal.

Rear lid, adjusting

Note:

„ Vehicle must be standing on its wheels for basic


setting of rear lid.

„ Rear lid lock is bolted directly to the lid. It does not


have longitudinal holes and therefore cannot be
adjusted.

„ Stops recognized in other vehicles do not serve to


adjust the lid. They serve to stabilize and to cushion
the lid.

Next, adjusting the rear lid is described in several steps.

To adjust or check the gap dimensions, use special tool


3371

Repair Manual, Body Collision Repair, Repair Group 00,


Technical data; Body gap dimensions

- Remove gas-filled strut 55-2, Removing gas-filled


strut

- Adjust rear lid at striker pin 55-2, Adjusting latch


bracket

- Adjust rear lid at rear lid hinge by loosening screws - 3 -


55-2, Removing

- Adjust rear lid with rear lid hinge by loosening hex head
nut - 3 - 55-2, Removing

- Adjustment buffer, adjusting 55-2, Adjustment buffer,


adjusting

Note:

„ Rear lid is properly adjusted when there is an overall


even gap dimension when closed, it is not too far
inward or outward and contours align.

Adjusting latch bracket


Rear lid Page 11 / 19

- Remove lock carrier cover

Repair Manual, Body Interior, Repair Group 70,


Luggage compartment trim; removing and installing lock
carrier cover

- Disengage the latch bracket - 2 - .

- Bring striker pin - 2 - to rear position - arrow - and


tighten screws - 1 - .

- Close rear lid and test the adjustment.

- Latch bracket - 2 - can be slid in oversized holes by


loosening bolts - 1 - .

- Tightening torque for bolts - 1 - : 23 Nm

Adjustment buffer, adjusting

Note:

„ The following adjustment is only for the right


adjustment buffer. Adjustment for the left adjustment
buffer is derived accordingly from this.
Rear lid Page 12 / 19

- Loosen clamping screw - 2 - far enough until it is visible


in rubber buffer.

- Now pull notched slider - 1 - out of adjustment buffer.

- Set notched slider to dimension - a - = 12.5 mm.

- Close rear lid to initial locking position using light


pressure over the center.
Rear lid Page 13 / 19

- Open rear lid again.

- Screw in adjustment buffer locking screw - 1 - to a depth


of dimension - a - 25 mm.

- Check the adjustment.

Locking and unlocking components of rear lid, assembly


overview

„ Rear Lid Handle Unlock Switch -


E234-

„ removing and installing


55-2, Unlocking element,
removing and installing

„ Screw

„ Qty. 5

„ 4 Nm
Rear lid Page 14 / 19

„ Emergency release

„ Emergency release is
accessed through an
opening in the rear lid trim.

„ Rear lid lock

„ removing and installing


55-2, Rear lid lock, removing
and installing

„ Lid lock connector

„ Angle bracket

„ Unlocking element connector

Unlocking element, removing and installing

Note:

„ If rear lid does not open, it can opened by hand via


the emergency release - 3 - on lid lock - 4 - .
Emergency release is accessed through an opening
in the rear lid trim.

Removing
Rear lid Page 15 / 19

- Remove rear lid trim

Repair Manual, Body Interior, Repair


Group 70;, Trim panels, insulation; rear
lid trim

- Rear window washer motor, removing

Repair Manual, Electrical Equipment,


Repair Group 92, Window wiper and
washer system; Rear window washer
system

- Disconnect harness connector - 7 -


from unlocking element - 1 - .

- Remove bolts - 2 - .
Rear lid Page 16 / 19

- Disengage unlocking element opposite


- arrow - angle brackets - 6 - .

- Then you can remove the unlocking


element - 1 - .

Installing

Installation is performed in the reverse order of removal.

- Tightening torques for unlocking element: 4 Nm

„ Before the rear lid is closed, a function test of the


unlocking components must be performed.

Rear lid lock, removing and installing

Note:

„ If rear lid does not open, it can opened by hand via


the emergency release - 1 - on lid lock - 2 - .
Emergency release is accessed through an opening
in the rear lid trim.

Removing

- Remove rear lid trim

Repair Manual, Body Interior, Repair Group 70;, Trim


Rear lid Page 17 / 19

panels, insulation; rear lid trim

- Disconnect harness connector - 4 - from lid lock - 2 - .

- Remove screws - 3 - and guide lid lock - 2 - downward


out of lid.

Installing

- Guide lid lock - 2 - into lid and install screws - 3 - .

- Tightening torque for bolts - 3 - : 23 Nm

- Connect harness connector - 4 - to lid lock - 2 - .

Further installation is in reverse order of removal.

„ Before the rear lid is closed, a function test of the


unlocking components must be performed.

Rear lid seal

Rear lid seals are equipped at the factory with sealant,


applied to rear lid flange and then rolled on.

Note:

„ During removal of the seal, sealant is distributed on


interior side of seal and flanks are bent up easily. If
the seal is re-installed, the sealing performance and
proper seating are no longer guaranteed.

„ For this reason, every completely removed seal


Rear lid Page 18 / 19

must be replaced with a so-called "hammer-stroke


seal" .

„ For partially removed seals, seal flanks must be


pressed together before installation.

Rear lid seal, removing and installing

Removing

- Pull off rear lid seal - 1 - from body flange.

Installing
Rear lid Page 19 / 19

- Align rear lid seal - 1 - with vulcanized point - arrow - to


center of left tail light.
Volkswagen Golf V: Tank lid unit Page 1 / 6

55 - 3

Tank lid unit


Tools

Special tools, testers and auxiliary items required

„ Socket wrench T 10010

Tank flap unit, assembly overview


Tank lid unit Page 2 / 6

„ Tank lid unit

„ removing 55-3, Fuel tank


flap unit, removing

„ Screw

„ 1.5 Nm

„ Drain hose

„ Assembly component

„ Release rod

„ Mounting bolt for actuator

„ Qty. 2

„ 1.5 Nm
Tank lid unit Page 3 / 6

„ Fuel Filler Cap Central Locking


Actuator (F219)

„ Removing 55-3, Actuator,


removing

„ Gasket

Fuel tank flap unit, removing

Note :

„ If tank flap does not open, it can be opened by hand


via the release rod - 5 - . Side trim must be
removed for this.

- Open fuel tank filler flap.

- Unscrew fuel tank cap.


Tank lid unit Page 4 / 6

- Remove bolt - 2 - .

- Remove rubber part from tank filler


flange.

- Pull tank flap unit - 1 - with drain hose -


3 - toward rear and swivel tank flap unit
out of side panel.

- Unclip assembly piece - 4 - from side


panel and pull off assembly piece from
release rod - 5 - .

Installing

„ Assembly piece - 4 - is slid on.

- Insert drain hose - 3 - through opening


in tank flap unit and pull drain hose
through until it stops.
Tank lid unit Page 5 / 6

- Guide drain hose into side panel.

- Slide tank flap unit - 1 - with hinge side


first into side panel.

- Then swivel tank flap unit completely


into side panel, make sure that upper and
lower catches engage correctly in side
panel.

- Pull rubber piece over tank filler neck


and tighten bolt - 2 - .

Tightening torque for bolt - 2 - : 1.5 Nm.

Actuator, removing

- Remove side luggage compartment


trim
Tank lid unit Page 6 / 6

Repair Manual, Body Interior, Repair


Group 70, Trim/noise insulation; luggage
compartment trim

- Disconnect harness connector at


actuator - 7 - .

- Remove actuator - 7 - using special


tool socket wrench T 10010 .

- Remove actuator - 7 - together with


release rod - 5 - from seal - 8 - .

Installing

Installation is performed in the reverse order of removal.


Volkswagen Golf V - Front door Page 1 / 44

57 - 1

Front door
Tools

Special tools, testers and auxiliary items


required

„ Socket wrench T 10072

„ Assembly tool T 10118

„ Door adjusting wrench 3320

„ Joint for 3320 3320/1

„ Box wrench 3320/2


Front door Page 2 / 44

„ Box wrench 3320/3

„ Application roller for door insulation


foil 3356

„ Torque wrench 550 Nm V.A.G


1331

„ Adjusting gauge 3371

Special tools, testers and auxiliary items


required

„ Cartridge gun V.A.G 1628


Front door Page 3 / 44

„ Cartridge heater V.A.G 1939 A

„ Trim removal wedge 3409

„ Assembly tool set T 10237

Materials

DH 009 100 01 1) 2)
„ 1C- window adhesive

D 009 200 02 3)
„ Glass primer/paint primer

D 009 401 04 3)
„ Cleaning solution

D 009 500 25 3)
„ Primer applicator

3) Materials are stored in box D 004 700.


1) Observe minimum curing time 57-1, Minimum curing
time
2) Heat according to manufacturers instructions using
cartridge heater V.A.G 1939 .

Door construction, assembly overview

The door consists of inner door part - 6 -


and outer door plate - 1 - .

Parts are joined by the front - 7 - and the


rear - 5 - retaining tracks.

Retaining tracks are bolted to inner door


part and bonded to outer door plate.

Inner door part - 6 - undertakes among


other things the function of the previously
known subframe. Loudspeakers, window
regulators, window regulator motors,
wires, window guide, exterior mirror and
door lock are installed on inner door part.

Outer door plate - 1 - is also bolted to


inner door part on the lower edge.
Front door Page 4 / 44

Exterior window shaft seal, insulation and


outer door handle are installed on outer
door plate.

Caution!

Various bolts are used to secure the


outer door plate. Outer door plate is
damaged if not allocated correctly.

„ Outer door plate

„ Removing and installing


58-1, Outer door plate,
removing and installing

„ Edge protection

„ Between outer door panel


and inner door part.
Front door Page 5 / 44

„ Screw

„ Characteristic: Bolt has point


and thinner washer.

„ 6 pieces on lower edge

„ 2 piece in rear rail area

„ 10 Nm

„ Rear retaining track

„ Adhesive: DH 009 100 03

„ Screw

„ Characteristic: Bolt without


point but with thick washer.

„ Qty. 10 for both retaining


tracks on 4-door version

„ Qty. 11 for both retaining


tracks on 2-door version

„ 14 Nm

„ Inner door part

„ Assembly overview 57-1,


Inner door part, assembly
overview

„ Front retaining track

„ Adhesive: DH 009 100 03

„ Screw

„ Characteristic: Bolt has point


and thick washer

„ Qty. 1 for front rail area

„ 10 Nm

„ Insulation

„ Self-adhesive
Front door Page 6 / 44

„ To adhere, insulation must


be preheated and then
pressed on firmly

„ Clip

„ Qty. 6

„ Window shaft seal

„ Must be installed before


installing outer door shell.

Door hinges, assembly overview

Caution!

The nut for eccentric pin - 9 - must


not be loosened under any
circumstances. It cannot be secured
again using workshop equipment.

Note :

„ The description applies to the right side. The left side


is derived accordingly from this.

„ Bolts for door hinges must always be replaced after


loosening.

„ Hinges are no longer manufactured as separated


parts.
Front door Page 7 / 44

„ Door

„ Removing and installing


57-1, Door, removing and
installing

„ Adjusting 57-1, Door,


adjusting

„ Guide bolt

„ 10 Nm

„ Door hinge with door arrester

„ Socket head bolt

„ 20 Nm + 1 / 4 turn further (90


)

„ Always replace bolts after


Front door Page 8 / 44

loosening

„ Socket head bolt

„ Installed from the vehicle


interior

„ Remove lower A-pillar trim

Repair Manual, Body Interior, Repair


Group 70, Trim panels/insulation; Pillar
and side trim

„ 20 Nm + 1 / 4 turn further (90


)

„ Always replace bolts after


loosening

„ Socket head bolt

„ 20 Nm + 1 / 4 turn further (90


)

„ Always replace bolts after


loosening

„ Socket head bolt

„ 20 Nm + 1 / 4 turn further (90


)

„ Always replace bolts after


loosening

„ Guide screws

„ 10 Nm

„ Nut

„ For the eccentric pin, must


not be loosened. Used for
making adjustments during
production.

„ Door hinge
Front door Page 9 / 44

„ Door hinge is no longer


manufactured as separated
parts.

„ Socket head bolt

„ 20 Nm + 1 / 4 turn further (90


)

„ Always replace bolts after


loosening

„ Socket head bolt

„ 20 Nm + 1 / 4 turn further (90


)

„ Always replace bolts after


loosening

„ Socket head bolt

„ 20 Nm + 1 / 4 turn further (90


)

„ Always replace bolts after


loosening

Door, removing and installing

Note:

„ Removing and installing is described only for the


right door. Removing and installing the left door is
derived accordingly from this.

Removing
Front door Page 10 / 44

- Release boots - 6 - by pressing on


locking mechanism - arrow a - and
remove boots from A-pillar.

- Swivel locking lever - 7 - downward -


arrow b - and disconnect electrical
harness connector - 8 - from connector
station.

- Remove screws - 4, 5 and 11 - using


door adjustment wrench 3320 and bit
insert 3320/3 from hinge.

- Pull door in - direction of arrow - from


guide bolts - 2 and 9 - .

Installing

Installation is performed in the reverse order of removal.

- Torque specification for screws - 4, 5 and 11 - : 20 Nm +


Front door Page 11 / 44

1 / 4 (90 ) additional turn.

„ Screws - 4, 5 and 11 - must always be replaced.

- Observe gap dimension of front door

Repair Manual, Body Collision Repair, Repair Group 00,


Technical data; Body gap dimensions

Door, adjusting

Warning!

The nut for eccentric pin - 9 - must


not be loosened under any
circumstances. The nut cannot be
secured again using workshop
equipment.
Front door Page 12 / 44

Note :

„ The door is properly adjusted when there is an


overall even gap dimension when closed, it is not too
far inward or outward and contours align.

„ Vehicle must stand on its wheels in order to be able


to perform the adjustment.

„ If outer door plate is removed, window frame of inner


door part must be adjusted in relation to roof frame
and B-pillar, and to rear door.

- Observe gap dimension of front door

Repair Manual, Body Collision Repair,


Repair Group 00, Technical data; Body
gap dimensions

For correct gap dimension adjustment,


screws - 5, 7, 12 and 13 - at A-pillar
must be loosened. For screw - 5 - ,
lower A-pillar trim must be removed

Repair Manual, Body Interior, Repair


Group 70, Pillar and side trim

Other measures, such as aligning the


door upward, are not effective. Excess
pressure thereafter will again cause the
door to sag.

For correct alignment adjustment, screws


- 4, 6 and 14 - and guide screws - 2 and
8 - must be loosened.

Door adjusting wrench 3320 with bit


insert 3320/3 must be used for this.

Outer door plate, removing and installing

Removing
Front door Page 13 / 44

- Pry off clips - 3 - beginning at bottom


of door - 1 - and remove cover - 2 - .
Front door Page 14 / 44

- Removing lock cylinder 57-1, Housing, removing and


installing

- Remove door handle 57-1, Door handle, removing and


installing

- Remove screw - 1 - from bearing bracket - 2 - , located


behind outer door plate.

- Remove all screws - 2, 3, 4 - .

- Carefully remove outer door plate.

Installing

Caution!

Various bolts are used to secure the outer door plate.


Outer door plate is damaged if not allocated correctly.
Front door Page 15 / 44

- Carefully set outer door plate in.

- Start all screws - 2, 3, 4 - .

„ Make sure that the various bolts


are used correctly.

„ Characteristic for bolt - 2 - : Bolt has point and


thinner washer.

„ Characteristic for bolt - 3 - : Bolt without point but


with thick washer.

„ Characteristic for bolt - 4 - : Bolt has point and thick


washer

- Check whether guide pins for retaining


tracks are located in the corresponding
guide holes of inner door part. Then
Front door Page 16 / 44

tighten all screws - 2, 3, 4 - .

„ Observe the correct tightening


torques for the various bolts.

Tightening torque for bolt - 2 - : 10 Nm.

Tightening torque for bolt - 3 - : 14 Nm.

Tightening torque for bolt - 4 - : 10 Nm.

Further installation is performed in the


reverse order of removal.

New outer door plate, installing

Caution!

Various bolts are used to secure the outer door plate.


Outer door plate is damaged if not allocated correctly.

Note:

„ Observe the chapter of installation notes, bonding


new outer door plate 57-1, Installation notes for
adhering a new outer door plate
Front door Page 17 / 44

„ Old (damaged) outer door plate


with retaining tracks removed
57-1, Outer door plate, removing
and installing

- Install front - 2 - and rear - 6 -


retaining tracks on inner door part. For
this, use the "bolt without point with thick
washer" .

Torque for bolt - 3 - and - 5 - : 10 Nm.

- Screw two guide screws into bottom


edge of inner door part.
Front door Page 18 / 44

The painted outer door plate is fitted first


without applying adhesive.

The assembly block from the assembly


tool set T 10237 is needed to fit the outer
door shell. One strip of "Tesa Power
Strips large" - 6 - is affixed onto the
lowered side. The pin has the minimum
dimension for the gap width. The surface
without adhesive is placed onto the
neighboring component until it makes
contact.

- Adhere assembly blocks - 3 - to outer


door plate.

- Guide the outer door plate - 1 - in


lower edge of inner door part via the
guide bolts.

- Using wedges - 4 - from assembly tool


set T 10237 , adjust gap dimension to sill
panel and outer door shell height.
Front door Page 19 / 44

- Lay outer door panel with assembly


blocks on adjoining components - 2 and
5- .

- Check gap dimension with adjustment


gauge 3371

Repair Manual, Body Collision Repair,


Repair Group 00, Technical data; Body
gap dimensions

- If gap dimensions can no longer be


adjusted, inner door part must be
adjusted 57-1, Door, adjusting

- Remove outer door plate again.

- Apply adhesive beads - 2 - onto front -


1 - and rear - 3 - retaining tracks
Front door Page 20 / 44

cartridge gun V.A.G 1628 .

The securing block from assembly tool


set T 10237 is needed to insert outer
door panel. Two strips of "Tesa Power
Strips large" - 5 - are affixed onto
contact surface.

- Guide the outer door plate - 1 - in


lower edge of inner door part via the
guide bolts.

- Bring outer door plate with assembly


blocks - 3 - into contact with neighboring
components.

- Using wedges - 4 - from assembly tool


set, adjust gap dimension to sill panel
and outer door plate height.

- Check gap dimensions with adjustment


gauge 3371
Front door Page 21 / 44

Repair Manual, Body Collision Repair,


Repair Group 00, Technical data; Body
gap dimensions

- Affix short securing blocks - 2 -


uniformly onto door to be replaced and
neighboring components.

Note:

„ A waiting time of 180 minutes must be observed


before performing further work on the affixed door.

- Rest of installation is performed in the reverse order of


removal 57-1, Installing

Retaining track on outer door plate, removing and


installing

Removing retaining track

Caution!

The following work must be performed very carefully.


Since the outer door plate is to be re-used, dents and
scratches must be prevented.

When cutting through adhesive bead, always hold


retaining track and outer door plate together as shown
in the illustration. Otherwise, outer door plate flaps off
the retaining track and must no longer be used again.

Note:

„ The following work is to be performed only with a


second technician.
Front door Page 22 / 44

Outer door plate with retaining tracks removed 57-1,


Removing

- Store the outer door plate - 1 - on a firm surface and


protect outer door plate against scratches.

- Secure spooling tool - 2 - .

- Secure cord - 5 - onto spooling tool and retainer - 4 - .

- Hold retaining track and outer door plate firmly together


when cutting through adhesive bead.

- Using cord, cut through adhesive bead from retaining


track - 3 - and outer door plate - 1 - until slightly out over
the center.
Front door Page 23 / 44

- After adhesive bead has been cut up to halfway in the


first step, move the spooling tool - 2 - and insert cord - 5 -
on the side not yet cut.

- Hold retaining track - 3 - and outer door plate - 1 - firmly


together when continuing to cut through adhesive bead.

- Cut through the second half of the adhesive bead.

Installing retaining track

- Carefully, cut remaining adhesive bead on outer door


plate up to the highest possible minimum without damaging
paintwork while doing so.

- Further work steps are described in chapter "installing


new outer door plate" 57-1, New outer door plate,
installing .

Note:

„ "Installation notes for adhering new outer door plate"


are also to be followed to install a new retaining
track.

- Install a new retaining track onto inner door part on


location of the removed retaining track.

- Apply adhesive onto the new retaining track.

- Firmly bolt door plate on lower edge and on the retaining


track.

- Secure outer door panel to new retaining track with


securing blocks.

Installation notes for adhering a new outer door plate

Note:

„ If both outer door plates must be replaced on a side,


follow the sequence. First the rear outer door plate
and then the front outer door plate is aligned and
adhered. For alignment of rear outer door panel to
front outer door panel, adhere long securing blocks.

„ If the cataphoretic paint coating of outer door plate is


damaged on the inside in the adhesion area, or was
damaged there, this area must be primed using
glass/paint primer D 009 200 02.

„ 1K window adhesive DH 009 100 must be heated for


Front door Page 24 / 44

20 minutes in cartridge heater V.A.G 1939 A .

- Clean application surfaces on retaining tracks with


cleaning solution D 009 401 04.

- Apply adhesive material using cartridge gun V.A.G 1628


onto application surfaces at a right angle to the retaining
track.

Warning!

Outer door plate must be installed within 10 minutes,


otherwise bonding properties of adhesive will be
impaired.

„ Place outer door panel on retaining tracks with help


of both assembly blocks, center with wedges and
adjustment gauge 3371 and press assembly block
application surfaces onto surrounding components.

„ Secure outer door panel during curing time with


securing blocks.

„ After installing, align outer door plate to the other


components and gap dimensions must be uniform.

„ If the adhesive bead has been applied too thickly


and the adhesive expands out between retaining
track and outer door plate, then the excess adhesive
must be removed.

Minimum curing time

Warning!

Special requirements must be fulfilled for replacing


bonded outer door plates. One of these standards for
Front door Page 25 / 44

example is, that a freshly bonded outer door plate


must comply with the safety elements, even in an
accident, once the adhesive has exceeded the
prescribed curing time.

The minimum curing time for outer door panel with 1K


adhesive DH 009 100 is 180 minutes.

By minimum curing time, it is meant the time from bonding


in the outer door plate up to use in the vehicle, or until
further work can be performed. During this time, the vehicle
must stand on an even surface at room temperature (at
least 15 C).

Warning!

The vehicle is operationally ready only after the


minimum curing time has elapsed.

Cleaning when soiled by adhesive sealing material

- It is recommended to use adhesive remover D 002 000


10 as a cleaning solution. Observe safety precautions
when processing.

Caution!

When cleaning the vehicle, outer door plate bonded in


immediately beforehand must not be shifted.

- First clean paint surface coarsely using a dry rag.


Eliminate remaining soiling using adhesive removal
solution D 002 000 10.

- Clean plastic trim: Allow adhesive sealing material to


harden (about 1 hour) and then peel off.

Inner door part, assembly overview

Note :

„ The description applies to the right side. The left side


is derived accordingly from this.
Front door Page 26 / 44

„ Inner door part

„ Window shaft seal

„ Loudspeaker

„ Window regulator motor

„ removing 64-2, Window


regulator motor, removing
and installing

„ Insulation

„ 4x

„ 20 mm x 40 mm
commercially available cloth
reinforced adhesive tape
Front door Page 27 / 44

Door handle and door lock, assembly overview

Note :

„ The illustration shows the left side. The right side is


similar and can be determined from this.

„ Door lock

„ Removing and installing


57-1, Door lock, removing
and installing

„ Cable

„ For disengaging lock of


exterior door handle.

„ Screw
Front door Page 28 / 44

„ For securing lock to inner


door part

„ 18 Nm

„ Qty. 2

„ Mounting bracket

„ Removing and installing


57-1, Bearing bracket,
removing and installing

„ Screw

„ For lock cylinder.

„ Bolt

„ Not available on all versions.

„ This screw is installed for


additional securing of
mounting bracket.

„ Backing

„ Lock cylinder housing

„ Only on drivers side.

„ Only one housing is installed


on front passengers side.

„ Removing and installing


57-1, Housing, removing and
installing

„ Cover cap

„ For the lock cylinder


housing.

„ Is secured to lock cylinder


housing with three tabs.

„ Key

„ Changing battery 57-2,


Radio-frequency remote
Front door Page 29 / 44

control key (foldable) battery


- assembly overview

„ Adapting new/additional
keys to remote control and
immobilizer 57-2,
Adaptation of keys with
radio-frequency remote
control

„ Door handle with backing plate

„ Removing and installing


57-1, Door handle, removing
and installing

„ Backing

„ Is a component of door
handle.

„ Torx screw

„ Socket wrench T 10072

„ Expanding rivet

„ Not installed in Rabbit/GTI.

„ Angle bracket

„ Not installed in Rabbit/GTI.

„ Cable

„ To lock release mechanism


of door handle.

„ Cover

„ Does not belong to


packaged contents of door
lock

„ Is secured to door lock with


three tabs.
Front door Page 30 / 44

Housing, removing and installing

Note:

„ Removing and installing is described only for the


housing. Removing and installing lock cylinder is
derived accordingly from this.

Removing

- Pry out cover cap in front of bolt - 1 - .

- Pull door handle - 2 - in - direction of arrow - and turn


screw - 1 - with socket wrench T 10072 until housing - 3 -
can be removed.

Installing

- Insert housing - 3 - in right angle - arrow - into door


handle bearing bracket.

Door handle - 2 - must make contact only lightly at door


plate.

- Install the bolt - 1 - into bearing bracket using socket


wrench T 10072 .

Door handle - 2 - engages again into housing - 3 - with a


Front door Page 31 / 44

very audible click.

Note:

„ During installation, housing must be pressed onto


door plate. The door handle rests only lightly against
the door panel.

Further installation is in reverse order of removal.

„ Then a function test must be performed with door


open, since the door cannot be opened if hood
release cable is not correctly adjustment or clipped
in.

Door handle, removing and installing

Note:

„ Removing and installing is described only for the


right door handle. Removing and installing the left
door handle is derived accordingly from this.

Removing

- Remove housing 57-1, Housing, removing and


installing .

- Pry out clip - 2 - from door handle - 1 - .

- Swivel door handle - 1 - out of door - arrow - .

Installing
Front door Page 32 / 44

- Guide assembly tool T 10118 into door


through opening in inner door plate.

- Light the inner part of door using a


flashlight for better view.

- Hook assembly tool T 10118 into


spring - arrow A - .

- Engage spring into door lock by pulling


assembly tool T 10118 - arrow B - .

Release lever is now locked in position.

Note :

„ Lock is secured by engaging spring in the operating


lever. This prevents the cable from subsequently
being clipped in at door handle incorrectly.
Front door Page 33 / 44

- Swivel door handle - 1 - into door.

- Pull clip - 2 - into plate cutout and engage clip into door
handle - 1 - - arrow - .

Note:

„ During installation, door handle - 1 - must be


pressed onto door plate.

„ Clip - 2 - must engage into door handle - 1 - with a


very audibly click.

Install housing 57-1, Installing .

„ Then a function test must be performed with door


open, since the door cannot be opened if hood
release cable is not correctly adjustment or clipped
in.

Bearing bracket, removing and installing

Note:

„ Removing and installing is described only for the


right bearing bracket. Removing and installing the
left bearing bracket is derived accordingly from this.

Removing
Front door Page 34 / 44

- Remove lock cylinder housing 57-1,


Housing, removing and installing

- Remove door handle 57-1, Door


handle, removing and installing

- Remove outer door panel 58-1,


Outer door plate, removing and
installing

- Pull retaining rubber - 4 - upward from


guide pin.

- Pull bearing bracket - 1 - in - direction


of arrow - with guide pin - 2 - out of
mounts - 3 - .

Installing
Front door Page 35 / 44

- Slide bearing bracket - 1 - with guide


pin - 2 - into mounts - 3 - .

- Secure retaining rubber - 4 - on guide


pin and mounting pin on bearing bracket
mount.

Further installation is in reverse order of


removal.

Door lock, removing and installing

Note:

„ Removing and installing is described only for the


right door lock. Removing and installing the left door
lock is derived accordingly from this.

Removing
Front door Page 36 / 44

- Remove outer door panel 58-1,


Outer door plate, removing and
installing

- Remove mounting bracket 57-1,


Bearing bracket, removing and installing

- Disconnect connector - 5 - .

- Remove bolts - 6 - .

- Disengage cable - 1 - from actuator


lever - 8 - and remove door lock - 4 - .

Cover - 3 - is not supplied with delivery


casing of door lock.

Installing

Installation is performed in the reverse order of removal.

Tightening torques for bolts: 18 Nm.


Front door Page 37 / 44

„ Then a function test must be performed with door


open, since the door cannot be opened if hood
release cable is not correctly adjustment or clipped
in.

Side impact protection, assembly overview

Caution!

The side impact member screws and nuts are painted


during production. That means that the threads could
shear off during removal with significant force.
Loosening of screws and nuts should be avoided
when possible

„ Side impact protection

„ Screw

„ 4x
Front door Page 38 / 44

„ 20 Nm

„ Insulation

„ Nut

„ Qty. 2

„ 20 Nm

Inner door seal

Inner door seals are equipped at the factory with sealant,


applied to door flange and then rolled on.

Note:

„ During removal of the seal, sealant is distributed on


interior side of seal and flanks are bent up easily. If
the seal is re-installed, the sealing performance and
proper seating are no longer guaranteed.

„ For this reason, every completely removed seal


must be replaced with a so-called "hammer-stroke
seal" .

„ For partially removed seals, seal flanks must be


pressed together before installation.

Inner door seal, removing and installing

Note:

„ Removing and installing is described only for the left


inner door seal. Removing and installing the right
inner door seal is derived accordingly from this.

Removing
Front door Page 39 / 44

- Pull off inner door seal from body


flange.

Installing
Front door Page 40 / 44

- Align inner door seal with vulcanized


point - arrow b - at the height of the
lower hinge.

- Start installation of inner door seal in


upper radius - arrow a - of door
opening.

Outer door seal, removing and installing

Note:

„ Removing and installing is described only for the


right outer door seal. Removing and installing the left
outer door seal is derived accordingly from this.

„ Remove protective foil only immediately prior to


assembly. Processing temperature approx. 20 C.

„ Adhesive remover D 002 000 10 is to be used


Front door Page 41 / 44

exclusively.

„ The outer door seal must be applied immediately


after cleaning.

„ After 10 minutes, check the seal for a secure fit.

Removing

- Pull off outer door seal from door.

Installing
Front door Page 42 / 44

- Remove any adhesive residue still


present using radial disc for streak
remover Z 432 290 TE

- Thoroughly clean the adhesion surface


with adhesive remover D 002 000 10
immediately before adhering the outer
door seal.

„ Adhesion surfaces must be free of


dust and grease and there must be
no residual adhesive present.

- Align outer door seal with cut-out -


arrow b - with door lock securing
screw.

- Vulcanized point - arrow c - of outer


door seal is then located in center area of
door entry sill.

- Pull off foil cover and apply seal onto


Front door Page 43 / 44

door. Do not stretch outer door seal


excessively so that the seal is not too
long at the end.

- Press entire adhesive area of seal all


around onto door using application roller
3356 , starting in upper radius - arrow a
- of door.

Note :

„ Part numbers are for reference only. Always check


with your Parts Department for the latest part
number information

Checking seal for secure seating

Check seal for firm setting 10 minutes


after adhering the seal.

- Place seal - 1 - facing outward by


Front door Page 44 / 44

hand.

- If adhered area does not pull off in any


areas, press seal on further once more
using application roller 3356 .
Volkswagen Golf V - Central locking system Page 1 / 9

57 - 2

Central locking system


Component locations overview of components for
central locking system

„ Coupling station

„ Location: A-pillar, right

„ To disconnect harness
connector, release boots at
pillar 57-1, Removing

„ Comfort System Central Control


Module -J393-

„ Location: below passenger


side instrument panel,
behind glove compartment
Central locking system Page 2 / 9

„ Removing

Repair Manual, Body Interior, Repair


Group 68, Interior equipment;
Compartments, covers and trim; Glove
compartment, removing and installing

„ Front Passengers Door Control


Module -J387-

„ Integrated in window
regulator motor.

„ Removing 64-2,
Removing

„ Door lock

„ Door lock is secured to inner


door part.

„ Electrical central locking


system is integrated in door
lock.

„ Removing 57-1,
Removing

„ Coupling station

„ Location: B-pillar, right.

„ To disconnect harness
connector, release boots at
pillar 58-1, Removing

„ Right Rear Door Control Module


-J389-

„ Integrated in window
regulator motor.

„ Removing 64-3,
Removing

„ Door lock

„ Door lock is secured to inner


Central locking system Page 3 / 9

door part.

„ Electrical central locking


system is integrated in door
lock.

„ Removing 58-1,
Removing

„ Right rear lid connector station

„ Location: behind C-pillar


trim.

„ Removing and installing

Repair Manual, Body Interior, Repair


Group 70, Trim/insulation; Pillars and
side trim; Upper C-pillar trim, removing
and installing

„ Fuel Tank Lid Unlock Motor -


V155-

„ Location: behind right


luggage compartment trim.

„ Removing 55-3, Actuator,


removing

„ Rear lid lock

„ Location: screwed to rear lid.

„ Removing 55-2,
Removing

„ Unlocking element with button

„ Location: screwed into rear


lid.

„ Removing 55-2,
Removing

„ Left rear lid connector station

„ Location: behind C-pillar


trim.
Central locking system Page 4 / 9

„ Removing and installing

Repair Manual, Body Interior, Repair


Group 70, Trim/insulation; Pillars and
side trim; Upper C-pillar trim, removing
and installing

„ Door lock, LR

„ Door lock is secured to inner


door part.

„ Electrical central locking


system is integrated in door
lock.

„ Removing 58-1,
Removing

„ Left Rear Door Control Module -


J388-

„ Integrated in window
regulator motor.

„ Removing 64-3,
Removing

„ Coupling station

„ Location: Left B-pillar.

„ To disconnect harness
connector, release boots at
pillar 58-1, Removing

„ Door lock, LF

„ Door lock is secured to inner


door part.

„ Electrical central locking


system is integrated in door
lock.

„ Removing 57-1,
Removing
Central locking system Page 5 / 9

„ Central switch for window


regulator

„ Location: installed in door


trim

„ Remove and installing


central window regulator
switch

Repair Manual, Electrical Equipment,


Repair Group 96, Electrical Equipment;
Lights, Lamps, switches - interior, lights
and switches in doors

„ Drivers Door Control Module -


J386-

„ Integrated in window
regulator motor.

„ Removing 64-2,
Removing and 57-1,
Removing

„ Coupling station

„ Location: Left A-pillar.

„ To disconnect harness
connector, release boots at
pillar 57-1, Removing

„ Alarm signal horn

„ Location: below plenum


chamber cover.

„ Removing 64-1, Remove


plenum chamber cover

„ Front Hood Switch -F266-

„ Contact switch for anti-theft


warning system, cannot be
replaced individually.

„ Location: On hood lock.


Central locking system Page 6 / 9

„ Removing 55-1,
Removing

Adaptation of keys with radio-frequency remote control

Adaptation of keys with remote control is performed using


Vehicle Diagnostic, Testing and Information System VAS
5051 A .

- Select "Guided Fault-Finding" on Vehicle Diagnostic,


Testing and Information System VAS 5051 A .

- Via the "Go to" button, select "Function-/Component


selection" and the following menu points in sequence:

„ Body

„ Body Repairs

„ 01 - On Board Diagnostic (OBD) capable systems

„ Comfort system

„ Functions - Comfort system

„ Adaptation of keys with radio-frequency remote


control

Radio-frequency remote control key (foldable) battery -


assembly overview
Central locking system Page 7 / 9

„ Key with variable code


transponder

„ Radio frequency unit - upper


part

„ LED

„ This LED must blink when


remote control is operated.

„ If LED does not blink when


remote control is operated,
the battery is completely
discharged and must be
replaced.

„ Battery

„ Removing battery 57-2,


Removing
Central locking system Page 8 / 9

„ Installing battery 57-2,


Installing

„ Radio frequency unit - lower


part

Battery for key with radio-frequency remote control


(foldable), removing and installing

Removing

- Insert screwdriver in the slot between radio-frequency


unit - 1 - and key - 2 - .

- Rotate screwdriver in - direction of arrow - and detach


radio frequency unit from key.

- Press radio frequency unit - 1 - apart with key bit on key


- 2- .
Central locking system Page 9 / 9

- Use a screwdriver to unclip battery - 1 - out of holders -


2 - in - direction of arrow - .

Installing

Note polarity and installation position of battery when


installing.

- Place battery - 1 - in radio-frequency unit - 2 - with


positive terminal downward (positive terminal is marked in
housing).

- Press on battery with light pressure to engage it in radio-


frequency unit.

- Attach the cover and the radio frequency unit together


(do not damage seal).

- Then lock radio-frequency unit with key.


Volkswagen Golf 5 - Rear door Page 1 / 44

58 - 1

Rear door
Tools

Special tools, testers and auxiliary items


required

„ Socket wrench T 10072

„ Assembly tool T 10118

„ Door adjusting wrench 3320

„ Joint for 3320 3320/1

„ Box wrench 3320/2


Rear door Page 2 / 44

„ Box wrench 3320/3

„ Application roller for door insulation


foil 3356

„ Torque wrench 550 Nm V.A.G


1331

„ Adjusting gauge 3371

Special tools, testers and auxiliary items


required

„ Cartridge gun V.A.G 1628


Rear door Page 3 / 44

„ Cartridge heater V.A.G 1939 A

„ Trim removal wedge 3409

„ Assembly tool set T 10237

Materials

DH 009 100 01 1) 2)
„ 1C- window adhesive

D 009 200 02 3)
„ Glass primer/paint primer

D 009 401 04 3)
„ Cleaning solution

D 009 500 25 3)
„ Primer applicator

3) Materials are stored in box D 004 700.


1) Observe minimum curing time 58-1, Minimum curing
time
2) Heat according to manufacturers instructions using
cartridge heater V.A.G 1939 .

Door construction, assembly overview

The door consists of inner door part - 6 -


and outer door plate - 1 - .

Parts are joined by the front - 7 - and the


rear - 4 - retaining tracks.

Retaining tracks are bolted to inner door


part and bonded to outer door plate.

Loudspeakers, window regulators,


window regulator motors, wires, window
guide and door lock are installed on inner
door part.

Outer door plate - 1 - is also bolted to


inner door part on the lower edge.
Exterior window shaft seal, insulation and
outer door handle are installed on outer
Rear door Page 4 / 44

door plate.

Caution!

Various bolts are used to secure the


outer door plate. Outer door plate is
damaged if not allocated correctly.

„ Outer door plate

„ Outer door plate, removing


and installing 58-1, Outer
door plate, removing and
installing

„ Edge protection

„ Between outer door panel


and inner door part.

„ Screw
Rear door Page 5 / 44

„ Characteristic: Bolt has point


and thinner washer.

„ 4 pieces on lower edge

„ 2 piece in rear rail area

„ 10 Nm

„ Rear retaining track

„ Adhesive: DH 009 100 03

„ Screw

„ Characteristic: Bolt without


point but with thick washer.

„ 11 pieces on both retaining


tracks

„ 14 Nm

„ Inner door part

„ Assembly overview 58-1,


Inner door part, assembly
overview

„ Front retaining track

„ Adhesive: DH 009 100 03

„ Screw

„ Characteristic: Bolt has point


but thick washer.

„ Qty. 1 for front rail area

„ 10 Nm

„ Insulation

„ Self-adhesive

„ To adhere, insulation must


be preheated and then
pressed on firmly
Rear door Page 6 / 44

„ Clip

„ Qty. 5

„ Window shaft seal

„ Must be installed before


installing outer door panel.

Door hinges, assembly overview

Caution!

The nut for eccentric pin - 9 - must


not be loosened under any
circumstances. It cannot be secured
again using workshop equipment.

Note :

„ The description applies to the right side. The left side


is derived accordingly from this.

„ Bolts for door hinges must always be replaced after


loosening.

„ Hinges are no longer manufactured as separated


parts.
Rear door Page 7 / 44

„ Door

„ Removing and installing


58-1, Door, removing and
installing

„ Adjusting 58-1, Door,


adjusting

„ Guide bolt

„ 10 Nm

„ Door hinge with door arrester

„ Socket head bolt

„ 20 Nm + 1 / 4 turn further (90


)

„ Always replace bolts after


Rear door Page 8 / 44

loosening

„ Socket head bolt

„ Installed from the vehicle


interior

„ Remove lower B-pillar trim

Repair Manual, Body Interior, Repair


Group 70, Trim panels/insulation; Pillar
and side trim

„ 20 Nm + 1 / 4 turn further (90


)

„ Always replace bolts after


loosening

„ Socket head bolt

„ 20 Nm + 1 / 4 turn further (90


)

„ Always replace bolts after


loosening

„ Socket head bolt

„ 20 Nm + 1 / 4 turn further (90


)

„ Always replace bolts after


loosening

„ Guide bolt

„ 10 Nm

„ Nut

„ For the eccentric pin, must


not be loosened. Used for
making adjustments during
production.

„ Door hinge
Rear door Page 9 / 44

„ Hinge is no longer
manufactured as separated
parts.

„ Socket head bolt

„ 20 Nm + 1 / 4 turn further (90


)

„ Always replace bolts after


loosening

„ Socket head bolt

„ 20 Nm + 1 / 4 turn further (90


)

„ Always replace bolts after


loosening

„ Socket head bolt

„ 20 Nm + 1 / 4 turn further (90


)

„ Always replace bolts after


loosening

Door, removing and installing

Note:

„ Removing and installing is described only for the


right door. Removing and installing the left door is
derived accordingly from this.

Removing
Rear door Page 10 / 44

- Release boots - 6 - by pressing on


locking mechanism - arrow a - and
remove boots from B-pillar.

- Swivel locking lever - 7 - downward -


arrow b - and disconnect electrical
harness connector - 8 - from connector
station.

- Remove screws - 4, 5 and 11 - using


door adjustment wrench 3320 and bit
insert 3320/3 from hinge.

- Pull door in - direction of arrow - from


guide bolts - 3 and 9 - .

Installing

Installation is performed in the reverse order of removal.

- Tightening torque: Screws - 4, 5 and 11 - : 20 Nm + 1 / 4


Rear door Page 11 / 44

(90 ) additional turn

„ Screws - 4, 5 and 11 - must always be replaced.

- Observe gap dimension of rear door

Repair Manual, Body Collision Repair, Repair Group 00,


Technical data; Body gap dimensions

Door, adjusting

Caution!

The nut for eccentric pin - 9 - must


not be loosened under any
circumstances. It cannot be secured
again using workshop equipment.

Note :
Rear door Page 12 / 44

„ The door is properly adjusted when there is an


overall even gap dimension when closed, it is not too
far inward or outward and contours align.

„ Vehicle must stand on its wheels in order to be able


to perform the adjustment.

„ If outer door plate is removed, window frame of inner


door part must be adjusted in relation to roof frame
and C-pillar, and front door.

- Observe gap dimension of rear door

Repair Manual, Body Collision Repair,


Repair Group 00, Technical data; Body
gap dimensions

To adjust the gap dimension correctly


screws - 5, 7, 12 and 13 - must be
loosened. For screw - 5 - , lower B-pillar
trim must be removed

Repair Manual, Body Interior, Repair


Group 70, Pillar and side trim

Other measures, such as aligning the


door upward, are not effective. Excess
pressure thereafter will again cause the
door to sag.

For correct alignment adjustment, screws


- 4, 6 and 14 - and guide screws - 2 and
8 - must be loosened.

Door adjusting wrench 3320 with bit


insert 3320/3 must be used for this.

Outer door plate, removing and installing

Removing
Rear door Page 13 / 44

- Pry off clips - 3 - beginning at bottom


of door - 1 - and remove rear cover - 2 -
.

- Pry off clips - 5 - beginning at bottom


of door - 1 - and remove rear cover - 4 -
.
Rear door Page 14 / 44

- Removing lock cylinder housing: 57-1, Housing,


removing and installing .

- Remove door handle 57-1, Door handle, removing and


installing

- Remove screw - 1 - from bearing bracket - 2 - , located


behind outer door plate.
Rear door Page 15 / 44

- Remove all screws - 2, 3 and 4 - .

- Carefully remove outer door plate.

Installing

Caution!

Various bolts are used to secure the outer door plate.


Outer door plate is damaged if not allocated correctly.
Rear door Page 16 / 44

- Carefully set outer door plate in.

- Start all screws - 2, 3, 4 - .

„ Make sure that the various bolts


are used correctly.

„ Characteristic for bolt - 2 - : Bolt has point and


thinner washer.

„ Characteristic for bolt - 3 - : Bolt without point but


with thick washer.

„ Characteristic for bolt - 4 - : Bolt has point and thick


washer

- Check whether guide pins for retaining


tracks are located in the corresponding
guide holes of inner door part. Then
Rear door Page 17 / 44

tighten all screws - 2, 3, 4 - .

„ Observe the correct tightening


torques for the various bolts.

Tightening torque for bolt - 2 - : 10 Nm.

Tightening torque for bolt - 3 - : 14 Nm.

Tightening torque for bolt - 4 - : 10 Nm.

Further installation is performed in the


reverse order of removal.

New outer door plate, installing

Caution!

Various bolts are used to secure the outer door plate.


Outer door plate is damaged if not allocated correctly.

Note:

„ Observe the chapter of installation notes, bonding


new outer door plate 58-1, Installation notes for
adhering a new outer door plate
Rear door Page 18 / 44

„ Old (damaged) outer door plate


with retaining tracks removed
58-1, Outer door plate, removing
and installing

- Install front - 2 - and rear - 6 -


retaining tracks on inner door part. For
this, use the "bolt without point with thick
washer" .

Torque for bolt - 3 - and - 5 - : 10 Nm.

- Screw two guide screws into bottem


edge of inner door part.
Rear door Page 19 / 44

The painted outer door plate is fitted first


without applying adhesive.

The assembly block from the assembly


tool set T 10237 is needed to fit the outer
door plate. One strip of "Tesa Power
Strips large" - 6 - is affixed onto the
lowered side. The pin has the minimum
dimension for the gap dimension. The
surface without adhesive is placed onto
the neighboring component until it makes
contact.

- Adhere assembly blocks - 3 - to outer


door plate.

- Guide the outer door plate - 1 - in


lower edge of inner door part via the
guide bolts.

- Using wedges - 4 - from assembly tool


set T 10237 , adjust gap dimension to sill
panel and outer door plate height.
Rear door Page 20 / 44

- Lay outer door panel with assembly


blocks on adjoining components - 2 and
5- .

- Check gap dimension with adjustment


gauge 3371

Repair Manual, Body Collision Repair,


Repair Group 00, Technical data; Body
gap dimensions

- If gap dimensions can not be adjusted,


inner door part must be adjusted 58-1,
Inner door part, assembly overview

- Remove outer door plate again.

- Apply adhesive beads - 2 - onto front -


1 - and rear - 3 - retaining tracks
Rear door Page 21 / 44

cartridge gun V.A.G 1628 .

The assembly block from the assembly


tool set T 10237 is needed to insert the
outer door plate. Two strips of "Tesa
Power Strips large" - 5 - are affixed onto
contact surface.

- Guide the outer door plate - 1 - in


lower edge of inner door part via the
guide bolts.

- Place outer door panel with assembly


blocks - 3 - on adjacent components.

- Using wedges - 4 - from set, adjust


gap dimension to sill panel and outer
door shell height.

- Check gap dimensions with adjustment


gauge 3371
Rear door Page 22 / 44

Repair Manual, Body Collision Repair,


Repair Group 00, Technical data; Body
gap dimensions

- Affix short securing blocks - 2 -


uniformly onto door to be replaced and
neighboring components.

Note:

„ A waiting time of 180 minutes must be observed


before performing further work on the affixed door.

- Rest of installation is performed in the reverse order of


removal 58-1, Installing

Retaining track on outer door plate, removing and


installing

Removing retaining track

Caution!

The following work must be performed very carefully.


Since the outer door plate is to be re-used, dents and
scratches must be prevented.

When cutting through adhesive bead, always hold


retaining track and outer door plate together as shown
in the illustration. Otherwise, outer door plate flaps off
the retaining track and must no longer be used again.

Note:

„ The following work is to be performed only with a


second technician.
Rear door Page 23 / 44

Outer door plate with retaining tracks removed 58-1,


Removing

- Store the outer door plate - 1 - on a firm surface and


protect outer door plate against scratches.

- Secure spooling tool - 2 - .

- Secure cord - 5 - onto spooling tool and retainer - 4 - .

- Hold retaining track and outer door plate firmly together


when cutting through adhesive bead.

- Using cord, cut through adhesive bead from retaining


track - 3 - and outer door plate - 1 - until slightly out over
the center.
Rear door Page 24 / 44

- After adhesive bead has been cut up to halfway in the


first step, move the spooling tool - 2 - and insert cord - 5 -
on the side not yet cut.

- Hold retaining track - 3 - and outer door plate - 1 - firmly


together when continuing to cut through adhesive bead.

- Cut through the second half of the adhesive bead.

Installing retaining track

- With utmost care, cut down remaining adhesive bead on


outer door plate up to the highest possible minimum
without damaging paintwork while doing so.

- Further work steps are described in chapter "installing


new outer door plate" 57-1, New outer door plate,
installing .

Note:

„ "Installation notes for adhering new outer door plate"


are also to be followed to install a new retaining
track.

- Install a new retaining track onto inner door part on


location of the removed retaining track.

- Apply adhesive onto the new retaining track.

- Firmly bolt door plate on lower edge and on the retaining


track not cut.

- Secure outer door panel to new retaining track with


securing blocks.

Installation notes for adhering a new outer door plate

Note:

„ If both outer door plates must be replaced on a side,


follow the sequence. First the rear outer door plate
and then the front outer door plate is aligned and
adhered. For alignment of rear outer door panel to
front outer door panel, adhere long securing blocks.

„ If the cataphoretic paint coating of outer door plate is


damaged on the inside in the adhesion area or if
there is paint there, this area must be primed using
glass/paint primer D 009 200 02.

„ 1K window adhesive DH 009 100 must be heated for


Rear door Page 25 / 44

20 minutes in cartridge heater V.A.G 1939 A .

- Apply adhesive material using cartridge gun V.A.G 1628


onto application surfaces at a right angle to the retaining
track.

Warning!

Outer door plate must be installed within 10 minutes,


otherwise bonding properties of adhesive will be
impaired.

„ Place outer door panel on retaining tracks with help


of both assembly blocks, center with wedges and
adjustment gauge 3371 and press assembly block
application surfaces onto surrounding components.

„ Secure outer door panel during curing time with


securing blocks.

„ After installing, align outer door plate to the other


components and gap dimensions must be uniform.

„ If the adhesive bead has been applied too thickly


and the adhesive expands out between retaining
track and outer door plate, then the excess adhesive
must be removed.

Minimum curing time

Warning!

Special requirements must be fulfilled for replacing


bonded outer door plates. One of these standards for
example is, that a freshly bonded outer door plate
must comply with the safety elements, even in an
accident, once the adhesive has exceeded the
Rear door Page 26 / 44

prescribed curing time.

The minimum curing time for outer door panel with 1K


adhesive DH 009 100 is 180 minutes.

By minimum curing time, it is meant the time from bonding


in the outer door plate up to use in the vehicle, or until
further work can be performed. During this time, the vehicle
must stand on an even surface at room temperature (at
least 15 C).

Warning!

The vehicle is operationally ready only after the


minimum curing time has elapsed.

Cleaning when soiled by adhesive sealing material

- Adhesive remover D 002 000 10 is to be used as a


cleaning solution. Observe safety precautions when
processing.

Warning!

When cleaning the vehicle, outer door plate bonded in


immediately beforehand must not be shifted.

- First clean paint surface coarsely using a dry rag.


Eliminate remaining soiling using adhesive removal
solution D 002 000 10.

- Clean plastic trim: Allow adhesive sealing material to


harden (about 1 hour) and then peel off.

Inner door part, assembly overview

Note :

„ The description applies to the right side. The left side


is derived accordingly from this.
Rear door Page 27 / 44

„ Window shaft seal

„ Insulation

„ Qty. 4

„ 20 mm x 40 mm
commercially available cloth
reinforced adhesive tape

Door handle and door lock, assembly overview

Note :

„ The description applies to the right side. The left side


is derived accordingly from this.
Rear door Page 28 / 44

„ Door lock

„ Door lock can only be


removed in conjunction with
the outer door plate.

„ Removing and installing


58-1, Door lock, removing
and installing

„ Angle bracket

„ Not installed in Rabbit/GTI.

„ Expanding rivet

„ Not installed in Rabbit/GTI.

„ Cable
Rear door Page 29 / 44

„ For disengaging lock of


interior door handle.

„ Cover

„ Does not belong to


packaged contents of door
lock

„ Is secured to door lock with


three tabs.

„ Mounting bracket

„ Removing 58-1, Bearing


bracket, removing

„ Screw

„ Backing

„ Component of door handle

„ Door handle with backing plate

„ Removing and installing


58-1, Door handle, removing
and installing

„ Cover cap

„ For lock cylinder housing


without opening for lock
cylinder.

„ Is secured to lock cylinder


housing with three tabs.

„ Housing

„ Removing and installing


58-1, Housing, removing and
installing

„ Without lock cylinder.

„ Backing

„ Torx screw
Rear door Page 30 / 44

„ Socket wrench T 10072

„ By loosening this bolt,


locking mechanism for the
housing Item - 11 - is
disengaged and may be
removed from mounting
bracket.

„ Screw

„ 18 Nm

„ Cable

„ For disengaging lock of


exterior door handle.

Housing, removing and installing

Note:

„ Removing and installing is described only for the


right housing. Removing and installing the left
housing is derived accordingly from this.

Removing

- Pry out cover cap in front of bolt - 1 - .

- Pull door handle - 2 - in - direction of arrow - and turn


screw - 1 - with socket wrench T 10072 until housing - 3 -
can be removed.

- Remove housing - 3 - at right angle to door from door


handle bearing bracket.
Rear door Page 31 / 44

Installing

- Insert housing - 2 - at right angle into door handle


mounting bracket.

Door handle - 1 - must make contact only lightly at door


plate.

- Now screw in the bolt - 3 - into bearing bracket using


socket wrench T 10072 .

Door handle engages again into lock cylinder housing with


a very audible click.

Note:

„ During installation, housing must be pressed onto


door plate. The door handle rests only lightly against
the door panel.

- Then, continue in reverse order of removal.

„ Then a function test must be performed with door


open, since the door cannot be opened if hood
release cable is not correctly adjustment or clipped
in.

Door handle, removing and installing

Note:

„ Removing and installing is described only for the


right door handle. Removing and installing the left
door handle is derived accordingly from this.

Removing
Rear door Page 32 / 44

- Removing housing: 58-1, Housing, removing and


installing .

- Pry out clip - 2 - from door handle - 1 - .

- Swivel door handle - 1 - out of door - arrow - .

Installing

- Guide assembly tool T 10118 into door


Rear door Page 33 / 44

through opening in inner door plate.

- Light the inner part of door using a


flashlight for better view.

- Hook assembly tool T 10118 into


spring - arrow A - .

- Engage spring into door lock by pulling


assembly tool T 10118 - arrow B - .

Release lever is now locked in position.

- Swivel door handle - 1 - into door.

- Pull clip - 2 - into plate cutout and engage clip into door
handle - 1 - - arrow - .

Note:

„ During installation, door handle - 2 - must be


pressed onto door plate.

„ Clip - 2 - must engage into door handle - 1 - with a


very audibly click.

Install housing 58-1, Installing

„ Then a function test must be performed with door


open, since the door cannot be opened if hood
release cable is not correctly adjustment or clipped
in.

Bearing bracket, removing

Note:

„ Removing and installing is described only for the


Rear door Page 34 / 44

right bearing bracket. Removing and installing the


left bearing bracket is derived accordingly from this.

Removing

- Remove housing 58-1, Housing,


removing and installing

- Remove door handle: 58-1, Door


handle, removing and installing

- Remove outer door panel: 58-1,


Outer door plate, removing and
installing

- Pull off retaining rubber - 4 - from


guide pin and retaining bolts on mount
upward.

- Pull bearing bracket - 1 - with guide pin


- 2 - out of mounts - 3 - .

Installing
Rear door Page 35 / 44

- Slide bearing bracket - 1 - with guide


pin - 2 - into mounts - 3 - .

- Secure retaining rubber - 4 - on guide


pin and retaining bolts on mount.

Door lock, removing and installing

Note:

„ Removing and installing is described only for the


right door lock. Removing and installing the left door
lock is derived accordingly from this.

Removing
Rear door Page 36 / 44

- Remove outer door panel 58-1, Removing

- Remove mounting bracket 58-1, Bearing bracket,


removing

- Disconnect harness connector - 4 - .

- Remove bolts - 6 - .

- Disengage cable - 3 - from actuator lever - 5 - and


remove door lock - 1 - .

Cover - 2 - is not supplied with delivery casing of door


lock.

Installing

Installation is performed in the reverse order of removal.

Tightening torques for bolts: 18 Nm

„ Then a function test must be performed with door


open, since the door cannot be opened if hood
release cable is not correctly adjustment or clipped
in.

Side impact protection, assembly overview

Caution!

The side impact member screws and nuts are painted


during production. That means that the threads could
shear off during removal with significant force.
Loosening of screws and nuts should be avoided
when possible
Rear door Page 37 / 44

„ Side impact protection

„ Bolts

„ Qty. 2

„ 20 Nm

„ Nut

„ Qty. 2

„ 20 Nm

„ Inner door part

Internal door seals

Inner door seals are equipped at the factory with sealant,


applied to door flange and then rolled on.
Rear door Page 38 / 44

Note:

„ During removal of the seal, sealant is distributed on


interior side of seal and flanks are bent up easily. If
the seal is re-installed, the sealing performance and
proper seating are no longer guaranteed.

„ For this reason, every completely removed seal


must be replaced with a so-called "hammer-stroke
seal" .

„ For partially removed seals, seal flanks must be


pressed together before installation.

Inner door seal, removing and installing

Note:

„ Removing and installing is described only for the


right inner door seal. Removing and installing the left
inner door seal is derived accordingly from this.

Removing
Rear door Page 39 / 44

- Pull off inner door seal from body


flange.

Installing
Rear door Page 40 / 44

- Align inner door seal with vulcanized


point - arrow b - at the height of the
lower hinge.

- Start installation of inner door seal in


upper radius - arrow a - of door
opening.

Outer door seal, removing and installing

Note:

„ Removing and installing is described only for the


right outer door seal. Removing and installing the left
outer door seal is derived accordingly from this.

„ Remove protective foil only immediately prior to


assembly. Processing temperature approx. 20 C.

„ It is exclusively adhesive remove D 002 000 10.


Rear door Page 41 / 44

„ The outer door seal must be applied immediately


after cleaning.

„ After 10 minutes, check the seal for a secure fit.

Removing

- Pull off outer door seal - 1 - from door -


2- .

Installing
Rear door Page 42 / 44

- Remove any adhesive residue that is


still present using the erasure disc for
stripe remover erase disc Z 432 290
TE .

- Always clean adhesion surface


immediately prior to adhering outer door
seal with adhesive removal solution D
002 000 10.

„ Adhesion surfaces must be free of


dust and grease and there must be
no residual adhesive present.

- Vulcanized point - arrow b - of outer


door seal - 1 - is located in center area
of door entry sill.

- Pull off foil cover and apply seal onto


door in upper radius - arrow a - . Do not
stretch outer door seal excessively so
that the seal is not too long at the end.
Rear door Page 43 / 44

- Press entire adhesive area of seal onto


door all around using application roller
3356 .

- After 10 minutes, perform test for


proper seal seating.

Note :

„ Part numbers are for reference only. Always check


with your Parts Department for the latest part
number information

Checking seal for secure seating

Check seal for firm setting 10 minutes


after adhering the seal.

- Try to put seal - 1 - outward by hand.

- If adhered area does not pull off in any


Rear door Page 44 / 44

areas, press seal on further once more


using application roller 3356 .
Volkswagen Golf V: Sunroof with glass panel (Meritor) Page 1 / 29

60 - 1

Sunroof with glass panel (Meritor)


Tools

Required special tools, workshop equipment, testing and


measuring equipment, and aids

„ Pinch roller 3356

„ Special hook 3370

„ Torque wrench 210 Nm V.A.G 1783

„ Trim removal wedge 3409


Sunroof with glass panel (Meritor) Page 2 / 29

Function

All moving functions of sunroof with glass panel can be


performed with ignition switched on.

After ignition is switched off, the movement functions can


be performed until either the driver or front passenger door
is opened.

The opening of glass panel for sliding and tilt position is


pre-selected using the rotary switch.

On the rotary switch, there are markings for preset sliding


and tilt positions of the glass panel.

Opening the sunroof in the so-called comfort position


prevents most driving noise which may occur when open
completely.

Switch for automatic preset

The sunroof with glass panel is equipped with a closing


force limit. Glass panel runs in the opposite direction if it
runs into an obstruction during the closing or opening
procedure from the tilt or sliding position.

In addition, there is an emergency close function. If there


are problems closing, sunroof with glass panel can be
forced closed by pressing the preselector, which must be
located in the "sunroof closed" position.

For the emergency close function, the closing force limit is


deactivated.

The drive motor for sunroof with glass panel is protected


against overheating via a running time limit. The protective
mechanism activates after an uninterrupted operation of
approx. two minutes. It can only be operated again after a
cool-off phase.

If current fails, sunroof with glass panel can be moved at


Sunroof with glass panel (Meritor) Page 3 / 29

drive motor using a hex wrench. The hex key wrench is


located in a holder on the back side of the molded
headliner near the cutout for the rear light unit.

Sunroof with glass panel, assembly overview

„ Glass panel for sunroof (one-


piece safety glass)

„ Remove glass panel for


sunroof 60-1, Glass panel
for sliding/tilting sunroof,
removing

„ Installing glass panel for


sunroof 60-1, Glass panel
for sliding/tilting sunroof,
installing

„ Adjusting glass panel for


sunroof 60-1, Glass panel
for sunroof, adjusting (height
Sunroof with glass panel (Meritor) Page 4 / 29

adjustment)

„ Panel seal

„ Adjusting panel seal 60-1,


Panel seal, adjusting

„ Seal joint at center in rear


area.

„ Panel seal, replacing 60-


1, Panel seal, replacing

„ Sun shield panel

„ Sun shield panel, removing


and installing 60-1, Sun
shield panel, removing and
installing

„ Screw

„ Screws are
microencapsulated and must
always be replaced after
removing.

„ 4x

„ 1.8 Nm

„ Spring glider

„ Bolted on to sun protection


panel.

„ 4x

„ Can be replaced separately

„ Removing 60-1,
Removing

„ Boots

„ For covering slotted guide


rail.

„ Removing 60-1,
Removing

„ Installing 60-1, Installing


Sunroof with glass panel (Meritor) Page 5 / 29

„ Water channel

„ Removing 60-1,
Removing

„ Guide locking hook

„ Removed together with


slotted rail

„ Removing 60-1,
Removing

„ End piece, upper part

„ Clipped to lower part of end


piece.

„ Removing 60-1,
Removing

„ End piece, lower part

„ Can be replaced separately

„ Use butyl adhesive sealing


cord AKL 450 005 05 for
sealing.

„ Assembly unit

„ Removing and installing


installation unit 60-1,
Installation unit, removing
and installing

„ If necessary use special


grease G 000 450 02
exclusively to grease guide
channels, otherwise the
functions cannot be
guaranteed.

Note :

„ Part numbers are for reference only. Always check


with your Parts Department for the latest part
number information

„ Screw
Sunroof with glass panel (Meritor) Page 6 / 29

„ Screws are
microencapsulated and must
always be replaced after
removing.

„ Qty. 3

„ 3.5 Nm

„ Hex key wrench for emergency


operation

„ Hex wrench is located in


molded headliner, at right
next to opening for rear
interior/reading light.

„ Rear interior and reading


lights, removing

Repair Manual, Electrical Equipment,


Repair Group 96, Rear interior and
reading lights, removing

„ Electrical drive motor

„ Removing 60-1, Drive


motor for glass panel of
sunroof, removing and
installing

„ Adjusting drive motor (zero


position) 60-1, Drive
motor for glass panel of
sunroof, adjusting (zero
position)

„ Spring

„ Qty. 2

„ To open wind deflector.

„ Clipped in on wind deflector


and cannot be replaced
individually.

„ Removing 60-1, Wind


deflector, removing and
installing
Sunroof with glass panel (Meritor) Page 7 / 29

„ Wind deflector

„ Removing 60-1, Wind


deflector, removing and
installing

„ Bearing for wind deflector

„ Qty. 2

„ Clipped in on wind deflector


and cannot be replaced
individually.

„ Removing 60-1, Wind


deflector, removing and
installing

„ Front guide

„ Can be slid individually out


of guide rail.

„ Removing 60-1,
Removing

„ Rear guide, lower part

„ Removed together with


slotted guide rail.

„ Removing 60-1,
Removing

„ Torx screw

„ Torx T25

„ 3 per side

„ 5 Nm

„ Slotted guide rail

„ Removing and installing


60-1, Slotted guide rail,
removing and installing

„ Spacer
Sunroof with glass panel (Meritor) Page 8 / 29

„ Removing and installing


60-1, Slotted guide rail,
removing and installing

Boots, removing and installing

Removing

- Slide sun shield panel toward rear.

- Tilt open sunroof glass panel.

- Carefully unclip boots - 1 - from lower


section of slotted guide rail - 3 - using a
trim removal wedge 3409 .

- Pull boots - 1 - off mounting pins - 4 -


.

- Disengage boots - 1 - at top - rear - 2 -


Sunroof with glass panel (Meritor) Page 9 / 29

- Remove boots - 1 - .

Installing

- Slide sun shield panel toward rear.

- Tilt open sunroof glass panel.

- Engage boots - 1 - first at top - rear - 2


- .

- Clip boots - 1 - with mounting pins - 4


- into slotted guide rail.

- Engage boots - 1 - at bottom, rear - 3 -


and clip boots in starting at front in lower
section of slotted guide rail.

Glass panel for sliding/tilting sunroof, removing


Sunroof with glass panel (Meritor) Page 10 / 29

- Remove boots 60-1, Removing .

- Remove mounting bolts - 1 - on left and right sides.

- Remove glass panel for sunroof - 2 - upward.

Warning!

Slotted guide rail must not be driven into "opened"


position with sunroof glass panel removed because
the rain channel is no longer pressed down by the
glass panel and may be wedged in roof.

Glass panel for sliding/tilting sunroof, installing

„ Panel must be installed in zero position (panel


closed).

Zero position:

Marking - arrow - on upper part of rear guide - 1 - must


be located on both sides between markings dimension - a
- at slotted guide rail - 2 - .

Link guide - 2 - must be engaged in guide rail (cannot be


moved by hand).

If this is not the case, adjust parallel movement 60-1,


Sunroof with glass panel (Meritor) Page 11 / 29

Parallel movement, adjusting

- Insert glass panel for sunroof - 2 - from above and screw


in mounting bolts - 1 - .

- Tighten mounting bolts - 1 - lightly.

- Adjust glass panel for sunroof (height adjustment): 60-


1, Glass panel for sunroof, adjusting (height adjustment)

Note:

„ Tighten bolts after panel height adjustment (4.5


Nm).

„ Install boots after panel height adjustment.

Glass panel for sunroof, adjusting (height adjustment)

Note:

„ The glass panel height adjustment is to be


performed after the glass panel has been closed out
of sliding position.

Zero position of glass panel for sunroof OK.


Sunroof with glass panel (Meritor) Page 12 / 29

- Remove boots: 60-1, Removing

- Loosen mounting bolts - 1 - for glass panel of sunroof -


2- .

- Drive sunroof glass panel into position "open" .

- Drive sunroof glass panel into position "closed" .

- Perform height adjustment for glass panel for sunroof at


front and rear on both sides as follows:

Panel adjustment at front:

- a - = 01 mm lower than roof

- arrow - = direction of travel

- Tighten front bolts to 5 Nm.

Panel adjustment at rear:

- b - = 01 mm higher than roof

- arrow - = direction of travel

- First tighten center, then rear bolts to 5 Nm.

Note:

„ To achieve the best possible exterior optical


Sunroof with glass panel (Meritor) Page 13 / 29

characteristics, make sure that the adjustment on left


and right sides is performed as evenly
(symmetrically) as possible.

„ Glass panel must not be higher than roof at any


point at front or lower than roof at any point at rear.

- Install boots 60-1, Installing .

Panel seal, adjusting

- Using a strip of cardboard about 0.3 mm thick (e.g.


business card), check if pretension between panel seal - 2
- and body is even all around. Cardboard should slide
through gap with firm resistance.

- Removing glass panel for sunroof 60-1, Glass panel


for sliding/tilting sunroof, removing

- If pretension is insufficient, the panel seal - 2 - can be


pressed open using a trim removal wedge 3409 - 1 - .

- If the pretension is excessive, press the panel seal - 1 -


closed around circumference using application roller
3356 .
Sunroof with glass panel (Meritor) Page 14 / 29

Panel seal, replacing

- Removing glass panel for sunroof 60-1, Glass panel


for sliding/tilting sunroof, removing

- Pull off seal - 1 - from glass panel for sunroof - 2 - .

- Pull new seal - 1 - at rear panel edge in center,


beginning from bottom to top, onto glass panel for sunroof -
2- .

Note:

„ Coat edge of panel with soapy water to facilitate


installation of seal.

„ If the seal is not correctly installed, the seal surface


is wavy.

„ Panel seal must be shortened corresponding to the


panel circumference.

- Installing glass panel for sunroof 60-1, Glass panel for


sliding/tilting sunroof, installing

- Adjusting panel seal 60-1, Panel seal, adjusting


Sunroof with glass panel (Meritor) Page 15 / 29

Wind deflector, removing and installing

Removing

- Open sunroof glass panel completely.

- Press wind deflector with height stop out of front roof cut-
out and tilt wind deflector open vertically.

- Insert special tool hook for front end 3370 between roof
edge and wind deflector bearing - arrow - .

- Pull wind deflector bearing out of side locking mechanism


of left and right guide rails using special tool hook for front
end 3370 in - direction of arrow - .

- Remove wind deflector upward from guide rail.

Installing

- Insert wind deflector into guide rail and slide wind


deflector with height stop under front roof cut-out at left and
right sides.

- Using light pressure, press wind deflector bearing into


guide rails.

Note:

„ Wind deflector bearing must engage in guide rails


audibly.

Sun shield panel, removing and installing

Removing

- Removing glass panel for sunroof: 60-1, Glass panel


for sliding/tilting sunroof, removing .
Sunroof with glass panel (Meritor) Page 16 / 29

- Slide sun shield panel slightly toward rear.

- Unthread front bolts - arrow - at left and right. Slide out


spring glider forward over the stop - 1 - .

- Slide sun shield panel forward and lift sun shield panel
slightly over the roof cutout and out.

- Unscrew rear bolts - arrow - at left and right. Slide


spring glider toward rear and remove sun shield panel - 1 -
upward.

Installing

Installation is performed in the reverse order of removal.

„ Then perform a function test.

Drive motor for glass panel of sunroof, removing and


installing

Removing

- Remove lights and operating unit


Sunroof with glass panel (Meritor) Page 17 / 29

Repair Manual, Electrical Equipment, Repair Group 96,


Interior lights, lamps, switches; lights and switches in roof
trim; removing and installing Front Interior Light -W1-,
vehicles with sunroof

Changing motor - detection of preselector switch:

Note:

„ In order to interrupt the release signal and thereby to


activate switch detection, the conditions described
below must be met.

„ If this is not the case, it may lead to the drive motor


incorrectly detecting the preset switch and the
selected position is not reached. If this happens, it
must be realized that glass panel will remain
stationary at a closed switch position approx. 10 cm
short of the actual closing position.

Warning!

Only remove and install drive motor for sunroof glass


panel when roof is closed (zero position).

Requirements for removing and installing the drive


motor are: Engine and ignition off, remove key and
open door.

- Switch off engine and ignition, remove key and open


door.

„ This state must be maintained up to installation of


the drive motor.

- Remove bolts - arrows - and pull off drive motor for


sunroof.

- Disconnect harness connector for drive motor of sunroof.


Sunroof with glass panel (Meritor) Page 18 / 29

Installing

„ The bolts for the sunroof drive motor are


microencapsulated and must always be replaced 3.5
Nm.

Installation is performed in the reverse order of removal.

- After installation has been performed, key can be


reinserted into lock cylinder of ignition/starter switch.

„ Then perform a function test.

Drive motor for glass panel of sunroof, adjusting (zero


position)

Adjustment of zero position may be necessary if the drive


motor was removed while not in zero position or the glass
panel of sunroof was closed or opened via emergency
operation.

Drive motor removed, but electrical wires connected.

- Move automatic rotary switch to "roof opened" position.

- Move automatic rotary switch to "roof closed" position.

- Move automatic rotary switch to "roof tilted" position.

- Move automatic rotary switch to "roof closed" position.

- Install drive motor in this position (zero position) with


sunroof glass panel closed.

„ Drive motor for glass panel of sunroof is in zero


position when a white dot can be seen in the
opening - arrow - of drive motor.

Automatic rotary switch for glass panel of sunroof,


Sunroof with glass panel (Meritor) Page 19 / 29

removing and installing

- Remove automatic rotary switch for sunroof glass panel

Repair Manual, Electrical Equipment, Repair Group 96,


Interior lights, lamps, switches; removing and installing
sunroof switch

Checking parallel movement

- Removing glass panel for sunroof 60-1, Glass panel


for sliding/tilting sunroof, removing .

Marking - arrow - on upper part of rear guide - 1 - must


be located on both sides between markings dimension - a
- at slotted guide rail - 2 - .

Link guide - 2 - must be engaged in guide rail (cannot be


moved by hand).

Parallel movement, adjusting

Note:

„ The parallel movement adjustment can only be


performed with removed drive motor and glass panel
(in zero position).
Sunroof with glass panel (Meritor) Page 20 / 29

- Remove drive motor for sunroof glass panel 60-1,


Drive motor for glass panel of sunroof, removing and
installing .

Marking - arrow - on upper part of rear guide - 1 - must


be located on both sides between markings dimension - a
- at slotted guide rail - 2 - .

Link guide - 2 - must be engaged in guide rail (cannot be


moved by hand).

- Slide upper part of guide - 1 - at left and right centered


between the markings.

- Install drive motor (zero position) in this position.

„ Then check zero position.

Installation unit, assembly overview


Sunroof with glass panel (Meritor) Page 21 / 29

„ Assembly unit

„ Removing and installing


60-1, Installation unit,
removing and installing

„ Screw

„ Qty. 12

„ 8 Nm

„ Connector

„ Connections for water drain


hoses

„ Drive motor for sunroof

„ Removing and installing


60-1, Drive motor for glass
Sunroof with glass panel (Meritor) Page 22 / 29

panel of sunroof, removing


and installing

Installation unit, removing and installing

Warning!

Only remove and install drive motor for sunroof glass


panel when roof is closed (zero position).

Requirements for removing and installing the drive


motor are: Engine and ignition off, remove key and
open door.

Removing

- Remove molded headliner


Sunroof with glass panel (Meritor) Page 23 / 29

Repair Manual, Body Interior, Repair


Group 70, Trim, noise insulation; roof
trim; removing and installing molded
headliner

- Disconnect water drain hoses - 4 -


from installation unit - 1 - .

- Disconnect harness connector - 3 -


from drive motor of glass panel for
sunroof - 5 - .

- Remove bolts - 2 - and remove


installation unit - 1 - from vehicle with a
second technician.

Installing

- With a second technician, insert


installation unit - 1 - into roof cutout.

- During installation, align installation unit


Sunroof with glass panel (Meritor) Page 24 / 29

- 1 - via two cylindrical pins (reversed


drill bit) 12 mm at right front - arrow -
and 10 mm left rear - arrow - in roof.

Installation unit must not make contact


with roof frame.

- Insert bolts - 2 - .

- Check wires and harness connectors


for electrical consumers at roof for
correct routing and reproduce if
necessary.

- Firmly bolt (8 Nm) installation unit - 1 -


of drive motor for sunroof - 5 - beginning
at left and right toward rear.

- Install water drain hoses - 4 - .

- Connect harness connector - 3 - for


drive motor of glass panel for sunroof - 5
- .

- Install molded headliner

Repair Manual, Body Interior, Repair


Group 70, Trim, noise insulation; roof
trim; removing and installing molded
headliner

Operation without electricity

Note:

„ If current fails, sunroof with glass panel can be


moved at drive motor using a hex wrench. Hex
wrench is located in molded headliner, at right next
to opening for rear interior/reading light.

- Illumination and control unit, removing

Repair Manual, Electrical Equipment, Repair Group 96,


Lights, lamps, switches - interior; Lights and switches in
roof trim
Sunroof with glass panel (Meritor) Page 25 / 29

- Guide hex wrench in bolt of drive motor.

- Push wrench upward - arrow - to release the drive


motor.

Bolt can be pushed inward by a few millimeters - a - .


Glass panel of sunroof can be moved only in this position.

Slotted guide rail, removing and installing

Removing

- Removing glass panel for sunroof 60-1, Glass panel


for sliding/tilting sunroof, removing

- Using a screwdriver, unclip spacer - 2 - at front of slotted


guide rail - 1 - and retaining hooks - arrows - at rear of
guide.

- Pull spacer - 2 - in - direction of arrow - out of slotted


guide rail - 1 - and guide retaining hook.
Sunroof with glass panel (Meritor) Page 26 / 29

- Fold up slotted guide rail - 1 - in - direction of arrow -


.

- Slide front guide - 2 - toward front and pull out slotted


guide rail - 1 - in - direction of arrow - from front guide -
2- .

Installing

Installation is performed in the reverse order of removal.

Link, removing and installing

Note:

„ Always replace guides with cable as a pair.

Removing

- Removing glass panel for sunroof 60-1, Glass panel


for sliding/tilting sunroof, removing

- Removing installation unit 60-1, Installation unit,


removing and installing .

- Remove drive motor for sunroof glass panel 60-1,


Drive motor for glass panel of sunroof, removing and
installing .
Sunroof with glass panel (Meritor) Page 27 / 29

- Remove slotted guide rail 60-1, Removing

- Using a screwdriver, carefully disengage rain channel - 1


- in - direction of arrow - on both sides at bearing on
guide retaining tabs - 2 - and remove rain channel.

- Disengage clip mechanism - arrows - of upper end


piece - 1 - from lower end piece - 2 - using a screw driver
and pull upper end piece off.

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


arrow - in guide rail - 3 - until the lock mechanism of
guide catch - 2 - is released.

- Pull lower part of rear guide - 1 - and guide catch - 2 -


together in - direction of arrow - out of guide rail - 3 - .
Sunroof with glass panel (Meritor) Page 28 / 29

Installing

Installation is performed in the reverse order of removal.

Water drain hoses, cleaning

Note:

„ For cleaning, an assisting tool is recommended,


such as a speedometer drive shaft inner cable,
approx. 2300 mm (90.5 in.) long.

Front water drain hoses:

Route water drain hoses at front on A-


pillar and end at facing wall
crossmember. Cleaning is performed
from the sliding/tilting roof cut-out.

Rear water drain hoses:


Sunroof with glass panel (Meritor) Page 29 / 29

The rear water drain hoses run through


the C-pillars and end in the rear wheel
housings. Start cleaning from the
wheelhousing outward, wheelhousing
liner must be removed to do so.
Volkswagen Golf 5 - Front bumper Page 1 / 10

63 - 1

Front bumper
Tools

Special tools, testers and auxiliary items required

„ Torque wrench 210 Nm V.A.G 1783

„ Torque wrench 40200 Nm V.A.G 1332

Bumper cover, repairing

Note:

„ Before replacing bumper cover, explore possibility of


repairing damage to plastic.

Description under Plastic repair methods

Bumper cover, assembly overview


Front bumper Page 2 / 10

„ Cover

„ Material PP/EPDM

„ Removing and installing


63-1, Front bumper cover,
removing and installing

„ Screw

„ 1.5 Nm

„ Screw

„ Qty. 4 per side

„ 2 Nm

„ Screw
Front bumper Page 3 / 10

„ Qty. 6

„ 1.5 Nm

„ Screw

„ Qty. 2

„ 5 Nm

„ Screw

„ Qty. 2

„ 5 Nm

Front bumper cover, removing and installing

Note:

„ Due to model variations, small deviations must be


considered during removal and installation.

Removing
Front bumper Page 4 / 10

- Remove radiator grille 66-3, Radiator


grille, removing and installing

- Remove bolts - 5 - and - 6 - .

- Remove bolts - 4 - from below.

- Unscrew bolts - 3 - and - 2 - (pointing


upward) in area of left and right
wheelhousing liners.

A second technician is required for the


rest of the removal procedure.

- With a second technician, pull cover - 1


- parallel out of guide profiles.

- Disconnect harness connectors of


installed electrical components and
hoses.

Installing
Front bumper Page 5 / 10

Installation is performed in the reverse order of removal.

- Make sure gaps are parallel and pay attention to gap


dimensions

Repair Manual, Body Collision Repair, Repair Group 00,


Technical data; Body gap dimensions

Front bumper attachments

„ Cover

„ Material PP/EPDM

„ Removing and installing


63-1, Front bumper cover,
removing and installing

„ Left protective molding


Front bumper Page 6 / 10

„ Material PP/EPDM

„ Locked to cover.

„ Protective molding can be


carefully released from
locking mechanisms using a
plastic wedge from outside
and removed.

„ Left vent grille

„ Pull forward out of locking


mechanism in - direction of
arrow -

„ Formed piece

„ Locked to cover.

„ Only to be removed from


removed bumper.

„ Spoiler bracket

„ Only to be removed from


removed bumper.

„ Spoiler

„ Material PC/ABS

„ Locked to cover.

„ Only to be removed from


removed bumper.

„ Center ventilation grid

„ Pull forward out of locking


mechanism in - direction of
arrow -

„ Screw

„ 1.5 Nm

„ Right vent grille


Front bumper Page 7 / 10

„ Remove screw - 8 - and pull


out forward in - direction of
arrow - .

„ Right protective molding

„ Material PP/EPDM

„ Locked to cover.

„ Protective molding can be


carefully released from
locking mechanisms using a
plastic wedge from outside
and removed.

Front bumper, substructure

„ Left air guide


Front bumper Page 8 / 10

„ Locked to lock carrier.

„ Left guide piece

„ Bolted to lock carrier.

„ Screw

„ Qty. 2 per bracket

„ 2 Nm

„ Cross member

„ Screw

„ Qty. 6

„ 8 Nm

„ Right air guide

„ Locked to lock carrier.

„ Screw

„ Qty. 2 per bracket

„ 2 Nm

„ Right guide piece

„ Bolted to lock carrier.

„ Spreader nut

„ Qty. 3

„ Guide trim

„ Left and right

„ Removing:

- Attach at sides to fender


with screws - 11 - .
Front bumper Page 9 / 10

„ Screw

„ Qty. 3

„ 2 Nm

Bumper carrier, assembly overview

„ Bumper carrier

„ Screw

„ Qty. 4 per side

„ 60 Nm

„ Screw

„ Qty. 6
Front bumper Page 10 / 10

„ 8 Nm

„ Foam piece

„ Self-adhesive
Volkswagen Golf 5 - Front bumper (GTI) Page 1 / 11

63 - 2

Front bumper (GTI)


Tools

Special tools, testers and auxiliary items required

„ Torque wrench 210 Nm V.A.G 1783

„ Torque wrench 40200 Nm V.A.G 1332

Bumper cover, repairing

Note:

„ Before replacing bumper cover, explore possibility of


repairing damage to plastic.

Description under Plastic repair methods

GTI front bumper cover, assembly overview


Front bumper (GTI) Page 2 / 11

„ Cover

„ Material PP/EPDM

„ Removing and installing


63-2, GTI front bumper
cover, removing and
installing

„ Screw

„ 1.5 Nm

„ Screw

„ Qty. 4 per side

„ 2 Nm

„ Screw
Front bumper (GTI) Page 3 / 11

„ Qty. 8

„ 1.5 Nm

„ Screw

„ Qty. 2

„ 5 Nm

GTI front bumper cover, removing and installing

Note:

„ Due to model variations, small deviations must be


considered during removal and installation.

Removing
Front bumper (GTI) Page 4 / 11

- Remove radiator grille: 66-3, GTI


radiator grille, removing

- Remove bolts - 5 - .

- Remove bolts - 4 - from below.

- Unscrew bolts - 3 - and - 2 - (pointing


upward) in area of left and right
wheelhousing liners.

A second technician is required for the


rest of the removal procedure.

- With a second technician, pull cover - 1


- parallel out of guide profiles.

- Disconnect harness connectors of


installed electrical components and
hoses.

Installing

Installation is performed in the reverse order of removal.

- Make sure gaps are parallel and pay attention to gap


dimensions

Repair Manual, Body Collision Repair, Repair Group 00,


Technical data; Body gap dimensions

GTI front bumper, components


Front bumper (GTI) Page 5 / 11

„ Cover

„ Material PP/EPDM

„ Removing and installing


63-2, GTI front bumper
cover, removing and
installing

„ Left protective molding

„ Material PP/EPDM

„ Locked to cover.

„ Protective molding can be


carefully released from
locking mechanisms using a
plastic wedge from outside
and removed.
Front bumper (GTI) Page 6 / 11

„ Left vent grille

„ Removing:

- Remove screw - 4 -

- Starting at front - arrow a


- , loosen from locking
tabs, then remove from
cover toward center of
vehicle - arrow b - .

„ Screw

„ 1.5 Nm

„ Upper part of spoiler

„ Material PC/ABS

„ Locked to cover.

„ Only to be removed with


bumper removed and lower
part of spoiler unscrewed.

„ Lower part of spoiler

„ Material PC/ABS

„ Screwed to the upper part of


spoiler and noise insulation.

„ Screw

„ 7x

„ 1.5 Nm

„ Center ventilation grid

„ Can only be removed with


radiator grille removed.

„ Center of vent grille can be


carefully loosened from
latches from outside with a
plastic wedge and removed.
Front bumper (GTI) Page 7 / 11

„ Right vent grille

„ Removing:

- Remove screw - 4 -

- Starting at front - arrow a


- , loosen from locking
tabs, then remove from
cover toward center of
vehicle - arrow b - .

„ Right protective molding

„ Material PP/EPDM

„ Locked to cover.

„ Protective molding can be


carefully released from
locking mechanisms using a
plastic wedge from outside
and removed.

Front bumper, substructure


Front bumper (GTI) Page 8 / 11

„ Left air guide

„ Locked to lock carrier.

„ Left guide piece

„ Bolted to lock carrier.

„ Screw

„ Qty. 2 per bracket

„ 2 Nm

„ Cross member

„ Screw

„ Qty. 6
Front bumper (GTI) Page 9 / 11

„ 8 Nm

„ Right air guide

„ Locked to lock carrier.

„ Screw

„ Qty. 2 per bracket

„ 2 Nm

„ Right guide piece

„ Bolted to lock carrier.

„ Spreader nut

„ Qty. 3

„ Guide trim

„ Left and right

„ Removing:

- Attach at sides to fender


with screws - 11 - .

„ Screw

„ Qty. 3

„ 2 Nm

Bumper carrier, assembly overview


Front bumper (GTI) Page 10 / 11

„ Bumper carrier

„ Screw

„ Qty. 4 per side

„ 60 Nm

„ Screw

„ Qty. 6

„ 8 Nm

„ Foam piece

„ Self-adhesive
Front bumper (GTI) Page 11 / 11

License plate bracket, installing

Note:

„ Guide - 4 - shown in illustration does not apply for


this application

- Place license plate bracket - 2 - on grille.

Note:

„ The correct position of the license plate bracket - 2 -


is obtained by inserting the slot - 3 - on the license
plate bracket, into the center uppermost opening of
the grille.

- After aligning bracket and making sure bracket is level,


mark four points - 5 - to be drilled on grille.

- Drill four points - 5 - .

Hole diameter: 7.7 +0.2 mm.

- Install license plate bracket with four plastic expanding


rivets - 1 - .
Volkswagen Golf 5 - Rear bumper Page 1 / 11

63 - 3

Rear bumper
Tools

Special tools, testers and auxiliary items required

„ Torque wrench 210 Nm V.A.G 1783

„ Torque wrench 550 Nm V.A.G 1331

Bumper cover, repairing

Note:

„ Before replacing bumper cover, explore possibility of


repairing damage to plastic.

Description under Plastic repair methods

Bumper cover, assembly overview


Rear bumper Page 2 / 11

„ Cover

„ Material PP/EPDM

„ Removing and installing


63-3, Bumper cover,
removing and installing

„ Screw

„ Qty. 2

„ 5 Nm

„ Screw

„ 4x

„ 5 Nm
Rear bumper Page 3 / 11

„ Expanding rivet

„ Qty. 2

„ Screw

„ 3 per side

„ 2 Nm

„ Screw

„ 4x

„ 5 Nm

Bumper cover, removing and installing

Note:

„ Due to model variations, small deviations must be


considered during removal and installation.

Removing
Rear bumper Page 4 / 11

- Remove tail light assemblies

Repair Manual, Electrical Equipment,


Repair Group 94, Lights, lamps, switches
- exterior; removing and installing tail
lamp assemblies

- Unscrew bolts - 5 - in area of left and


right wheelhousing liner.

- Pry out expanding rivet - 4 - in area of


left and right wheel housing liners using a
screwdriver.

- Remove bolts - 2 - and - 3 - from


below.

- Remove bolts - 6 - from above.

A second technician is required for the


rest of the removal procedure.
Rear bumper Page 5 / 11

- With a second technician, pull cover - 1


- parallel out of guide profiles.

- Disconnect connectors of electrical


components present, license plate light

Repair Manual, Electrical Equipment,


Repair Group 94, Lights, lamps, switches
- exterior; License plate light

and, if equipped,

Repair Manual, Electrical Equipment,


Repair Group 94, Lights, lamps, switches
- exterior; parking assist system

Installing

Installation is performed in the reverse order of removal.

- Make sure gaps are parallel and pay attention to gap


dimensions

Repair Manual, Body Collision Repair, Repair Group 00,


Technical data; Body gap dimensions

Rear bumper attachments


Rear bumper Page 6 / 11

„ Cover

„ Material PP/EPDM

„ Removing and installing:


63-3, Bumper cover,
removing and installing

„ License plate lighting

„ Qty. 2

„ Removing

Repair Manual, Electrical Equipment,


Repair Group 94, Lights, lamps, switches
- exterior; license plate light

„ Towing eyelet cap


Rear bumper Page 7 / 11

„ Locked into the cover.

„ Spoiler

„ Material PC/ABS

„ Locked into the cover

„ Only to be removed from


removed bumper.

Rear bumper, substructure

„ Securing strip

„ Hex nut

„ 4x
Rear bumper Page 8 / 11

„ 2 Nm

„ Guide trim

„ Left and right

„ Hex nut

„ 3 per side

„ 2 Nm

„ Foil

„ Left and right

„ Self-adhesive

Bumper carrier, assembly overview


Rear bumper Page 9 / 11

„ Cross member

„ Screw

„ Qty. 6

„ 20 Nm

Tow hitch, assembly overview

Bolts - 3 - are sealing threaded connections and seal


the interior from exhaust gases and must be installed
in any case.

Note:

„ Tightening torques only refer to tow hitches


manufactured at the factory.
Rear bumper Page 10 / 11

„ Tightening torques of other trailer hitches must be


obtained from the respective manufacturer.

„ Tow hitch

„ Trailer hitch with removable


ball head is depicted.

„ Ball head

„ The removable ball head is


located in the left luggage
compartment storage
compartment.

„ Screw

„ Sealing threaded
connections
Rear bumper Page 11 / 11

„ 4x

„ 20 Nm

„ Screw

„ 4x

„ 50 Nm + 90 turn

„ Always replace bolts after


loosening

„ Cover

„ Material PP/EPDM

„ Removing and installing


63-3, Bumper cover,
removing and installing

„ Spring clamp

„ Qty. 2

„ Cover cap - trailer hitch

„ Rotary fastener

„ Qty. 2

„ Retaining washer

„ Qty. 2
Volkswagen Golf 5 - Flush bonded windows Page 1 / 25

64 - 1

Flush bonded windows


Tools

Special tools, testers and auxiliary items required

„ Cutting tool kit V.A.G 1474 A

„ Suction lifter V.A.G 1344

„ Cutting tools for glass V.A.G 1351

„ Window removing kit V.A.G 1755

„ Cartridge gun V.A.G 1628

„ Cartridge heater V.A.G 1939


Flush bonded windows Page 2 / 25

„ Electric cutter V.A.G 1561 A

„ Cutting blade V.A.G 1561/2

„ Scraper V.A.G 1561/8

„ Cutting blade V.A.G 1561/10

„ Cutting blade V.A.G 1561/19

„ Double cartridge gun VAS 5237


Flush bonded windows Page 3 / 25

Materials

DA 004 600 A2 1) 2)
„ 2C- window adhesive

DH 009 100 03 3) 4)
„ 1C- window adhesive

D 181 801 A1 5)
„ Activator

D 009 200 02 5)
„ Glass primer/paint primer

D 009 401 04 5)
„ Cleaning solution

D 009 500 25 5)
„ Primer applicator
Flush bonded windows Page 4 / 25

D 002 000 10 5)
„ Adhesive remover

357 853 999


„ Cutting cord

5) Materials are stored in box D 004 700.


1) Observe minimum curing time: 64-1, Minimum curing
time
4) Heat according to manufacturers instructions using
cartridge heater V.A.G 1939
2) Double cartridge pistol VAS 5237 must be used to
process this material.
3) Smallcartridge (110 ml) for sealing and/or when a 400
ml double cartridge is not sufficient.

Windshield, assembly overview


Flush bonded windows Page 5 / 25

„ Windshield

„ Removing 64-1,
Windshield, removing

„ Installing 64-1,
Windshield, installing

„ Window adjuster

„ 443 845 631 A

„ Plenum chamber cover

„ Must only be pulled out of


binding profile by hand.

„ Removing 64-1, Remove


plenum chamber cover

„ Installing 64-1, Installing


plenum chamber cover

„ Binding profile

„ Is part of windshield.

„ Spacer

„ Is part of windshield.

„ PUR adhesive sealant

„ Bead cross section: Width =


6.5 mm, height = 10 mm
(including residual material
on window glass and window
flange)

„ Minimum curing time 64-


1, Minimum curing time

„ Water deflector

„ Removing 66-4,
Removing

„ Installing 66-4, Installing


Flush bonded windows Page 6 / 25

„ Sealing lip

„ If sealing lip is damaged


when cut out, a new
windshield must be installed.

Plenum chamber cover, assembly overview

„ Plenum chamber cover

„ Must only be pulled out of


binding profile by hand.

„ removing 64-1, Remove


plenum chamber cover

„ Installing 64-1, Installing


plenum chamber cover
Flush bonded windows Page 7 / 25

„ Plenum chamber - bulkhead

„ Windshield

„ Seal - plenum chamber

„ Binding profile

„ Is part of windshield.

Remove plenum chamber cover

- Remove wiper arms

Repair Manual, Electrical Equipment,


Repair Group 92, Front windshield wiper
system; Front windshield wiper system,
removing and installing; Wiper arms,
Flush bonded windows Page 8 / 25

removing and installing

Warning!

Plenum chamber cover must not be


pried off using any tool. Window will
be damaged and may crack later

- Pull off seal of plenum chamber - 4 -


on the entire length of facing wall - 2 - of
plenum chamber.

- Pull out plenum chamber cover - 1 -


starting at right carefully upward from
binding profile - 5 - .

Installing plenum chamber cover

Warning!

Striking the plenum chamber cover


can cause cracks in the windshield.
Flush bonded windows Page 9 / 25

- Spray binding profile - 5 - with soap


solution so that plenum chamber cover -
1 - can be pressed in more easily.

- Place plenum chamber cover - 1 - onto


binding profile - 5 - and engage it with
binding profile - 5 - starting from center
using light pressure.

- Install plenum chamber seal - 4 - and


windshield wiper.

Note :

„ In new windshields, an insert is installed in the


binding profile. This insert must be removed before
installing the plenum chamber cover.

Windshield, removing

- Remove A-pillar trim

Repair Manual, Body Interior, Repair Group 70,


Trim/insulation; Pillars and side trim

- Remove all sun visors

Repair Manual, Body Interior, Repair Group 68, Interior


equipment; storage compartments, covers and panels

- Remove interior mirror

Repair Manual, Body Interior, Repair Group 68, Interior


equipment; interior mirror

- Remove left and right drip rails 66-4, Drip rail,


removing and installing
Flush bonded windows Page 10 / 25

- Push the cover for instrument panel V.A.G 1474/8 - 1 -


in between the windshield and instrument panel.

- Thrust awl V.A.G 1474/2 - 2 - through adhesive bead.

- Push cutting cord end - 3 - using awl V.A.G 1474/2 - 2 -


through adhesive sealing material into the vehicle interior.

- Secure cutting cord end on the inside against pulling out


using pull handle V.A.G 1351/1 - 3 - .

- Loosen sealing lip from window flange in upper area of


windshield with a plastic wedge and spray with cleaning
solution D 009 401 04 (as a substitute for lubricant).

- Insert cutting cord - 2 - in upper area of windshield by


aid of small tube - 1 - .

- For very narrow gap dimensions, guide cutting cord from


outside and press under lip using plastic wedge.

- Lay cutting cord - 2 - around the window and also guide


inside the second cord end.

„ Make sure that cutting cord - 2 - is inserted under


the window at the corners.
Flush bonded windows Page 11 / 25

- Secure second cutting cord end onto spooling tool V.A.G


1654 A .

- Set spooling tool V.A.G 1654 A to "position I" .

- Relocate spooling tool V.A.G 1654 A appropriately and


cut window free.

- While cutting free, press cutting cord against window


using a wedge V.A.G 1474/5 to prevent damage to
instrument panel and to have clearance at window flange.

Windshield, installing

Preparing undamaged window for glazing 64-1,


Undamaged window, preparing for glazing

Preparing new window for glazing 64-1, Preparing new


window without pre-coating for glazing

Preparing window flange for glazing 64-1, Window


flange, preparing for glazing

Installation notes 64-1, Installation notes

Minimum curing time 64-1, Minimum curing time

Rear window, assembly overview


Flush bonded windows Page 12 / 25

„ Rear window

„ rRemoving 64-1,
Undamaged rear window,
removing

„ Installing 64-1, Rear


window, installing

„ Gasket

„ for rear window wiper

„ Rear lid

„ PUR adhesive sealant

„ Bead cross section: Width =


6.5 mm, height = 10 mm
(including residual material
on window glass and window
Flush bonded windows Page 13 / 25

flange).

„ Minimum curing time 64-


1, Minimum curing time

„ Trim

„ Removing trim

Repair Manual, Body Interior, Repair


Group 70, Trim/insulation; Rear lid trim

„ Window antenna contact

„ Right and left

Undamaged rear window, removing

- Removing side luggage compartment trim

Repair Manual, Body Interior, Repair Group 70,


Trim/noise insulation; luggage compartment trim

- Removing rear window wiper motor

Repair Manual, Electrical Equipment, Repair Group 92,


Rear window wiper and washer system, servicing
Flush bonded windows Page 14 / 25

- Disconnect left and right heated rear window and window


antenna connectors - 1 - .

- Thrust awl V.A.G 1474/2 - 1 - through adhesive bead.

- Pull cutting cord - 2 - inside through adhesive material


using awl V.A.G 1474/2 - 1 - .

- Secure end of cutting cord - 3 - with handle - 1 - before


Flush bonded windows Page 15 / 25

pulling out.

- Lay cutting cord - 3 - around the window and also guide


inside the second cord end.

- Secure end of cutting cord to spooling tool V.A.G 1654 -


2- .

- Place spooling tool V.A.G 1654 - 2 - in "position I" .

- Relocate spooling tool V.A.G 1654 - 2 - appropriately


and cut window free.

- While cutting free, press cutting cord - 3 - against


window using wedge V.A.G 1474/5 to have clearance to
window flange.

Damaged rear window, removing

- Protect body and interior from glass splinters.

- Remove glass pieces from adhesive material.

- Disconnect harness connectors for window defroster and


window antenna.

- Bond flange - 1 - all around with fabric reinforced


adhesive tape.

- Cut through adhesive material (with glass residue) in


window cutout with electric cutter V.A.G 1561 A - 3 - and
cutting blade V.A.G 1561/10 - 2 - .

Warning!

Always wear protective goggles and leather gloves.


Flush bonded windows Page 16 / 25

Rear window, installing

Preparing undamaged window for glazing 64-1,


Undamaged window, preparing for glazing

Preparing new window for glazing 64-1, Preparing new


window with pre-coating for glazing

Preparing window flange for glazing 64-1, Window


flange, preparing for glazing

Installation notes 64-1, Installation notes

Minimum curing time 64-1, Minimum curing time

Rear side window, assembly overview

„ Side window

„ Remove side window 64-


1, Undamaged rear side
window, removing
Flush bonded windows Page 17 / 25

„ Installing side window 64-


1, Rear side window,
installing

„ PUR adhesive sealant

„ Bead cross section: Width =


6.5 mm, height = 10 mm
(including residual material
on window glass and window
flange).

„ Minimum curing time 64-


1, Minimum curing time

„ Window flange

„ Seal with spacer

„ Component part of side


window.

Undamaged rear side window, removing

- Loosen interior trim in upper area

Repair Manual, Body Interior, Repair Group 70,


Trim/insulation; Luggage compartment trim

- Remove B- and C-pillar trim

Repair Manual, Body Interior, Repair Group 70, Trim


panels/insulation; Pillar and side trim
Flush bonded windows Page 18 / 25

- Thrust awl V.A.G 1474/2 - 1 - through adhesive bead.

- Push cutting cord through adhesive sealing material into


vehicle interior - 3 - using awl V.A.G 1474/2 - 2 - .

- Secure end of cutting cord on inside against pulling out


using pull handle V.A.G 1351/1 - 1 - .

- Loosen sealing lip all around from window flange and


spray with cleaning solution D 009 401 01 (as a substitute
for lubricant).

- Place cutting cord - 2 - around side window.

- Using a small tube - 3 - , guide cutting cord - 2 -


between lip and window flange and also guide second cord
end inside.

- Secure second cord end to spooling tool V.A.G 1654 A


and cut window free by positioning spooling tool.

- While cutting free, press cutting cord against window


using wedge V.A.G 1474/5 to have clearance to window
flange.

Damaged rear side window, removing

Removing a damaged side window is performed the same


as for removing a damaged rear window.
Flush bonded windows Page 19 / 25

Rear side window, installing

Preparing undamaged window for glazing 64-1,


Undamaged window, preparing for glazing

Preparing new window for glazing 64-1, Preparing new


window without pre-coating for glazing

Preparing window flange for glazing 64-1, Window


flange, preparing for glazing

Installation notes 64-1, Installation notes

Minimum curing time 64-1, Minimum curing time

Undamaged window, preparing for glazing

Note:

„ When re-using an undamaged window, cut back


remaining adhesive sealant to 12 mm shortly before
re-adhering, do not damage primer and ceramic
coating.

„ Remaining material serves as adhesion base for


newly applied adhesive sealing compound.

Warning!

Do not prime or use a cleaning solution on the


adhesive surface. Keep adhesive surface free of dirt
and grease.

Exception: If bonding is not performed immediately after


cutting back, the remaining material must be activated
using the activator D 181 801 A1.

Note:

„ Part numbers are for reference only. Always check


with your Parts Department for the latest part
Flush bonded windows Page 20 / 25

number information

Preparing new window without pre-coating for glazing

Ceramic coating is only still applied on all new windows


and sprayed on sealing lips with spacer.

Exception: Rear window has no sealing lip and no spacer.

1 - Sealing lip
2 - Spacer
3 - Window

Note:

„ The application area for adhesive bead 3 is not pre-


coated and not primed.

- Clean window circumference to width of 20 mm all


around using cleaning solution D 009 401 04.

- Then rub window circumference dry using a lint-free rag.

Warning!

Ceramic application on window is not primer! It must


be primed before the application of adhesive sealing
material! Only use primer D 009 200 02!
Flush bonded windows Page 21 / 25

- Apply primer - 4 - evenly in one motion using applicator


D 009 500 25 - 3 - to the previously cleaned area - 1 - of
window.

Make sure that glass adhesive is applied to primed area at


a distance of approx. 2 mm from sealing lip - 2 - .

„ Air dry time approx. 10 minutes

Preparing new window with pre-coating for glazing

The replacement rear window is pre-coated. A PUR


application area for adhesive bead is sprayed onto this
window.

- Rub off pre-coating with a dry, lint-free cloth.

Warning!

Do not prime or use a cleaning solution on the pre-


coating!
Flush bonded windows Page 22 / 25

- Now apply activator - 2 - uniformly in one stroke using


applicator D 009 500 25 - 1 - .

„ Allow activator to air dry for at least 10 minutes.

Note:

„ Activator must not come into contact with the paint,


otherwise paint will be damaged.

Window flange, preparing for glazing

- Cut back remaining material on body flange using electric


cutter V.A.G 1561 A and scraper V.A.G 1561/8 , do not
remove all residue under any circumstances.

Note:

„ Remaining material serves as adhesion base for


newly applied adhesive sealing compound. Keep
adhesive surfaces free of dirt and grease.
Flush bonded windows Page 23 / 25

Warning!

Activator must not come into contact with the paint -


otherwise paint will be damaged.

Exception: If bonding is not performed immediately after


cutting back, the remaining material must be activated
using the activator D 181 801 A1.

Note:

„ Part numbers are for reference only. Always check


with your Parts Department for the latest part
number information

„ If body flange is being worked on or is partially


replaced, it must be cleaned and primed again after
painting the corresponding area.

Installation notes

- Using double cartridge pistol VAS 5237 , apply adhesive


material all around on primed area - 1 - and onto cut back
adhesive head at right angle to window.

Warning!

Window must be installed within 10 minutes, otherwise


bonding properties of window adhesive will be
impaired.

„ Insert window into window cut out using two double


Flush bonded windows Page 24 / 25

suction lifters (V.A.G 1344), center and press in up


to spacer.

„ Secure windshield using window adjuster (443 845


631 A) during curing time.

„ The plenum chamber cover must always be installed


as described on page 64-1, Installing plenum
chamber cover .

„ Replace stickers (e.g. for airbag).

„ Insert rubber seal for axle of rear windshield wiper


motor into rear window.

„ Activator must not be applied onto distributing wire


for window heater.

„ Markings are placed at left and right on rear window


for applying adhesive material.

„ After installing, sides of rear window must not project


out beyond the contour of the rear lid under any
circumstances!

„ Secure rear window using adhesive tape during


curing time.

„ If the adhesive bead has been applied too thick and


the adhesive expands onto the area of the window
heating, then the excess adhesive must be
removed.

Minimum curing time

Warning!

Special requirements must be fulfilled for replacing


bonded windows. One of these standards for example
is, that a freshly bonded windshield must comply with
the safety elements, even in an accident, once the
adhesive has exceeded the prescribed curing time.

The minimum curing time for 2K adhesive DA 004 600 A2


is 3 hours for all windows.
Flush bonded windows Page 25 / 25

Curing time means the time from when the window is


bonded to when the vehicle is put back into use. During
this time, the vehicle must stand on an even surface at
room temperature (at least 15 C).

Warning!

The vehicle is operationally ready only after the


minimum curing time has elapsed.

Paint damage, repairing

For paint damage in visible areas and for severely


damaged points in the non-visible area of removed
window, paint structure must be repaired according to
specifications of "Paint Repair Manual" .

The following repair method applies to minor paint damage


in an area of removed window which is not visible: Apply
two coats of glass/paint primer D 009 200 02 over each
other (wet on wet) in opposite directions.

- Apply once over damaged area.

- Air dry for 10 minutes.

- Apply a second coat but apply it in the opposite direction


as the first one.

Cleaning when soiled by adhesive sealing material

- It is recommended to use adhesive remover D 002 000


10 as a cleaning solution. Observe safety precautions
when processing.

Warning!

When cleaning from vehicle interior, the window that


was just installed must not be pressed outward.

- First clean paint surface coarsely using a dry rag.


Eliminate remaining soiling using adhesive removal
solution D 002 000 10.

- Clean plastic trim: Allow adhesive sealing material to


harden (about 1 hour) and then peel off.
Volkswagen Golf 5 - Front door window Page 1 / 17

64 - 2

Front door window


Tools

Special tools, testers and auxiliary items required

„ Torque wrench 210 Nm V.A.G 1783

Front door window, assembly overview

Note :

„ The description applies to the right side. The left side


is derived accordingly from this.

„ Bolt - 4 - is accessible from inside and outside. The


bolt as viewed from the outside has a right-hand
thread. This means: seen from the outside, bolt is
loosened by turning toward left, seen from the
inside, bolt is loosened by turning toward right.
Front door window Page 2 / 17

„ Door window

„ Removing and installing


64-2, Door window,
removing and installing

„ Window guide

„ Removing and installing


64-2, Window guide,
removing and installing

„ Mount

„ Screw

„ Accessible from outside


(right-hand threads), loosen
by turning left, remove outer
door plate 58-1, Outer
door plate, removing and
Front door window Page 3 / 17

installing

„ Accessible from insdie,


loosen by turning right,
remove trim from door

Repair Manual, Body Interior, Repair


Group 70, Trim/insulation; Door trim

„ Qty. 2

„ 8 Nm

„ Window regulator

„ Removing and installing


64-2, Window regulator,
removing and installing

„ Cover cap

„ Qty. 2

„ Window regulator motor

„ Removing and installing


64-2, Window regulator
motor, removing and
installing

Door window, removing and installing

Note:

„ Removing and installing is described only for the


right door window. Removing and installing the left
door window is derived accordingly from this.

„ Bolt - 4 - is accessible from inside and outside. The


bolt as viewed from the outside has a right-hand
thread. This means: seen from the outside, bolt is
loosened by turning toward left, seen from the
inside, bolt is loosened by turning toward right.

Removing
Front door window Page 4 / 17

- Remove front door trim

Repair Manual, Body Interior, Repair


Group 70, Trim panels/insulation; Door
trim

- Pry out cover caps - 4 - .

- Lower door window - 1 - until locking


screws - 3 - for mount - 2 - are
accessible.

Warning!

Loosen screw - 3 - from inside by


turning toward right.

- Loosen bolts - 3 - (do not remove)


from inside by turning toward right and
Front door window Page 5 / 17

press apart clamping brackets.

Note :

„ If the work step is not possible due to a malfunction


via the electrical window regulator, window regulator
motor can be unscrewed to be able to slide window
down.

- Raise rear door window - 1 - and swivel out of door


toward front in - direction of arrow - .

Installing

- Insert door window - 1 - into door in - direction of


arrow - .

- Make sure that door window - 1 - is inserted correctly in


window guide.

- Now bolt must be tightened by turning toward left.

Further installation is in reverse order of removal.

„ Then perform function test.


Front door window Page 6 / 17

Door window, adjusting

- Remove front door trim

Repair Manual, Body Interior, Repair


Group 70, Trim panels/insulation; Door
trim

- Pry out cover caps - 4 - .

- Lower door window - 1 - until locking


screws - 3 - for mount - 2 - are
accessible.

Warning!

Loosen screw - 3 - from inside by


turning toward right.
Front door window Page 7 / 17

- Loosen bolts - 3 - (do not remove)


from inside by turning toward right and
press apart clamping brackets.

- Press door window - 1 - using light pressure into


clamping brackets - direction of arrow - and align door
window to rear window guide without exerting pressure.

- While doing this, make sure that door window - 1 -


stands parallel to window guide.

- Tighten clamping brackets with screws - 3 - from inside


by turning toward left.

Tightening torque for bolt: 8 Nm.

„ Then perform function test.

Further installation is in reverse order of removal.

Window regulator motor, assembly overview

Note :

„ The description applies to the right side. The left side


is derived accordingly from this.
Front door window Page 8 / 17

„ Window regulator motor

„ Removing and installing


64-2, Window regulator
motor, removing and
installing

„ Screw

„ Qty. 3

„ 3.5 Nm

Window regulator motor, removing and installing

Note:

„ Removing and installing is described only for the


right window regulator motor. Removing and
Front door window Page 9 / 17

installing the left window regulator motor is derived


accordingly from this.

„ Window regulator motor should also be removed


with mounting plate with outer door plate removed.

Removing

- Remove front door trim

Repair Manual, Body Interior, Repair


Group 70, Trim panels/insulation; Door
trim

- Fix window using adhesive tape so that


it does not slip down.
Front door window Page 10 / 17

- Disconnect harness connectors -


arrows - using a screwdriver in -
direction of arrow - .

- Remove the three bolts - 2 - .

- Remove window regulator motor with


control module - 1 - from mounting
plate.

Installing

- Attach window regulator motor - 1 -


and connect harness connector - arrows
- .

- Pull door window lightly up and down


so that splines are located better
between motor and cable drum.

- Tighten bolts - 2 - for window regulator


motor to torque setting 3.5 Nm).
Front door window Page 11 / 17

- Drive the window regulator up and


down to the limit stops, twice. By doing
this, window regulator motor is normed
and ready for operation and activates
pinch protection.

Then, continue in reverse order of


removal.

Window guide, assembly overview

Note :

„ The description applies to the right side. The left side


is derived accordingly from this.

„ For reasons of clarity, outer door plate is not


depicted in the illustration.

„ Window guide
Front door window Page 12 / 17

„ Trim

„ Screw

„ Qty. 2

„ 2 Nm

„ Window frame at inner door


part

Window guide, removing and installing

Note:

„ Removing and installing is described only for the


right window guide. Removing and installing the left
window guide is derived accordingly from this.

„ For reasons of clarity, outer door plate is not


depicted in the removal and installation.

Removing
Front door window Page 13 / 17

- Remove rearview mirror 66-2,


Exterior rearview mirror, removing and
installing .

- Pull window guide - 1 - out of mount.

- Remove bolts - 3 - (two pieces) and


pull off panel - 2 - in direction of B-pillar -
direction of arrow - .

- Pull window guide - 1 - all around from


window frame - 4 - and upward out of
window shaft.

Installing

Installation is performed in the reverse order of removal.

Note:

„ While installing window guide, make sure it is seated


evenly (wind noise).
Front door window Page 14 / 17

Window regulator, assembly overview

Note :

„ The description applies to the right side. The left side


is derived accordingly from this.

„ Window regulator

„ Removing and installing


64-2, Window regulator,
removing and installing

„ Screw

„ 4x

„ 8 Nm
Front door window Page 15 / 17

„ Screw

„ Qty. 5, 4 door

„ Qty. 4, 2 door

„ 8 Nm

„ Drive motor

„ Mounting plate

Window regulator, removing and installing

Note:

„ Removing and installing is described only for the


right window regulator. Removing and installing the
left window regulator is derived accordingly from
this.

„ Depending on model variations with 2 and 4 doors,


small deviations must be considered when removing
and installing.

Removing
Front door window Page 16 / 17

- Remove outer door panel 58-1,


Outer door plate, removing and
installing

- Remove side impact protection 57-1,


Side impact protection, assembly
overview

- Remove door window 64-2, Door


window, removing and installing

- Remove bolts - 2 - from mounting plate


- 5- .

- Remove bolts - 3 - for window


regulator.

- Remove window regulator - 1 - with


drive motor - 4 - and mounting plate - 5
- for window regulator motor from inner
door part.

- Disconnect harness connectors for


Front door window Page 17 / 17

window regulator motor 64-2,


Removing

Installing

Installation is performed in the reverse order of removal.

„ A function test must be performed before outer door


plate is installed.
Volkswagen Golf 5 - Rear door window Page 1 / 17

64 - 3

Rear door window


Tools

Special tools, testers and auxiliary items required

„ Release tool T 10236

„ Torque wrench 210 Nm V.A.G 1783

Rear door windows, assembly overview

Note :

„ The description applies to the right side. The left side


is derived accordingly from this.
Rear door window Page 2 / 17

„ Door window

„ Removing and installing


64-3, Door window,
removing and installing

„ Window guide

„ Component of fixed door


window.

„ Removing and installing


64-3, Fixed door window
with window guide, removing
and installing

„ Fixed door window

„ Is component of window
guide.
Rear door window Page 3 / 17

„ Removing and installing


64-3, Fixed door window
with window guide, removing
and installing

„ Window regulator guide

„ Spreader pin

„ Always replace when


performing assembly work at
door window

„ Spreader plug

„ Always replace when


performing assembly work at
door window

„ Cover cap

„ Window regulator

„ Removing and installing


64-3, Window regulator,
removing and installing

„ Window regulator motor

„ Removing and installing


64-3, Window regulator
motor, removing and
installing

Door window, removing and installing

Note:

„ Removing and installing is described only for the


right rear door window. Removing and installing the
left rear door window is derived accordingly from
this.

„ When removing and installing door window,


spreader pin and spreader plug are also accessible
from outside when outer door plate has been
removed.
Rear door window Page 4 / 17

Removing

- Remove rear door trim

Repair Manual, Body Interior, Repair Group 70, Trim


panels/insulation; Door trim

- Pry out cover caps - 5 - .

- Lower door window until spreader pin - 3 - and spreader


plug - 4 - are accessible in window regulator cut-out.

Note:

„ If the work step is not possible due to a malfunction


via the electrical window regulator, window regulator
motor can be unscrewed to be able to slide window
down.

- Screw in a 5 mm bolt (approx. 70 mm long) into spreader


pin - 3 - and pull bolt out of spreader plug - 4 - .

- Screw a 8 mm bolt (approx. 80 mm long) into spreader


plug - 4 - .

Note:

„ When screwing the bolt into spreader plug, do not


use excessive force on the plug otherwise it may fall
inside into the door.
Rear door window Page 5 / 17

- Pull spreader plug - 4 - our of clamping bracket - 1 -


and thereby out of door window.

- Pull window guide - 3 - out of mount.

- Remove bolts - 2 - and pull off panel - 1 - in direction of


B-pillar - direction of arrow - .

- Pull door window upward - arrow - out of window shaft.

Installing

Note:

„ Spreader plug and spreader pin must always be


replaced when performing assembly work on door
window.

„ Before inserting spreader plug and spreader pin,


check window for damage.
Rear door window Page 6 / 17

- With door window - 1 - removed, insert spreader plug -


3 - centered.

- Press spreader pin - 2 - flush into spreader plug - 3 - .

- Guide door window - 1 - into door and insert door


window onto mount of window regulator guide - 4 - .

- Using a light pressure from above - arrow - , engage


window - 1 - into window regulator guide - 4 - .

- Then, continue in reverse order of removal.

„ A function test must be performed before door trim is


installed.

Fixed door window with window guide, assembly


overview
Rear door window Page 7 / 17

„ Window guide

„ Component of fixed door


window

„ Removing and installing


64-3, Fixed door window
with window guide, removing
and installing

„ Fixed door window

„ Component of window guide

„ Removing and installing


64-3, Fixed door window
with window guide, removing
and installing

„ Window frame at inner door


part
Rear door window Page 8 / 17

Fixed door window with window guide, removing and


installing

Note:

„ Removing and installing is described only for the


right fixed window with window guide. Removing and
installing the left fixed window with window guide is
derived accordingly from this.

„ When removing and installing door window,


spreader pin and spreader plug are also accessible
from outside when outer door plate has been
removed.

Removing

- Remove outer door panel 58-1, Outer door plate,


removing and installing

- Remove door window 64-3, Door window, removing


and installing

- Pull window guide - 1 - out of center bar - 3 - and guide


window guide inward.

- Remove screws - 2 - and slide center bard - 3 -


downward - arrow a - .

- Remove center bar - 3 - from seal of fixed door window -


arrow b - .
Rear door window Page 9 / 17

- Disengage window guide - 1 - with fixed door window -


2 - on inside and outside all around from window frame - 4
- .

- Using release tool T 10236 , disengage retaining tab on


guide pin - 3 - in window frame - 4 - .
Rear door window Page 10 / 17

- Remove complete window guide - 1 -


with fixed door window - 2 - from window
frame - 3 - in - direction of arrow - .

Installing

Installation is performed in the reverse order of removal.

Torque specification for screws on middle bar: 5.5 Nm

Note:

„ While installing fixed door window with window


guide, make sure it is seated evenly (wind noise).

Window regulator motor, assembly overview

Note :

„ The description applies to the right side. The left side


is derived accordingly from this.
Rear door window Page 11 / 17

„ Connector

„ Screw

„ Qty. 3

„ 3.5 Nm

„ Window regulator motor

„ Removing and installing


64-3, Window regulator
motor, removing and
installing

Window regulator motor, removing and installing


Rear door window Page 12 / 17

Note:

„ Removing and installing is described only for the


right window regulator motor. Removing and
installing the left window regulator motor is derived
accordingly from this.

„ Window regulator motor should also be removed


with mounting plate with outer door plate removed.

Removing

- Remove door trim

Repair Manual, Body Interior, Repair


Group 70, Trim/noise insulation; door trim

- Fix window using adhesive tape so that


Rear door window Page 13 / 17

it does not slip down.

- Remove the three bolts - 2 - .

- Disconnect connector - 1 - .

- Remove window regulator motor with


control module - 3 - from mounting
plate.

Installing

- Attach window regulator motor - 3 -


and connect harness connector - 1 - .

- Pull door window lightly up and down


so that splines are located better
between motor and cable drum.

- Tighten bolts - 2 - for window regulator


motor.
Rear door window Page 14 / 17

- Screw torque specification - 2 - 3.5


Nm

- Drive the window regulator up and


down to the limit stops, twice. By doing
this, window regulator motor is normed
and ready for operation and activates
pinch protection.

Then, continue in reverse order of


removal.

Window regulator, assembly overview

Note :

„ The description applies to the right side. The left side


is derived accordingly from this.

„ Window regulator
Rear door window Page 15 / 17

„ Removing and installing


64-3, Window regulator,
removing and installing

„ Screw

„ 4x

„ 8 Nm

„ Mounting plate

„ Drive motor

„ Screw

„ Qty. 2

„ 8 Nm

Window regulator, removing and installing

Note:

„ Removing and installing is described only for the


right window regulator. Removing and installing the
left window regulator is derived accordingly from
this.

Removing
Rear door window Page 16 / 17

- Remove outer door panel 58-1,


Outer door plate, removing and
installing

- Remove side impact member 58-1,


Side impact protection, assembly
overview

- Remove door window 64-3, Door


window, removing and installing

- Remove bolts - 2 - from mounting plate


- 3- .

- Remove bolts - 5 - for window


regulator.

- Remove window regulator - 1 - with


drive motor - 4 - and mounting plate - 3
- for window regulator motor from inner
door part.

- Disconnect harness connectors for


Rear door window Page 17 / 17

window regulator motor 64-3,


Removing

Installing

Installation is performed in the reverse order of removal.

„ A function test must be performed before outer door


plate is installed.
Volkswagen Golf V - Wheel housing liner Page 1 / 7

66 - 1

Wheel housing liner


Tools

Special tools, testers and auxiliary items required

„ Torque wrench 210 Nm V.A.G 1783

Front wheel housing liner, assembly overview

Note :

„ The illustration shows the left side. The right side is


similar and can be determined from this.

„ Due to model variations, small deviations must be


considered during removal and installation.

„ Front wheelhousing liner consists of front and rear


parts.
Wheel housing liner Page 2 / 7

„ Rear part of wheel housing liner

„ Material - PP/EPDM

„ Screw

„ Qty. 7

„ 2 Nm

„ Front part of wheel housing liner

„ Material - PP/EPDM

„ Screw

„ Qty. 11

„ 2 Nm
Wheel housing liner Page 3 / 7

„ Spreader nut

„ Qty. 6

Front wheel housing liner, removing and installing

Note:

„ Removing and installing is described only for the left


wheelhousing liner. Removing and installing right
wheelhousing liner is derived accordingly from this.

Removing

Rear part of wheel housing liner

- Unbolt wheel
Wheel housing liner Page 4 / 7

Repair Manual, Suspension, Wheels,


Steering, Repair Group 44, Tightening
torques for wheel bolts

- Remove bolts - 2 - (Qty. 7).

- Remove rear part of wheelhousing liner


- 1- .

Front part of wheel housing liner

- Remove bolts - 4 - (Qty. 11).

- Remove front part of wheelhousing liner


- 3- .

Installing

Installation is performed in the reverse order of removal.

Rear wheel housing liner, assembly overview

Note :

„ The illustration shows the left side. The right side is


similar and can be determined from this.
Wheel housing liner Page 5 / 7

„ Wheel housing liner

„ Material - PP/EPDM

„ Screw

„ Qty. 9

„ 2 Nm

„ Spreader nut

„ Qty. 4

Rear wheel housing liner, removing and installing

Note:
Wheel housing liner Page 6 / 7

„ Removing and installing is described only for the left


wheelhousing liner. Removing and installing right
wheelhousing liner is derived accordingly from this.

Removing

- Unbolt wheel

Repair Manual, Suspension, Wheels,


Steering, Repair Group 44, Tightening
torques for wheel bolts

- Remove bolts - 2 - (Qty. 9).

- Pull off wheelhousing liner - 1 - .

Installing
Wheel housing liner Page 7 / 7

Installation is performed in the reverse order of removal.


Volkswagen Golf V - Exterior rearview mirror Page 1 / 8

66 - 2

Exterior rearview mirror


Tools

Special tools, testers and auxiliary items required

„ Pry lever - RMV outside mirror 80-200

„ Torque wrench 210 Nm V.A.G 1783

Rearview mirror, assembly overview

Note :

„ The illustration shows the left side. The right side is


similar and can be determined from this.
Exterior rearview mirror Page 2 / 8

„ Mirror base plate

„ Removing and installing


66-2, Exterior rearview
mirror, removing and
installing

„ Screw

„ Qty. 3

„ 8 Nm

„ Assembly component

„ Removing and installing


66-2, Side turn signals,
removing and installing

„ Screw
Exterior rearview mirror Page 3 / 8

„ Qty. 2

„ 1 Nm

„ Screw

„ Qty. 2

„ 1 Nm

„ Side turn signal

„ Removing and installing


66-2, Side turn signals,
removing and installing

„ Trim

„ Removing and installing


66-2, Trim panel, removing
and installing

„ Mirror glass

„ Removing and installing


66-2, Mirror glass, removing
and installing

„ Mirror housing

„ Material - ABS

„ Removing and installing


66-2, Mirror housing,
removing and installing

Mirror glass, removing and installing

Note:

„ Removing and installing is performed only for the left


mirror glass. Removing and installing right mirror
glass is derived accordingly from this.

Warning!

Wear protective eyewear and gloves when working!


Exterior rearview mirror Page 4 / 8

Removing

- Protect housing edge - 1 - from paint damage e.g. cover


using fabric-reinforced adhesive tape.

- Press mirror glass - 2 - at bottom into mirror housing - 1


- .

- Press off mirror glass - 2 - using pry lever 80-200 from


bracket - 5 - and housing - 1 - - arrow 6 - .

- Swivel mirror glass - 2 - to the side - arrow 4 - and


disconnect the installed connector terminals - 3 - for
electric dimming function and mirror heater from rear side
of mirror glass - 2 - .

Installing

- Insert connector terminals for mirror heater to mirror


glass.

- Press mirror glass at center onto holder in housing.

- Mirror glass will engage audibly.

„ Then perform a function test.

Mirror housing, removing and installing

Note:

„ Removing and installing is performed only for the left


mirror housing. Removing and installing right mirror
housing is derived accordingly from this.
Exterior rearview mirror Page 5 / 8

Removing

- Remove mirror glass 66-2, Removing

- To facilitate installation, fold rearview mirror forward.

- Press mirror housing using a screwdriver beneath


catches - 2 - out of locking mechanisms.

- Pull mirror housing in front area slightly off mirror carrier.

- Then, remove mirror housing - 1 - upward from mirror


carrier.

Installing

- Place mirror housing - 1 - onto mirror carrier and press


mirror housing downward until catches - 2 - engage
audibly.

- Re-install mirror glass 66-2, Installing .

„ Then perform a function test.

Trim panel, removing and installing

Note:

„ Removing and installing is described only for the left


Exterior rearview mirror Page 6 / 8

trim. Removing and installing right trim is derived


accordingly from this.

Removing

- Remove mirror glass 66-2, Removing

- Remove mirror housing 66-2, Mirror housing, removing


and installing

- Release retaining tabs - 2 - from mirror carrier using a


screwdriver.

- Remove trim - 1 - in - direction of arrow - .

Installing

Installation is performed in the reverse order of removal.

„ Then perform a function test.

Side turn signals, removing and installing

Note:

„ Removing and installing is described only for the left


side turn signals. Removing and installing right side
turn signals is derived accordingly from this.

„ There are no conventional bulbs, but rather durable


light emitting diodes (LEDs) installed in the side turn
signals.

„ Therefore it is not necessary to change light bulbs.


In case of damage, the entire turn signal assembly
must be replaced.
Exterior rearview mirror Page 7 / 8

Removing

- Remove mirror glass 66-2, Mirror glass, removing and


installing

- Remove mirror housing 66-2, Mirror housing, removing


and installing

- Remove trim 66-2, Trim panel, removing and


installing

- Remove screws - 4 - and remove assembly piece - B -


downward.

- Disconnect harness connector - 5 - from turn signal - 3 -


.

- Remove screws - 2 - and remove turn signal - 3 - from


assembly piece - 1 - .

Installing

Installation is performed in the reverse order of removal.

„ Then perform a function test.

Exterior rearview mirror, removing and installing

Note:

„ Removing and installing is described only for the left


rearview mirror. Removing and installing right rear
view mirror is derived accordingly from this.

Removing
Exterior rearview mirror Page 8 / 8

- Remove front drivers side trim

Repair Manual, Body Interior, Repair Group 70,


Trim/insulation; Door trim; Front door, drivers side,
removing and installing

- Remove cable bracket - 2 - and disconnect harness


connector - 1 - for rearview mirror.

- Pry cover cap - 3 - out of door and remove bolts - 2 - .

- Remove rearview mirror - 1 - and guide wire through


opening in door.

Installing

Installation is performed in the reverse order of removal.

- Tightening torques: Rearview mirror screws 8 Nm

„ Before installing door trim, check function of door


window.
Volkswagen Golf V - Radiator grille Page 1 / 8

66 - 3

Radiator grille
Tools

Special tools, testers and auxiliary items required

„ Torque wrench 210 Nm V.A.G 1783

Radiator grille, assembly overview


Radiator grille Page 2 / 8

„ Radiator grille

„ Material - ASA

„ Catches

„ Qty. 6

„ Emblem

„ Clipped into radiator grille.

„ Can be removed only when


radiator grille is removed

„ Removing: Release catches


on rear side of emblem with
radiator grille removed.

„ Installing: Guide
manufacturers emblem with
Radiator grille Page 3 / 8

catch into recesses in


radiator grille - arrow b - ,
then twist slightly in direction
- arrow c - until
manufacturers emblem
engages in radiator grille.

„ Screw

„ Qty. 2

„ 2 Nm

Radiator grille, removing and installing

Removing

- Remove bolts - 4 - .

- Using a small screwdriver, disengage


Radiator grille Page 4 / 8

clips - arrows - from lock carrier.

- Tilt radiator grille - 1 - back slightly and


remove catches - 2 - upward out of
bumper cover.

Installing

- Insert radiator grille - 1 - tipped forward


slightly with catches. - 2 - in bumper
cover.

- Tip radiator grille - 1 - toward lock


carrier and engage clips - arrows - in
lock carrier.

- Screw in bolts - 4 - .

GTI radiator grille, assembly overview


Radiator grille Page 5 / 8

„ Radiator grille

„ Material - ASA

„ Screw

„ Qty. 2

„ 2 Nm

„ Decorative frame

„ Locked with radiator grille.

„ Can be carefully removed


from radiator grille.

„ Expanding rivet

„ 4x
Radiator grille Page 6 / 8

„ License plate bracket

„ Secured to radiator grille


with expanding clips.

„ Emblem

„ Clipped into radiator grille.

„ Can be removed only when


radiator grille is removed

„ Removing: Release catches


on rear side of emblem with
radiator grille removed.

„ Installing: Guide
manufacturers emblem with
catch into recesses in
radiator grille - arrow b - ,
then twist slightly in direction
- arrow c - until
manufacturers emblem
engages in radiator grille.

„ Front GTI name plate

„ Locked with radiator grille.

„ Can be removed only when


radiator grille is removed

„ Loosen catches from


behind.

„ Screw

„ Qty. 2

„ 2 Nm

„ Catches

„ Qty. 2

„ Guide hooks

„ 4x
Radiator grille Page 7 / 8

GTI radiator grille, removing

- Remove bolts - 3 - and - 6 - .

- Loosen catches - 2 - and - 4 - .

- Lift radiator grille - 1 - upward - arrow


a - out of guide hooks - 5 - .

- Tip upper edge of radiator grille forward


- arrow b - .

- Remove radiator grille from bumper


cover - arrow c - .

GTI radiator grille, installing


Radiator grille Page 8 / 8

- Place radiator grille horizontally - arrow


a - with lower edge in bumper cover.

- Lift radiator grille upward - arrow b - .

- Guide radiator grille upward - arrow c -


into guide hooks - 5 - .

Catches - 2 - and - 4 - engage audibly.

- Secure screws - 3 - and - 6 - , torqe


specification: 2 Nm.
Volkswagen Golf V - Strips and trim Page 1 / 20

66 - 4

Strips and trim


Tools

Special tools, testers and auxiliary items required

„ Torque wrench 210 Nm V.A.G 1783

„ Heat gun V.A.G 1416

Water deflector, assembly overview

Note :

„ The description applies to the right side. The left side


is derived accordingly from this.
Strips and trim Page 2 / 20

„ Water deflector

„ Retaining strip

„ Pop rivet

„ Qty. 5

„ Clip

„ Bracket

Drip rail, removing and installing

Removing
Strips and trim Page 3 / 20

- Pry drip rail - 1 - from retaining strip -


2 - starting from top.

- Remove clip - 4 - from bracket - 5 - in


lower fender area.

Installing
Strips and trim Page 4 / 20

- Engage clip - 4 - in bracket - 5 - .

- Press drip rail - 1 - from bottom to top


into retaining strip - 2 - .

Side protective moldings, assembly overview

Note :

„ The illustration shows the left side. The right side is


similar and can be determined from this.
Strips and trim Page 5 / 20

„ Side protective molding, front


door

„ Material PP/EPDM

„ Self-adhesive

„ Left and right protective


moldings have a different
hole pattern.

„ Side protective molding, side


panel

„ Material PP/EPDM

„ Self-adhesive

„ Left and right protective


moldings have a different
hole pattern.
Strips and trim Page 6 / 20

Replacing side protective moldings

Note :

„ The description applies to the left side. The right side


is similar and can be determined from this.

„ Remove protective foil only immediately prior to


assembly. Processing temperature approx. 21 C.

„ Stand time after installing side protective moldings


approx. 4 hours at an ambient temperature of
approx. 21 C.

„ Adhesive remover D 002 000 10 is to be used


exclusively.

„ Side protective moldings must be applied


immediately after cleaning.
Strips and trim Page 7 / 20

- Before removing, heat side protective


moldings - 1 - and - 2 - using a hot air
gun V.A.G 1416 and remove side
protective moldings.

- Remove any adhesive residue present


using erasure disc for stripe removal Z
432 290 TE .

- Thoroughly clean the adhesion surface


with adhesive remover D 002000 10
immediately before adhering side
protective moldings.

Note :

„ Part numbers are for reference only. Always check


with your Parts Department for the latest part
number information

- Pull off protective foil on side protective


moldings - 1 - and - 2 - only before
Strips and trim Page 8 / 20

installation.

„ Adhesion surfaces must be free of


dust and grease.

- Place the side protective moldings - 1 -


and - 2 - on vehicle and press side
protective moldings on forcefully.

Stone chip protective moldings, removing and installing

Removing

- Guide a small screwdriver from below


through the opening in the side trim and
release the catch - 2 - by pressing the
screwdriver upward - arrow a - .

- Slide stone chip protective molding - 1


- forward - arrow b - until screwdriver
comes in contact with screw - 3 - . Then
Strips and trim Page 9 / 20

remove screwdriver. Slide stone chip


protective molding farther until it can be
removed from all retaining screws.

Installing

Note:

„ Stone chip protective molding screws are corrosion-


resistant. It does not need any further treatment.

„ If a screw was over-torqued, this must be replaced


with a "black" oversize screw.

„ There are no holes for the screws.

- Secure template - 1 - to side members


with commercially-available adhesive
tape - 4 - .
Strips and trim Page 10 / 20

The template must be flush with upper


edge - 3 - and front edge of side
members - 2 - .

Template must not sag.

- Punch holes - 5 - for screws, template


can not be removed.

- Drill holes with a 1.5 mm bit.

„ All screw holes are present.

- Install self-tapping screws - 2 - with battery thread tap


VAS 5036 at highest speed until threads catch. Battery
thread tap must now be removed.

- Tighten screw with lowest torque so that screw is not


over-torqued.
Strips and trim Page 11 / 20

- Position stone chip protective molding - 1 - evenly -


arrow a - with openings on rear side over all screws - 2 -
until molding comes in contact with side members - 3 - .

Position stone chip protective molding with a second


technician so that all screws remain in the openings when
molding is slid on.

- Slide stone chip protective molding forcefully opposite


direction of travel - arrow b - to stop.

Sill panel extension, assembly overview

„ Sill panel extension

„ Removing 66-4, Sill panel


extension, removing and
installing

„ Installing 66-4, Installing


Strips and trim Page 12 / 20

„ Screw

„ Secures sill panel extension


to bracket

„ 4x

„ 2 Nm

„ Screw

„ Secures retaining stip to sill


panel

„ 9x

„ 1.2 Nm

„ Installing 66-4, Installing

„ Retaining strip

„ Removing 66-4, Sill panel


extension retaining strip

„ Installing 66-4, Installing

„ Sill panels

„ Bracket

„ Secured to underbody with


expanding clip.

„ Adhesive tape

Sill panel extension, removing and installing

Removing
Strips and trim Page 13 / 20

- Remove bolts - 2 - .

- Warm sill panel extension - 1 - in


adhesive surface area - 4 - before
removal with hot air gun V.A.G 1416 .

- Loosen adhesive tape - 4 - by guiding


a plastic wedge - 5 - carefully between
sill panels - 3 - and sill panel extension -
1- .

- As soon as adhesive connection


loosens, life sill panel extension - 1 -
upward out of retaining strip - arrow - .

Installing

Note:

„ The description applies to the left side. The right side


is similar and can be determined from this.
Strips and trim Page 14 / 20

„ Remove protective foil only immediately prior to


assembly. Processing temperature approx. 21 C.

„ Stand time after installing side protective moldings


approx. 4 hours at an ambient temperature of
approx. 21 C.

„ Adhesive remover D 002 000 10 is to be used


exclusively.

„ Side protective moldings must be applied


immediately after cleaning.

„ Retaining strip is installed 66-4,


Sill panel extension retaining strip

- Thoroughly clean the adhesion surface


with adhesive remover D 002000 10
Strips and trim Page 15 / 20

immediately before adhering sill panel


extension.

Note :

„ Part numbers are for reference only. Always check


with your Parts Department for the latest part
number information

- Remove protective foil on sill panel


extension - 5 - just before installing.

„ Adhesion surfaces must be free of


dust and grease.

- Position sill panel extension - 3 - from


above - arrows - evenly in retaining strip
- 2 - and press sill panel extension into
retaining stip until both parts engage with
each other.

- Forcefully press sill trim extension on in


adhesive area.

- Secure secures - 4 - , beginning wtih


front screw on fender. With the rear
screw, tab - 5 - should be inserted first.

Sill panel extension retaining strip

Removing
Strips and trim Page 16 / 20

„ Sill panel extension is removed


66-4, Sill panel extension,
removing and installing

- Slide retaining strip - 1 - in direction of


travel - arrows - from screws - 3 - and
remove from sill panels - 2 - .

Installing

Note:

„ Stone chip protective molding screws are corrosion-


resistant. It does not need any further treatment.

„ If a screw was over-torqued, this must be replaced


with a "black" oversize screw.
Strips and trim Page 17 / 20

„ There are no holes for the screws.

- Secure template - 1 - to side members


with commercially-available adhesive
tape - 4 - .

The template must be flush with upper


edge - 3 - and front edge of side
members - 2 - .

Template must not sag.

- Punch holes - 5 - for screws, template


can not be removed.

- Drill holes with a 1.5 mm bit.


Strips and trim Page 18 / 20

„ All screw holes are present 66-


4, Installing

- Install self-tapping screws - 3 - with


battery thread tap VAS 5036 at highest
speed until threads catch. Battery thread
tap must now be removed.

- Tighten screw with lowest torque so


that screw is not over-torqued.

- Position retaining strip - 1 - evenly -


arrow a - with openings on all screws -
2 - until retaining strip comes in contact
with sill panels - 2 - .

Position retaining strip with a second


technician so that all screws remain in
the openings when molding is slid on.

- Slide retaining strip forcefully opposite


direction of travel - arrow b - to stop.
Strips and trim Page 19 / 20

Dimensions of rear name plates

Note:

„ Remove protective foil only immediately prior to


assembly. Processing temperature approx. 21 C.

„ Adhesive remover D 002 000 10 is to be used


exclusively.

„ Name plates must be applied immediately after


cleaning.

„ Dimension - a - = 50 mm

„ From outer edge of rear lid


up to name plate.

„ Dimension - b - = 90 mm
Strips and trim Page 20 / 20

„ From lower edge of rear lid


to lower edge of name plate.
Volkswagen Golf V - Roof edge spoiler Page 1 / 11

66 - 5

Roof edge spoiler


Tools

Special tools, testers and auxiliary items


required

„ Cutting tools for glass V.A.G


1351

„ Cutting tool kit V.A.G 1474 A

„ Window removing kit V.A.G 1755

„ Double cartridge gun VAS 5237


Roof edge spoiler Page 2 / 11

Materials

DA 004 600 A2 1) , 2)
„ 2C- window adhesive

D 002 001
„ Mixer with cone shaped nozzle

D 181 801 A1 3)
„ Activator

D 181 711 A1
„ Primer

D 009 401 04 3)
„ Cleaning solution

D 009 500 25 3)
„ Primer applicator

D 002 000 10 3)
„ Adhesive remover

357 853 999 A


„ Cutting cord

3) Materials are stored in box D 004 700.


1) Observe minimum curing time 66-5, Minimum curing
time .
2) Double cartridge pistol VAS 5237 must be used to
process this material.

Roof edge spoiler, assembly overview


Roof edge spoiler Page 3 / 11

„ Rearlid

„ Primer surface

„ For adhesive bead on


retaining strip.

„ Position of primer surface


should be transferred from
adhesive bead depression to
retaining strip.

„ Primer surface

„ For adhesive bead on roof


edge spoiler.

„ Position of primer surface is


to be transferred from roof
edge spoiler.

„ Retaining strip

„ With adhesive bead


depression.

„ Removing 66-5, Retaining


strip, removing

„ Installing 66-5, Retaining


strip, installing

„ Installation notes 66-5,


Installation notes
Roof edge spoiler Page 4 / 11

„ Foam band

„ Self-adhesive

„ Foam band should be


checked for damage and
replaced if necessary before
installing roof edge spoiler.

„ Adhesive tape

„ Two strips for securing sides


of roof edge spoiler.

„ Adhesive surface

„ Is marked in interior side of


roof edge spoiler.

„ Roof edge spoiler

„ Material PC/PET

„ Removing 66-5,
Removing

„ Installing 66-5, Installing

„ Installation notes 66-5,


Installation notes

Roof edge spoiler, removing and installing

Removing

Warning!

When disassembling roof edge spoiler, a cutting cable


must not be used because of the danger of damaging
painted surfaces.
Roof edge spoiler Page 5 / 11

- Thread cutting cord - 6 - between rear


lid - 1 - and roof edge spoiler - 4 - .

- With "sawing motion" of both pull


handles - 5 - , cut through adhesive tape
- 2 - and adhesive bead - 3 - on one
side.

- Repeat cutting of adhesive tape and


adhesive bead on other side.
Roof edge spoiler Page 6 / 11

Vehicles as of 02.05

- Insert trim removal wedge 3409


between rear lid and roof edge spoiler
until middle catch - 3 - engages.

All vehicles

- To release remaining four catches - 2 -


, forcefully press roof edge spoiler onto
rear lid.

- Grasp between roof edge spoiler and


rear lide and carefully loosen roof edge
spoiler upward - arrow - from the four
catches - 4 - on the retaining strip,
beginning at sides and working toward
center of vehicle.

- After all catches have been released,


remove roof edge spoiler from retaining
strip.
Roof edge spoiler Page 7 / 11

Installing

„ Retaining strip - 6 - is installed


66-5, Retaining strip, installing

„ Brake light is installed in roof edge


spoiler

Repair Manual, Electrical Equipment,


Repair Group 94,

„ Surfaces of roof edge spoiler - 3 -


and rear lid - 2 - are primed.

- Apply adhesive bead to primed surface


- 3 - or roof edge spoiler.

- Place roof edge spoiler - 5 - on


retaining strip - 6 - .

- Align roof edge spoiler - 5 - to rear lid -


1 - and press roof edge spoiler into catch
on retaining strip.

- With new rear edge spoilers, remove


adhesive tape protective foil - 4 - and
press roof edge spoiler firmly into
retaining strip.

- With reused roof edge spoiler, secure


corners to rear lid with commercially-
Roof edge spoiler Page 8 / 11

available adhesive tape.

Retaining strip

Retaining strip, removing

„ Roof edge spoiler is removed


66-5, Removing

- Cut through adhesive bead - 2 - with


help of cutting cord and pull handles.

Retaining strip, installing

„ Adhesive surfaces - 2 - on
Roof edge spoiler Page 9 / 11

retaining strip and rear lid are


primed.

- Apply adhesive bead in retaining strip


depression.

- Center retaining strip - 4 - on original


brake light cutout - 3 - .

- Secure retaining strip with commercially


available adhesive tape.

Preparing bodywork for adhesive

Note:

„ Remaining material serves as adhesion base for


newly applied adhesive sealing compound. Keep
adhesive surfaces free of dirt and grease.

Exception: If bonding is not performed immediately after


cutting back, the remaining material must be activated
using the Activator D 181 801 A1 .

Warning!

Activator must not come into contact with the paint -


otherwise paint will be damaged.

Note:

„ Part numbers are for reference only. Always check


with your Parts Department for the latest part
number information

„ If bodywork is being worked on or is partially


replaced, it must be cleaned and primed again after
painting the corresponding area.

Installation notes

The surfaces of the components to be primed must be free


of dirt.

- Remove adhesive residue using adhesive removal


solution D 002 000 10 .

- Saturate a cloth with silicone remover LSE 020 100 A3 .

- Always wipe application area for adhesive bead twice


Roof edge spoiler Page 10 / 11

using saturated cloth and allow to air dry.

- Now apply primer uniformly in one stroke using applicator


D 009 500 25 .

„ Air dry time approx. 10 minutes

- Adhesive material must be applied to the primed surfaces


of the component.

Warning!

Components must be installed within 10 minutes,


otherwise bonding properties of adhesive will be
impaired.

„ Keep gap dimensions as narrow as possible,


approx. 1 mm.

„ Secure components using adhesive tape during


curing time.

Note:

„ Part numbers are for reference only. Always check


with your Parts Department for the latest part
number information

Minimum curing time

Minimum curing time for newly bonded components is 3


hours.

Minimum curing time is the time from applying the


components up to vehicle use. During this time, the vehicle
must stand on an even surface at room temperature (at
least 15 C).

Warning!

The vehicle is operationally ready only after the


minimum curing time has elapsed.

Paint damage, repairing

The paint structure must be re-established according to


specifications of "Paint Repair Manual" .

The following repair method is used for paint damage in


areas that are not visible:
Roof edge spoiler Page 11 / 11

- Paint twice (wet on wet) using glass/paint primer D 009


200 02 - minimum air drying time 10 minutes.

Cleaning when soiled by adhesive sealing material

- Adhesive removal solution D 002 000 10 is the


recommended cleaning solution. Observe safety
precautions when processing.

- Roughly clean paint surfaces with a dry cloth. Remove


further material using adhesive removal solution D 002 000
10 .

Note:

„ Part numbers are for reference only. Always check


with your Parts Department for the latest part
number information
Volkswagen Golf 5 2004-> VW Rabbit GTI 2006->
(A5)

Interior rearview mirror


Tools

Required special tools, workshop equipment, testing and


measuring equipment, and aids

„ Trim removal wedge 3409

Automatic dimming interior rearview mirror

The automatically dimming interior rearview mirror dims


progressively when the driver is blinded from the rear.

It consists of a mirror element and an electrical element


with two photo sensors.

The electronic element registers light incidence from the


front and rear through the photo sensors.

If the incident light from the rear is greater than that from
the front, a current flows through the electronic element to
a conductive coating.

The applied current changes the color of the electrolytes.


The electrolyte becomes darker, the greater the current is.
The incident light will be reflected to a lesser degree.

The dimming function cuts out when reverse gear is


engaged. So one can back out of a dark garage, for
example, using the rearview mirror.

Interior rearview mirror with rain sensor, removing and


installing

Removing

- In vehicles with rain sensor, switch ignition off.


Interior rearview mirror Page 2 / 6

- Using trim removal wedge 3409 ,


operate locking mechanism - 1 - of right
cover cap - 2 - .

- Remove right - 2 - and left cover caps -


3 - from mirror base.

- Disconnect connector - 4 - .

- Slide interior mirror downward out of


mount along front windshield.

Installing

- Installation is performed in the reverse order of removal.

Holding plate for interior rearview mirror with rain


sensor, bonding

Removal of windshield is no longer necessary, as with


previous repair procedure.
Interior rearview mirror Page 3 / 6

At the same time, it is possible to re-use the old, detached


mirror base.

Preparing windshield

- All adhesive and primer residue must be removed up to


ceramic coating.

- Clean adhesion surface using cleaning solution D 009


401 04 .

- Dry off period must be at least 10 minutes.

- Apply glass-/paint primer D 009 200 02.

- Dry off period until bonding: at least 10 minutes to a


maximum of 1 hour.

Preparing detached and new mirror base

- Use a tool to remove adhesive residue (only for detached


mirror base).

- Prepare adhesive surface by wet-sanding with fine emery


paper (800-1200 grit) until water remains (does not bead
and run off) on adhesive surface.

- Then clean using D 009 401 04 cleaning solution.

Bonding mirror base

- Apply two part polyurethane adhesive D 180 KD2 A1


direct to prepared and cleaned mirror base adhesive
surface.

- Adhesive bead diameter: approx. 2.5 to 3 mm.

- Immediately after applying adhesive on mirror base,


press onto prepared windshield.

- Align mirror base on its designated position on ceramic


coating and secure using adhesive tape.

Cleaning and removing excess adhesive

- Carefully remove adhesive tape 0.5 to 1 hour after


attaching mirror base.

- Remove excess soft adhesive all around using spatula.

- Then remove any remaining excess adhesive using a


primer applicator or rag, saturated with cleaning solution.

Installation of rain sensor and mirror


Interior rearview mirror Page 4 / 6

- Mirror can be installed 2.5 hours after mirror base has


been attached!

Interior rearview mirror, removing and installing

Removing

- Rotate interior mirror - 1 - 90


counterclockwise - arrow - and remove
it from adhesive plate - 2 - .

Installing

- Installation is performed in the reverse order of removal.

Holding plate for interior rearview mirror without rain


sensor, bonding

Materials:
Interior rearview mirror Page 5 / 6

„ Glass-metal adhesive set D 000 703 A1

Tools:

1 - Window scraper (commercially available)


2 - Blade (commerically available)

- Remove retaining plate from mirror base.

- Remove PUR adhesive material from retaining plate with


wire brush.

- Grind the three spacer knobs off of adhesive surface. To


do this, lay sandpaper (360/400 grit) on flat surface.

- Keep sanded surface free of dirt and grease.

- Scrape off PUR adhesive and primer from windshield


down to ceramic layer using glass scraper.

- Clean adhesive surface with adhesive remover D 002


000 10 or cleaning solution D 009 401 04 .

Caution!

Do not damage ceramic layer. Scratches always


remain visible.

- Cut nylon mesh to exact dimensions of mirror base.

Note:

„ Protective gloves (rubber gloves) should be worn.

- Spread thick layer of adhesive evenly on mirror base.

- Lay nylon mesh on mirror base.

- While continuing to apply adhesive with tube dab nylon


mesh.
Interior rearview mirror Page 6 / 6

30 seconds are available from laying the nylon mesh on


the adhesive to pressing on the windshield.

- Press mirror base (without force) onto windshield and


hold for 15 seconds.

- Use a rag to remove excess adhesive.

Note:

„ Mirror can be installed after 15 minutes.


Storage compartments, covers and trim Page 1 / 40

68 - 2

Storage compartments, covers and trim


Tools

Required special tools, workshop equipment, testing and


measuring equipment, and aids

„ Release lever T10039

„ Trim removal wedge 3409

Front center console without adjustable/folding armrest


with storage compartment, removing and installing

Removing

- Switch off ignition.

Vehicles with automatic transmission

- Loosen boot from cover


Storage compartments, covers and trim Page 2 / 40

Repair Manual, 6 Spd. Direct Shift Automatic


Transmission 02E Front Wheel Drive, Repair Group 34,

Vehicles with manual transmission and Direct Shift


Gearbox (DSG)

- Loosen boot from cover

Repair Manual, Manual Transmission, Repair Group 34,

All vehicles

- Remove parking brake lever trim

Repair Manual, Brake System, Repair Group 46,

- Remove the two carpet mats - 1 - from


extension - 3 - .

- Remove the three bolts - 2 - (1.5 Nm).

- Loosen extension from mounts.


Storage compartments, covers and trim Page 3 / 40

- Pull parking brake lever extension


forward through opening.

- Remove gear selector insulation - 1 -


from center console.

- Remove the two bolts - 2 - (1.5 Nm).

- Remove storage compartment - 3 -


from center console and (depending on
vehicle equipment) disconnect wiring
harnesses.

Note :

„ An ashtray may be installed instead of the storage


compartment - 3 - , removal is the same.
Storage compartments, covers and trim Page 4 / 40

- Unclip cover - 1 - from trim using a


small screw driver.

- Remove bolt - 2 - (1.5 Nm).

- Pull left footwell trim - 3 - out of


mounts.

Note :

„ Removal of right footwell trim is identical.


Storage compartments, covers and trim Page 5 / 40

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- Using trim removal wedge 3409 ,


unclip trim panels - 4 - on both sides in
area of locking mechanisms.

- Remove two bolts - 1 - and - 2 - (1.5


Nm) respectively.

- Remove two bolts - 3 - and - 4 - (1.5


Nm) respectively.

- Remove bolt - 5 - (1.5 Nm).

Note :

„ When installing, bolts must be installed in the


sequence - 1 - , - 2 - , - 3 - , - 4 - and - 5 - .
Storage compartments, covers and trim Page 6 / 40

- Remove center console from vehicle.

Installing

- Installation is performed in the reverse order of removal.

Front center armrest adjustable/folding with storage


compartment, removing and installing

Removing

- Switch off ignition.

Vehicles with automatic transmission

- Loosen boot from cover

Repair Manual, 6 Spd. Direct Shift Automatic


Transmission 02E Front Wheel Drive, Repair Group 34,
Storage compartments, covers and trim Page 7 / 40

Vehicles with manual transmission and Direct Shift


Gearbox (DSG)

- Loosen boot from cover

Repair Manual, Manual Transmission, Repair Group 34,

All vehicles

- Remove parking brake lever trim

Repair Manual, Brakes, Repair Group 46,

Vehicles with CD changer.

- Remove CD changer - 1 -

Repair Manual, Electrical Equipment,


Repair Group 91,

- Remove carpet mat - 2 - from storage


compartment.
Storage compartments, covers and trim Page 8 / 40

- Remove bolt - 3 - (1.5 Nm).

Vehicles with cooled storage


compartment

- Remove carpet mat - 1 - from storage


compartment.

- Remove cover - 2 - out of mounts in


storage compartment.
Storage compartments, covers and trim Page 9 / 40

- Remove bolt - 3 - (1.5 Nm).

All vehicles

- Open beverage holder - 1 - and


remove two bolts - 2 - (1.5 Nm).

- Pull cup holder out of center console.

Note :

„ When installing, beverage holder must be inserted


(first at bottom) into center console while in a closed
state. Then it must be opened and then install the
two bolts - 2 - .
Storage compartments, covers and trim Page 10 / 40

- Remove trim panel - 1 - from mounts


in lower area - arrow - .
Storage compartments, covers and trim Page 11 / 40

- Remove trim panel from mounts in


center console in upper area.

- Remove bolts - 1 - and - 2 - (1.5


Nm).
Storage compartments, covers and trim Page 12 / 40

- Release extension - 3 - from mounts in


lower area.

- Remove gear selector insulation - 1 -


from center console.

- Remove the two bolts - 2 - (1.5 Nm).

- Remove storage compartment - 3 -


from center console and (depending on
vehicle equipment) disconnect wiring
harnesses.

Note :

„ An ashtray may be installed instead of the storage


compartment - 3 - , removal is the same.
Storage compartments, covers and trim Page 13 / 40

- Unclip cover - 1 - from trim using a


small screw driver.

- Remove bolt - 2 - (1.5 Nm).

- Pull left footwell trim - 3 - out of


mounts.

Note :

„ Removal of right footwell trim is identical.


Storage compartments, covers and trim Page 14 / 40

- Using trim removal wedge 3409 ,


unclip trim panels - 4 - on both sides in
area of locking mechanisms.

- Remove carpet mat - 1 - from storage


compartment.

- Remove the two sets of bolts - 2 - and


- 3 - (1.5 Nm).

- Remove the two sets of bolts - 4 - and


- 5 - (1.5 Nm).

- Remove bolt - 6 - (1.5 Nm).

Note :

„ When installing, bolts must be installed in the


sequence - 2 - , - 3 - , - 4 - , - 5 - and - 6 - .
Storage compartments, covers and trim Page 15 / 40

- Remove center console from vehicle.

- Remove bolts - 1 - , - 2 - , - 3 - and -


4 - (1.5 Nm).
Storage compartments, covers and trim Page 16 / 40

- Remove center console trim carrier - 5


- from vehicle.

Installing

- Installation is performed in the reverse order of removal.

Center console mounting bracket, removing and


installing

Removing

- Switch off ignition.

- Remove center console:

„ Front center console without adjustable/folding


armrest with storage compartment 68-2, Front
center console without adjustable/folding armrest
with storage compartment, removing and installing
Storage compartments, covers and trim Page 17 / 40

„ Front center console with adjustable/folding armrest


with storage compartment 68-2, Front center
armrest adjustable/folding with storage
compartment, removing and installing

- Remove two nuts - 1 - (8 Nm) and


remove mounting bracket - 2 - .

Installing

- Installation is performed in the reverse order of removal.

Storage compartment/ashtray unit, removing and


installing

Removing

- Switch off ignition.

Vehicles with automatic transmission


Storage compartments, covers and trim Page 18 / 40

- Loosen boot from cover

Repair Manual, 6 Spd. Direct Shift Automatic


Transmission 02E Front Wheel Drive, Repair Group 34,

Vehicles with manual transmission and Direct Shift


Gearbox (DSG)

- Loosen boot from cover

Repair Manual, Manual Transmission, Repair Group 34,

- Remove the two bolts - 1 - (1.5 Nm).

- Remove storage compartment - 2 - from center console


and (depending on vehicle equipment) disconnect wiring
harnesses.

Note:

„ An ashtray may be installed instead of the storage


compartment, removal is the same.

Installing

- Installation is performed in the reverse order of removal.

Instrument panel center vent (vehicles without


Climatronic), removing and installing

Note:

„ To provide a better overview, components are


shown removed in the following illustration.
Storage compartments, covers and trim Page 19 / 40

Removing

- Remove carpet mat - 1 - from storage


compartment.

- Remove the two bolts - 2 - (1.5 Nm).

- Remove storage compartment - 3 -


from air outlet - 4 - .

Vehicles with Climatronic

Items - 5 - , - 6 - , - 7 - , - 8 - and - 9 -
only apply to vehicles with Climatronic.

Instrument panel center vent (vehicles


with Climatronic), removing 68-2,
Instrument panel center vent, removing
and installing (vehicles with Climatronic)

Note :
Storage compartments, covers and trim Page 20 / 40

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огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

„ The two screws - 1 - in this location are already


removed on vehicles without Climatronic.

- Place two trim removal wedges 3409 in


lower vent seam - arrows - and press
vent upward out of instrument panel
mounts.

- Press the corresponding catches and


disconnect wiring harnesses from
passenger airbag warning light switch
and indicator light.

Installing

- Installation is performed in the reverse order of removal.

Instrument panel center vent, removing and installing


(vehicles with Climatronic)
Storage compartments, covers and trim Page 21 / 40

Removing

- Switch off ignition.

- Pry sensor - 1 - out of indirect ventilation - 2 - using trim


removal wedge 3409 .

- Disconnect wiring harness from sunlight photo sensor.

- Remove bolt - 3 - (1.5 Nm).

Note :

„ To provide a better overview, components are


shown removed in the following illustration.

- Insert two trim removal wedges 3409


as shown in seam between indirection
ventilation - 1 - and vent - 2 - .
Storage compartments, covers and trim Page 22 / 40

- Press metal clips - 3 - and - 4 - back


with trim removal wedge 3409 and
remove indirect ventilation upward out of
mounts in vent - arrow - .

- Remove the two bolts - 1 - (1.5 Nm).

- Remove vent - 2 - in front area from


mounts.

- Place two trim removal wedges 3409 in


lower vent seam - arrows - and press
vent upward out of instrument panel
mounts.
Storage compartments, covers and trim Page 23 / 40

- Press the corresponding catches and


disconnect wiring harnesses from
passenger airbag warning light switch
and indicator light.

Installing

- Installation is performed in the reverse order of removal.

Center instrument panel trim, removing and installing

Removing

- Remove instrument panel center vent:

„ Vehicles without Climatronic 68-2, Instrument


panel center vent (vehicles without Climatronic),
removing and installing

„ Vehicles with Climatronic 68-2, Instrument panel


Storage compartments, covers and trim Page 24 / 40

center vent, removing and installing (vehicles with


Climatronic)

- Remove the two bolts - 1 - (1.5 Nm).

- Using trim removal wedge 3409 , pry


trim in area of locking mechanisms out of
mounts in instrument panel.

Installing

- Installation is performed in the reverse order of removal.

Instrument panel side covers, removing and installing

Removing

- Using trim removal wedge 3409 , pry


right side instrument panel cover - 1 -
out of locking mechanisms.
Storage compartments, covers and trim Page 25 / 40

- Using trim removal wedge 3409 , pry


left side instrument panel cover - 2 - out
of locking mechanisms.

Installing

- Installation is performed in the reverse order of removal.

Steering column trim, removing and installing

Removing

- Disconnect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

- Remove driver-side airbag unit 69-4, Driver airbag


module, removing and installing
Storage compartments, covers and trim Page 26 / 40

- Remove steering wheel 69-4, Steering wheel,


removing and installing

- Disengage steering wheel adjustment


locking lever.

- Pull out steering wheel and push it


downward.

- Remove gap cover - 1 - and upper


steering column trim - 2 - from mounts.

- Remove bolt - 3 - (1.5 Nm).

- Remove the two bolts - 4 - (1.5 Nm).

- Remove lower steering column trim - 5


- from mounts.

Installing

- Installation is performed in the reverse order of removal.


Storage compartments, covers and trim Page 27 / 40

Drivers side left trim, removing and installing

Removing

Note:

„ For clarity, the steering wheel is not depicted in the


illustration, it is not necessary to remove it.

- Switch off ignition.

- Remove side instrument panel cover on front passenger-


side 68-2, Instrument panel side covers, removing and
installing

- Press rotary light switch toward front, rotate it toward


right until it stands vertically, now pull it out and disconnect
wiring harness.

- Remove steering column trim gap cover from instrument


panel 68-2, Steering column trim, removing and
installing . It is not necessary to remove the complete
steering column trim.

- Remove storage compartment - 1 -


from mounts.

- Remove the two bolts - 2 - (1.5 Nm).

- Remove the two bolts - 3 - (1.5 Nm).

- Remove bolt - 4 - (1.5 Nm).


Storage compartments, covers and trim Page 28 / 40

- Disengage trim panel from instrument


panel and disconnect wiring harness
from headlight range control.

Installing

- Installation is performed in the reverse order of removal.

Note :

„ When installing, bolts must be installed in the


sequence - 2 - , - 3 - and - 4 - (1.5 Nm).
Storage compartments, covers and trim Page 29 / 40

Drivers side right trim, removing and installing

Removing

- Switch off ignition.

- Remove side instrument panel cover on front passenger-


side 68-2, Instrument panel side covers, removing and
installing

- Remove right trim panel on drivers side 68-2, Drivers


side left trim, removing and installing

- Remove center cover 68-2, Center cover, removing


and installing

- Remove bolts - 1 - , - 2 - , - 3 - and -


4 - (1.5 Nm).
Storage compartments, covers and trim Page 30 / 40

- Using trim removal wedge 3409 ,


disengage trim panel from mounts.

Installing

- Installation is performed in the reverse order of removal.

Note :

„ When installing, bolts must be installed in the


sequence - 1 - , - 2 - , - 3 - , and - 4 - (1.5 Nm).
Storage compartments, covers and trim Page 31 / 40

Sun visor, removing and installing

Note:

„ Removal and installation is described for the left-


hand side of the vehicle. Removal and installation for
the right-hand side is performed in the same
manner.

Removing

- Switch off ignition.

Note :

„ If only the sun visor is to be removed, screw - 3 -


and sun visor mount - 6 - do not have to be
removed.

- Using a small screwdriver, open cover


Storage compartments, covers and trim Page 32 / 40

caps - 1 - and - 2 - .

- Remove bolts - 3 - and - 4 - (2 Nm).

- Carefully pull sun visor mount - 1 - out


of mount.

Caution!

Hold sun visor securely. Allowing sun


visor to hang by wiring harness is not
permitted!
Storage compartments, covers and trim Page 33 / 40

- Grasp sun visor wiring harness - 1 -


with thumb and forefinger as shown in
area by molded headliner opening.

Caution!

When removing connector from


retaining clips as follows, it is
possible that the wiring harness may
be damaged. This is the case if the
connector is removed from the
retaining clip with a jerking motion.
For this reason, remove it extremely
carefully with one hand on wiring
harness while supporting the hand
with the ball of the hand on the
vehicle. This allows the pulling force
on the wiring harness to be measured
out better, thus avoiding rough
removal of the connector.
Storage compartments, covers and trim Page 34 / 40

- Hold onto roof grab handle firmly, then


pull lightly on wiring harness in direction
of windshield until connector comes out
of retaining clip in molded headliner.

- Carefully pull connector - 1 - out


through opening in molded headliner,
pulling out just far enough until connector
is located closely beneath molded
headliner.

Caution!

„ Do not pull harness connector further, since the


excess length of flat wire - 2 - is limited and
there is a hazard it will shear off.

„ Flat wire must only be pulled a maximum of 1 cm


out of opening in molded headliner.

- Carefully disconnect connector without


Storage compartments, covers and trim Page 35 / 40

pulling on flat wire.

Installing

Note:

„ Slide a small foam pipe (part number 535.971.790)


over harness connector when installing sun visor.

- Installation is performed in the reverse order of removal.

Center cover, removing and installing

Removing

- Lift cover - 1 - out of mounts using trim


removal wedge 3409 .

Installing
Storage compartments, covers and trim Page 36 / 40

- Installation is performed in the reverse order of removal.

Glove compartment, removing and installing

Removing

- Switch off ignition.

- Remove side instrument panel cover on front passengers


side 68-2, Instrument panel side covers, removing and
installing

- Disengage sill panel trim from body in area of juncture to


lower A-pillar trim.

„ 2door 68-3, Sill panel trim (2-door), removing and


installing

„ 4door 68-3, Sill panel trim (4-door), removing and


installing

- Remove passengers side A-pillar trim 70-3, Passenger


side lower A-pillar trim, removing and installing

- Remove center cover 68-2, Center cover, removing


and installing

- Remove 7 screws - 1 - , - 2 - , and - 3


- (1.5 Nm)

- Slide glove compartment outward until


stops - arrow A - .

- Disengage glove compartment from


instrument panel - arrow B - .

- Disconnect wiring harness from lights


and contact switch.

- In vehicles with glove compartment


cooling, disconnect A/C channel from
glove compartment.
Storage compartments, covers and trim Page 37 / 40

- In vehicles with footwell lights,


disconnect wiring harness from lights.

Installing

- Installation is performed in the reverse order of removal.

Glove compartment lock cylinder, removing and


installing

Removing

- Open glove compartment.

Note :

„ It is not possible to remove separately from lock


cylinder - 1 - , release button - 2 - must be
replaced.
Storage compartments, covers and trim Page 38 / 40

- Remove screw - 3 - and remove


release button - 2 - from glove
compartment lid.

Installing

- Installation is performed in the reverse order of removal.

Drivers side footwell cover, removing and installing

Removing

- Switch off ignition.

- Remove the two bolts - 1 - (1.5 Nm).

- Remove cover from mounts and


disconnect wiring harness from footwell
lights.
Storage compartments, covers and trim Page 39 / 40

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


огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

- Press the two locking mechanisms -


arrows - and disconnect diagnostic
connector from cover.

Installing

- Installation is performed in the reverse order of removal.

Instrument panel decor trim, removing and installing

Note:

„ Trim is only installed with "Front center console with


adjustable/folding armrest with storage
compartment" version.

Removing

- Pry trim panels - 1 - and - 2 - out of


instrument panel on drivers side using
Storage compartments, covers and trim Page 40 / 40

trim removal wedge 3409 .

- Pry trim panel - 3 - out of mounts on


front passengers side using trim removal
wedge 3409 .

Installing

- Installation is performed in the reverse order of removal.


Sill panel trim Page 1 / 6

68 - 3

Sill panel trim


Sill panel trim (2-door), removing and installing

Note:

„ Removal and installation is described for the right-


hand side of the vehicle. Removal and installation for
the left-hand side is performed in the same manner.

Removing

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove sill panel trim - 1 - out of


mounts in sill, side trim and door seal
molding.

Note :

„ Before installing, check the seven securing clips for


damage and replace if necessary.
Sill panel trim Page 2 / 6

Installing

- Installation is performed in the reverse order of removal.

Sill panel trim (4-door), removing and installing

Note:

„ Removal and installation is described for the left-


hand side of the vehicle. Removal and installation for
the right-hand side is performed in the same
manner.

Removing

- Remove rear seat bench 72-2, Rear seat bench,


removing and installing

- Remove 4-door side upholstery:


Sill panel trim Page 3 / 6

„ with rear side airbags 72-2, Side upholstery with


side airbag (4-door), removing and installing

„ without rear side airbags 72-2, Side upholstery (4-


door,), removing and installing

- Wheel housing trim, 4-door, removing 68-3, Wheel


housing trim (4-door), removing and installing

- Pull sill panel trim out of front sill panel


and door seal tubing.

- Remove guide - 1 - from lower B-pillar


trim.

- Pull sill panel trim out of rear sill panel


and door seal tubing.

- Remove guide - 2 - from lower B-pillar


trim.

- Open strap - 3 - and feed seatbelt


through it.

Note :

„ Before installing, check the five securing clips for


damage and replace if necessary.
Sill panel trim Page 4 / 6

Installing

- Installation is performed in the reverse order of removal.

Wheel housing trim (4-door), removing and installing

Note:

„ Removal and installation is described for the left-


hand side of the vehicle. Removal and installation for
the right-hand side is performed in the same
manner.

Removing

- Remove rear seat bench 72-2, Rear seat bench,


removing and installing

- Remove 4-door side upholstery:


Sill panel trim Page 5 / 6

„ with rear side airbags 72-2, Side upholstery with


side airbag (4-door), removing and installing

„ without rear side airbags 72-2, Side upholstery (4-


door,), removing and installing

- Remove the two bolts - 1 - (1.2 Nm).

- Remove clip - 2 - from body flange.

- Pull trim - 3 - from door seal tubing - 4


- .

- Pull trim out of mounts in sill panel trim


- 5- .

- Pull out trim in direction of travel under


C-pillar trim panel.

Removing
Sill panel trim Page 6 / 6

- Installation is performed in the reverse order of removal.


Grab handles Page 1 / 2

68 - 4

Grab handles
Grab handles (roof), removing and installing

Note:

„ Illustration shows the right front grab handle,


removing and installing the remaining grab handles
is identical.

Removing

- Swing down grab handle and open the


two cover caps - 1 - and - 2 - using a
small screwdriver.

- Remove two screws - 3 - (2 Nm) and


remove grab handle.
Grab handles Page 2 / 2

Installing

- Installation is performed in the reverse order of removal.


Volkswagen Golf 5 2004-> VW Rabbit GTI 2006->
(A5)

Seat belts
Safety regulations for belt tensioners

„ Testing, removing, installing and repair work may


only be performed by qualified personnel.

„ Belt tensioner components may not be opened nor


repaired; always use new parts (risk of injury).

„ Belt tensioners that were subject to hard blows or


have been dropped on the floor, must not be
installed in a vehicle.

„ Belt tensioners that are mechanically damaged


(dents, cracks) must always be replaced.

„ Storage and transport is subject to laws governing


explosive materials.

„ Belt tensioners should be installed immediately after


removing them from the shipping package.

„ An impact wrench may not be used to remove the


belt tensioner.

„ Belt tensioner is to be returned to shipping package


when work is interrupted.

„ It is not acceptable to leave belt tensioner


unattended.

„ The belt tensioner may not be treated with grease,


cleaning agents, or similar materials, and may not be
exposed, even briefly, to temperatures above 212
F (100 C)

„ The pyrotechnic propellant has no expiration date,


i.e. it has unlimited service life and is maintenance-
free.
Seat belts Page 2 / 22

Disposing of belt tensioner units

„ Make sure that your dealership complies with


federal, state and local regulations for explosive
substances.

„ Deployed airbags and pyrotechnic seatbelts can be


disposed of as normal scrap.

„ Undeployed airbags and pyrotechnic seatbelts are


considered to be hazardous materials. When
disposing of an undeployed airbag or pyrotechnic
seatbelt that is either defective or expired, use the
appropriate repair information and Airbag
Deployment Device J-44210. DO NOT deploy
airbags and pyrotechnic seatbelts in the vehicle

„ All airbags and pyrotechnic seatbelts of a vehicle


scheduled to be scrapped must be deployed using
the Airbag Deployment Device J-44210.

„ When using Airbag Deployment Device J-44210,


wear appropriate eye and ear protection.

„ If the airbag or pyrotechnic seatbelt cannot be safely


deployed or removed from the vehicle, contact the
Volkswagen Dealer Technicians Helpline.

„ Shipment of active airbag gas generators and


pyrotechnic seatbelt retractors must be in
accordance with the regulations published in the
latest edition of the Code of Federal Regulations #49
(49 CFR). Shipment must be initiated and received
by certified individuals. The penalties for
noncompliance are severe. Civil penalties range the
$250 to $27,500 per violation, per day. Criminal
penalties, for willfully violating the regulations, range
up to $250,000 for individuals and $500,000 for
corporations.

Front seat belts (2-door), removing and installing

Assembly overview
Seat belts Page 3 / 22

„ Screw

„ 20 Nm

„ Screw

„ 40 Nm

„ Window

„ Anchor rail

„ Screw

„ 40 Nm

„ B-pillar belt retractor

„ Wiring harness
Seat belts Page 4 / 22

„ Bolts

„ Qty. 2

„ 4.5 Nm

„ Belt guide

„ Screw

„ 40 Nm

„ Belt guide ring

„ Belt latch

„ Removing 69-1, Belt latch


(2-door), removing and
installing

Removing

Note:

„ Removal and installation is described for the left-


hand side of the vehicle. Removal and installation for
the right-hand side is performed in the same
manner.

Warning!

Observe safety precautions for belt tensioners 69-1,


Safety regulations for belt tensioners .

- Disconnect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

- Remove upper B-pillar trim 70-3, Upper B-pillar trim,


removing and installing

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove backrest 72-2, Backrest, removing and


installing
Seat belts Page 5 / 22

- Remove 2-door sill panel trim 68-3, Sill panel trim (2-
door), removing and installing

- Remove side trim 70-3, Side trim (2-door), removing


and installing

- Remove screw Item - 1 - (20 Nm).

- Remove screw Item - 2 - (40 Nm)


and remove window Item - 3 - .

- Remove anchor rail Item - 4 -


through loop in belt webbing.

- Remove screw Item - 5 - (40 Nm)


and remove belt retractor Item - 6 -
from B-pillar.

Warning!

Electrostatic charges may result in


involuntary deployment of the belt
tensioner. Therefore the technician
must discharge static electricity from
the body before separating the
ignition and ground wiring. This is
done e.g. by briefly touching the body
or the door striker or pin.

- Disconnect wiring harness Item - 7 -


.

- Remove screws Item - 8 - (4.5 Nm)


and remove belt guide Item - 9 - .
Seat belts Page 6 / 22

- Remove screw Item - 10 - (40 Nm)


and remove belt relay Item - 11 - from
belt height adjuster.

Installing

- Installation is performed in the reverse order of removal.

- Connect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

Front seat belts (4-door), removing and installing

Assembly overview
Seat belts Page 7 / 22

„ Screw

„ 40 Nm

„ Micro-encapsulated

„ Belt anchor

„ Screw

„ 40 Nm

„ B-pillar belt retractor

„ Wiring harness

„ Bolts

„ Qty. 2

„ 4.5 Nm
Seat belts Page 8 / 22

„ Belt guide

„ Screw

„ 40 Nm

„ Belt guide ring

„ Belt latch

„ Removing 69-1, Belt latch


(4-door) removing and
installing

Removing

Note:

„ Removal and installation is described for the left-


hand side of the vehicle. Removal and installation for
the right-hand side is performed in the same
manner.

Warning!

Observe safety precautions for belt tensioners 69-1,


Safety regulations for belt tensioners .

- Disconnect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

- Remove upper B-pillar trim 70-3, Upper B-pillar trim,


removing and installing

- Remove lower B-pillar trim 70-3, Lower B-pillar trim,


removing and installing

- Remove screw Item - 1 - (40 Nm)


and remove belt anchor Item - 2 - from
body.

Caution!

Screw Item - 1 - is micro-


encapsulated. For this reason, it must
always be warmed with hot air gun
before loosening. While doing this,
protect the neighboring seatbelt
Seat belts Page 9 / 22

against excessive heat with a moist


towel.

Note :

„ The bolt is micro-encapsulated and must be


replaced every time it is loosened.

„ Before installing the new screw, threads on nut must


be cleaned, re-cut if necessary.

- Remove screw Item - 3 - (40 Nm)


and remove belt retractor Item - 4 -
from B-pillar.

Warning!

Electrostatic charges may result in


involuntary deployment of the belt
tensioner. Therefore the technician
must discharge static electricity from
the body before separating the
ignition and ground wiring. This is
done e.g. by briefly touching the body
or the door striker or pin.

- Disconnect wiring harness Item - 5 -


.

- Remove screws Item - 6 - (2 Nm)


and remove belt guide Item - 7 - .
Seat belts Page 10 / 22
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

- Remove screw Item - 8 - (40 Nm)


and remove belt relay Item - 9 - from
belt height adjuster.

Installing

- Installation is performed in the reverse order of removal.

- Connect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

Front seatbelt height adjuster, removing and installing

Note:

„ Removal and installation is described for the left-


Seat belts Page 11 / 22

hand side of the vehicle. Removal and installation for


the right-hand side is performed in the same
manner.

Removing

- Remove upper B-pillar trim 70-3, Upper B-pillar trim,


removing and installing

Note:

„ Belt anchor or anchor rail does not need to be


removed on seat belt.

- Remove bolt - 1 - (40 Nm) and remove


belt relay - 2 - from belt height adjuster.

- Remove bolt - 3 - (20 Nm) and


separate belt height adjuster - 4 - from
mounting in carrier plate.
Seat belts Page 12 / 22

Installing

- Installation is performed in the reverse order of removal.

Belt latch (2-door), removing and installing

Note:

„ Removal and installation is described for belt latch of


left seat. The same instructions apply for removal
and installation for belt latch of right seat.

Removing

- Remove front seat 72-1, Front seat, removing and


installing

- Position seat as far forward as possible.

- If present, disconnect wiring harness -


1 - from seat frame.
Seat belts Page 13 / 22

- Remove bolt - 2 - (20 Nm).

Note :

„ The screw is micro-encapsulated and must be


replaced every time it is loosened.

„ Before new bolts are installed, the thread of the


corresponding nut must be cleaned.

- Turn belt latch 90 clockwise - arrow


A - .

- Swivel belt latch toward outside - arrow


B - .

- Remove belt latch from mount in seat


rail - arrow C - .

Installing

- Installation is performed in the reverse order of removal.

Belt latch (4-door) removing and installing

Note:

„ Removal and installation is described for belt latch of


left seat. The same instructions apply for removal
and installation for belt latch of right seat.

Removing

- Remove front seat 72-1, Front seat, removing and


installing

- Position seat as far forward as possible.

- If present, disconnect wiring harness


from seat frame.

- Remove bolt - 1 - (20 Nm).

Note :

„ The screw is micro-encapsulated and must be


replaced every time it is loosened.

„ Before new bolts are installed, the thread of the


corresponding nut must be cleaned.
Seat belts Page 14 / 22

- Remove belt latch - 2 - from mount in


seat rail - arrow - .

Installing

- Installation is performed in the reverse order of removal.

Rear outer seatbelts, removing and installing

Assembly overview
Seat belts Page 15 / 22

„ Screw

„ 40 Nm

„ Belt anchor

„ Wiring harness

„ Screw

„ 40 Nm

„ Automatic belt retractor with belt


tensioner

„ Screw

„ 40 Nm

„ Automatic belt retractor without


Seat belts Page 16 / 22

belt tensioner

Removing

Note:

„ Removal and installation is described for the left-


hand side of the vehicle. Removal and installation for
the right-hand side is performed in the same
manner.

2-door vehicles

- Remove upper B-pillar trim 70-3, Upper B-pillar trim,


removing and installing

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove backrest 72-2, Backrest, removing and


installing

- Remove side trim 70-3, Side trim (2-door), removing


and installing

- Remove luggage compartment cover side compartment


70-5, Luggage compartment cover side storage
compartment, removing and installing

- Remove roof end strip 70-6, Roof end strip, removing


and installing

- Remove C-pillar trim 70-3, C-pillar trim, removing and


installing

4-door vehicles

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove 4-door side upholstery:

„ with rear side airbags 72-2, Side upholstery with


side airbag (4-door), removing and installing

„ without rear side airbags 72-2, Side upholstery (4-


door,), removing and installing

- Remove luggage compartment cover side compartment


70-5, Luggage compartment cover side storage
compartment, removing and installing

- Remove roof end strip 70-6, Roof end strip, removing


Seat belts Page 17 / 22

and installing

- Remove C-pillar trim 70-3, C-pillar trim, removing and


installing

- Unscrew bolt - 1 - (40 Nm) and remove


seatbelt guide - 2 - from body.

Vehicles with belt tensioner

- Disconnect vehicle battery

Repair Manual, Electrical Equipment,


Repair Group 27,

Warning!

Electrostatic discharges can lead to


an unintended deployment of the
airbag. Therefore the technician must
discharge static electricity from the
body before separating the ignition
and ground wiring. This is done e.g.
by briefly touching the body or the
door striker or pin.

- Disconnect wiring harness - 3 - .

- Remove screw - 4 - (40 Nm) and


remove automatic belt retractors - 5 -
from body - arrow A - .

Vehicles without belt tensioner


Seat belts Page 18 / 22

- Remove screw - 6 - (40 Nm) and


remove automatic belt retractors - 7 -
from body - arrow B - .

Installing

- Installation is performed in the reverse order of removal.

Rear center 3-point seatbelt, removing and installing

Assembly overview
Seat belts Page 19 / 22

„ Screw

„ Belt latch

„ Hex nut

„ 40 Nm

„ Automatic belt retractor

„ Console

Removing

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove backrest 72-2, Backrest, removing and


installing

- Remove cover and upholstery from backrest 74-2,


Seat belts Page 20 / 22

Cover and cushion for backrest, removing and installing

- Remove screw - 1 - (40 Nm) and


remove belt latch - 2 - from body.

- Remove hex nut - 3 - (40 Nm) and


remove automatic belt retractors - 4 -
from console - 5 - .

- Guide belt latch - 2 - through console -


5- .

Installing

- Installation is performed in the reverse order of removal.

Center rear lap belt, removing and installing

Removing

- Remove seat bench 72-2, Rear seat bench, removing


Seat belts Page 21 / 22

and installing .

- Remove backrest 72-2, Backrest, removing and


installing

- Remove screw - 1 - (40 Nm) and


remove lap belt - 2 - from body.

Installing

- Installation is performed in the reverse order of removal.

Rear double belt latch, removing and installing

Removing

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove backrest 72-2, Backrest, removing and


installing
Seat belts Page 22 / 22

- Remove screw - 1 - (40 Nm) and


remove double belt latch - 2 - from
body.

Installing

- Installation is performed in the reverse order of removal.


Seat belts, inspecting Page 1 / 5

69 - 2

Seat belts, inspecting


Warning!

After every accident the seat belt system must be


inspected systematically! If damage is determined
when inspecting the check points, customer must be
informed regarding necessity of changing belts.

Check points:

„ Check belt webbing

„ Check retractor (locking function)

„ Visually check belt latch

„ Check belt latch function

„ Check belt guide rings and locking tongue

„ Check securing components and anchorage points

Check points

Check belt webbing

- Pull belt completely out of retractor or lap belt adjustment


tongue.

- Inspect belt webbing for contamination and, if necessary,


wash with mild soap solution also refer to Operating
Manual.

„ If any of the following illustrated damage examples


(1 and 2) are discovered on an accident vehicle -
replace complete seat belt with belt latch and belt
height adjuster.

„ If one kind of damage under points 1, 2, 3 and 4 is


detected on a vehicle which has not been in an
accident, only the damaged seatbelt needs to be
replaced.
Seat belts, inspecting Page 2 / 5

„ Belt webbing cut, torn or chafed.

„ Webbing loops on belt edge torn.

„ Burn marks from cigarettes or similar.


Seat belts, inspecting Page 3 / 5

„ One side of belt edge deformed or area of belt edge


is wavy.

Check retractor (locking function)

The belt retractor has two locking functions.

„ The first locking function is initiated by belt being


jerked out of the retractor (belt extraction
acceleration).

Checking

- Pull belt webbing out of retractor with a firm jerk.

„ No locking function - replace compete seat belt with


belt latch.

„ If difficulties are experienced when pulling out or


retracting belt, first check whether position of
retractor has been altered.

„ The second locking function is initiated by change in


vehicle velocity (vehicle-dependent locking function).
For this, the vehicle must be moved on a level
surface.

Checking

- Fasten seat belt.

- Accelerate vehicle to 12 mph (20 km/h) and then perform


a full braking maneuver with foot brake.

„ If the locking mechanism does not lock the seat belt


during the braking maneuver, the complete seat belt
with belt latch must be replaced.
Seat belts, inspecting Page 4 / 5

Warning!

For safety reasons, road test should be carried out on


traffic-free stretch to ensure that other
motorists/pedestrians etc. are not endangered.

Visually check belt latch

- Inspect belt latch for cracks and chipping.

„ If damage is discovered, replace complete seat belt


with belt latch.

Check belt latch function

Check belt latch:

- Insert locking tongue into belt latch until it audibly


engages. Check whether locking mechanism is properly
engaged by giving belt webbing a firm jerk.

„ If locking tongue fails to engage properly in belt latch


even once during at least 5 tests, replace complete
seat belt with belt latch.

Check release mechanism:

- Release seat belt by pressing button on belt latch with


finger pressure.

- When belt is slack, locking tongue must spring out of belt


latch on its own.

„ Perform test at least 5 times. If locking tongue fails


even once to spring out, replace complete seat belt
with belt latch.

Warning!

Under no circumstances may grease be used to


eliminate noise or stiffness at belt buckle buttons.

Check belt guide rings and locking tongue

The plastic-covered guides show fine parallel scoring after


straining belt system (belt was fastened during accident).
(Wear which has been brought about by frequent belt use
can be identified by smooth signs of wear which are free of
scoring.)
Seat belts, inspecting Page 5 / 5

- Inspect for deformation, chipping and cracks in plastic.

„ If scoring and/or damage is discovered, replace


complete seat belt with belt latch.

Check securing components and anchorage points

„ Latch bracket deformed (stretched)

„ Height adjuster not functional

„ Anchorage points (seat, pillar, vehicle floor) distorted


or thread damaged

„ If damage is discovered on these components,


replace complete seat belt with belt latch.

„ Replace anchorage points.

Note:

„ In damage is discovered that is not accident-related,


e.g. wear, replace the particular part which is
damaged.
Inspecting child seat anchors (LATCH system "Lower Anchors and Tethers for CHildr... Page 1 / 1

69 - 3

Inspecting child seat anchors (LATCH system


"Lower Anchors and Tethers for CHildren"), after
accident
Check points

„ After an accident, child seat anchors must be


inspected for damage and deformation.

„ Child seat anchors that are welded into the body


cannot be repaired or corrected.

„ Child seat anchors that are bolted to the body must


be replaced if damaged or deformed.
Airbag Page 1 / 29

69 - 4

Airbag
Airbag components, Location overview,

„ Driver airbag unit

„ Removing 69-4, Driver


airbag module, removing
and installing

„ Airbag malfunction indicator


lamp (MIL) K75

„ Front passenger airbag module

„ Removing 69-4,
Passengers side airbag
module, removing and
installing
Airbag Page 2 / 29

„ Side airbag, driver side

„ Removing 69-4, Side


airbags for driver and front
passenger, removing and
installing

„ Side airbag, front passenger


side

„ Removing 69-4, Side


airbags for driver and front
passenger, removing and
installing

„ Rear driver-side side airbag

„ 4-door only

„ Removing 69-4, Rear side


airbag (4-door), removing
and installing

„ Rear side-airbag, front


passengers side

„ 4-door only

„ Removing 69-4, Rear side


airbag (4-door), removing
and installing

„ Airbag Control Module J234

„ Removing 69-4, Airbag


control module J234 ,
removing and installing

„ Adapting components
(coding) 69-4,
Components, adapting

„ Diagnostic connector
Airbag Page 3 / 29

10 - Front passenger-side side curtain


airbag

„ removing 69-4, Driver and


passenger side curtain airbags,
removing and installing

11 - Driver-side side curtain airbag

„ removing 69-4, Driver and


passenger side curtain airbags,
removing and installing

Safety precautions for work on airbags

„ Testing, removing, installing and repair work may


only be performed by qualified personnel.

„ When working on the airbag system, the battery


Ground (GND) strap must be disconnected. No
waiting time is necessary after disconnecting battery.
Airbag Page 4 / 29

When connecting the airbag system to a voltage


source, there must be no person present inside the
vehicle.

„ Before picking up (touching) the airbag unit, the


technician must electrostatically discharge
him/herself. This is achieved by touching a suitable
metal part, for example, a water pipe, heater pipe or
metal frame.

„ Airbag units should be installed immediately upon


removal from shipping package.

„ Airbag unit is to be returned to shipping package


when there is an interruption in work.

„ It is not acceptable to leave airbag unit unattended.

„ Airbag units which have been removed should be


stored so that padded side is facing up.

„ Airbag units that have fallen onto a hard surface or


show signs of damage must not be installed in
vehicle.

Additional safety precautions for side curtain airbag

„ Always replace damaged pillar trim panels, never


repair.

„ Head curtain airbags must not be kinked or twisted.

„ After body repairs, inspect the body for weld splatter,


deformations and chafing areas near the head
curtain airbag (compare with opposite side if
necessary).

„ If a deployed side curtain airbag is replaced, the


headliner, door seals with weather stripping, curtain
airbag guides, grab handle brackets, and the A, B, C
and (if equipped) D-pillar trim must be replaced. If
damaged, the rear interior lights, the roof grab
handles and the roof close-out molding must be
replaced.
Airbag Page 5 / 29

Disposing airbag units

„ Make sure that your dealership complies with


federal, state and local regulations for explosive
substances.

„ Deployed airbags and pyrotechnic seatbelts can be


disposed of as normal scrap.

„ Undeployed airbags and pyrotechnic seatbelts are


considered to be hazardous materials. When
disposing of an undeployed airbag or pyrotechnic
seatbelt that is either defective or expired, use the
appropriate repair information and Airbag
Deployment Device J-44210. DO NOT deploy
airbags and pyrotechnic seatbelts in the vehicle

„ All airbags and pyrotechnic seatbelts of a vehicle


scheduled to be scrapped must be deployed using
the Airbag Deployment Device J-44210.

„ When using Airbag Deployment Device J-44210,


wear appropriate eye and ear protection.

„ If the airbag or pyrotechnic seatbelt cannot be safely


deployed or removed from the vehicle, contact the
Volkswagen Dealer Technicians Helpline.

„ Shipment of active airbag gas generators and


pyrotechnic seatbelt retractors must be in
accordance with the regulations published in the
latest edition of the Code of Federal Regulations #49
(49 CFR). Shipment must be initiated and received
by certified individuals. The penalties for
noncompliance are severe. Civil penalties range the
$250 to $27,500 per violation, per day. Criminal
penalties, for willfully violating the regulations, range
up to $250,000 for individuals and $500,000 for
corporations.

Airbag units, replacing after an accident

Accident with airbag deployment

Note:

„ The airbag control module does not need to be


replaced after deployment unless "Control module
Airbag Page 6 / 29

faulty" DTC is set in the control module, or the


control module is physically damaged.

Always replace the following components after an


accident when airbag has deployed:

„ All deployed airbag units.

„ Supports and bracket from passenger module with a


deployed passenger airbag.

„ Return ring with slip ring, if drivers side airbag


deployed.

„ All seat belts with deployed seat belt tensioners.

„ If necessary (visual check) also replace the


following: All damaged components.

Accident without airbag deployment

„ The airbag control module does not need to be


replaced after deployment unless "Control module
faulty" DTC is set in the control module, or the
control module is physically damaged.

„ If the airbag malfunction indicator lamp (MIL) K 75


does not indicate a malfunction, it is not necessary
to replace any of the airbag components. Seat belts
must be inspected separately.

Airbag control module J234 , removing and installing

Warning!

Observe safety precautions for working on airbags


69-4, Safety precautions for work on airbags .

Removing

- Disconnect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

- Remove right and left footwell trim from center console


Airbag Page 7 / 29

(other center console components do not need to be


removed):

„ Front center console without adjustable/folding


armrest with storage compartment 68-2, Front
center console without adjustable/folding armrest
with storage compartment, removing and installing

„ Front center console with adjustable/folding armrest


with storage compartment 68-2, Front center
armrest adjustable/folding with storage
compartment, removing and installing

Note :

„ For the sake of illustration, center console is not


depicted in the illustration.

- Open locking mechanism of connector -


1 - and disconnect wiring harness from
control module - 2 - .

- Remove three nuts - 3 - (9 Nm).


Airbag Page 8 / 29

- Remove the control module from the


vehicle.

Installing

- Installation is performed in the reverse order of removal.

- Switch on ignition.

Warning!

Make sure that no persons are in the vehicle.

- Connect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

- If the control module was replaced, it must be coded.


Airbag Page 9 / 29

Adapting components (coding) 69-4, Components,


adapting

Driver airbag module, removing and installing

Note:

„ Removal and installation of airbag unit is described


for multi-function steering wheel.

„ The screwdriver mentioned in the following should


be about 175 mm long and have a blade width of 7
mm.

Removing

Warning!

Observe safety precautions for working on airbags


69-4, Safety precautions for work on airbags .

- Disconnect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

- Adjust steering wheel height so that it is located in the


highest position.

- Adjust steering wheel depth (reach) so it is in the fully


extended position.

- Turn steering wheel into the position


depicted.

- Insert a screwdriver into hole on rear


side of steering wheel until it stops
(approx. 8 mm).

- Turn the screwdriver in the direction of


passengers side door - arrow - ; this
unlocks the airbag unit locking frame on
the right side of the steering wheel.

- Turn steering wheel 180 and


disengage airbag unit locking mechanism
on left side of steering wheel as
described.

- Turn steering wheel back 90 into


center position.
Airbag Page 10 / 29

- Remove airbag unit from steering


wheel.

Warning!

Electrostatic discharges can lead to


an unintended deployment of the
airbag. Therefore the technician must
discharge static electricity from the
body before separating the ignition
and ground wiring. This is done e.g.
by briefly touching the body or the
door striker or pin.

- Press connector lock and disconnect


connector - 1 - .

Note :

„ This connector is only installed with multifunction


steering wheel.
Airbag Page 11 / 29

- Release connector lock in - direction


of arrow - and disconnect airbag
connector - 2 - .

Installing

- Check whether wiring harness - 3 - is


routed as shown in the illustration.

- Insert airbag connector - 2 - into


connector coupling. Airbag connector
must engage audibly.

- Insert connector - 1 - into connector


coupling.

- Push airbag unit into steering wheel.


Airbag Page 12 / 29

- Check whether airbag unit is engaged


on the left and right-hand side of the
steering wheel.

- Switch on ignition.

Warning!

Make sure that no one is in the vehicle.

- Connect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

Steering wheel, removing and installing

Removing
Airbag Page 13 / 29

- Disconnect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

- Remove driver-side airbag unit 69-4, Driver airbag


module, removing and installing

- Turn steering wheel into center position


(wheels in straight ahead position).

- Remove bolt - 1 - and pull steering


wheel off of steering column.

Installing

- Place steering wheel onto steering


column.

- Center markings for steering wheel and


steering column - arrows - must align.
Airbag Page 14 / 29

- The coil spring connector socket and


pin must be positioned in the openings
provided at the base of the steering
wheel.

- Fasten steering wheel with bolt - 1 - ;


torque is 50 Nm.

Airbag Spiral Spring/Return Spring With Slip Ring F138 ,


removing and installing

Airbag spiral spring/return spring with slip ring is a


component of steering column switch, depending on
construction type.

Repair Manual, Electrical equipment, Repair Group 94,


Steering column switch
Airbag Page 15 / 29

Passengers side airbag module, removing and installing

Removing

Warning!

Observe safety precautions for working on airbags


69-4, Safety precautions for work on airbags .

- Disconnect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

- Remove side instrument panel cover 68-2, Instrument


panel side covers, removing and installing

- Remove center cover 68-2, Center cover, removing


and installing

- Remove glove compartment 68-2, Glove


compartment, removing and installing

Warning!

Electrostatic discharges can lead to


an unintended deployment of the
airbag. Therefore the technician must
discharge static electricity from the
body before separating the ignition
and ground wiring. This is done e.g.
by briefly touching the body or the
door striker or pin.

- Disconnect wiring harness from front


passengers side airbag.

- Remove the two bolts - 1 - (9 Nm).

- Remove the two sets of bolts - 2 - and


- 3 - (9 Nm).
Airbag Page 16 / 29

- Remove front passengers airbag and


brackets - 4 - and - 5 - from mounts.

Installing

- Installation is performed in the reverse order of removal.

- Switch on ignition.

Warning!

Make sure that no one is in the vehicle.

- Connect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

.
Airbag Page 17 / 29

Side airbags for driver and front passenger, removing


and installing

Note:

„ Removal and installation is described for the left-


hand side of the vehicle. Removal and installation for
the right-hand side is performed in the same
manner.

Removing

Warning!

Observe safety precautions for working on airbags


69-4, Safety precautions for work on airbags .

- Remove front seat 72-1, Front seat, removing and


installing

- Remove front right seat trim 72-1, Right seat trim,


removing and installing

Vehicles with manual seat adjustment

- Remove front left seat trim 72-1, Left seat trim,


removing and installing

Vehicles with electric seat adjustment

- Remove left power seat trim 72-1, Left power seat


trim, removing and installing

All vehicles

- Remove front seat backrest 72-1, Front seat backrest,


removing and installing

- Remove cover and upholstery from front seat backrest


74-1, Front seat backrest cover and padding, removing and
installing

- Separate wiring harness - 1 - from


backrest frame.

- Remove bolt - 2 - (9 Nm).


Airbag Page 18 / 29

- Remove side airbag - 3 - from


mounting in backrest frame.

Installing

- Installation is performed in the reverse order of removal.

- Switch on ignition.

Warning!

Make sure that no persons are in the vehicle.

- Connect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

.
Airbag Page 19 / 29

Rear side airbag (4-door), removing and installing

Note:

„ Removal and installation is described for the right-


hand side of the vehicle. Removal and installation for
the left-hand side is performed in the same manner.

Removing

Warning!

Observe safety precautions for working on airbags


69-4, Safety precautions for work on airbags .

- Disconnect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove side upholstery with side


airbag (4-door), - 1 - 72-2, Side
upholstery with side airbag (4-door),
removing and installing

- Remove the two bolts - 2 - (9 Nm).

Note :

„ The bolts are microencapsulated and must therefore


be replaced after every removal.

„ Before installing the new bolts, the threads of the


corresponding nuts must be cleaned.

- Remove rear side airbag connector


coupling - 3 - from mount in side
upholstery - 1 - .
Airbag Page 20 / 29

- Remove rear side airbag - 3 - from


side upholstery.

Installing

- Installation is performed in the reverse order of removal.

- Switch on ignition.

Warning!

Make sure that no persons are in the vehicle.

- Connect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

.
Airbag Page 21 / 29

Driver and passenger side curtain airbags, removing and


installing

Note:

„ Removal and installation is described for the right-


hand side of the vehicle. Removal and installation for
the left-hand side is performed in the same manner.

„ Removal and installation for 4-door vehicle is


described. Removal and installation for 2-door
vehicle is identical.

Removing

Warning!

Observe safety precautions for working on airbags


69-4, Safety precautions for work on airbags .

- If present, open sunroof.

- Disconnect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

- Remove sun visors 68-2, Sun visor, removing and


installing

- Remove roof grab handle 68-4, Grab handles (roof),


removing and installing

- Remove lights and switch in molded headliner

Repair Manual, Electrical Equipment, Repair Group 96.,

- Remove roof end strip 70-6, Roof end strip, removing


and installing

- Remove upper A-pillar trim 70-3, Upper A-pillar trim,


removing and installing

- Remove upper B-pillar trim. Belt anchors or front belt


anchor rails do not have to be removed 70-3, Upper B-
pillar trim, removing and installing

2-door only

- Remove seat bench 72-2, Rear seat bench, removing


and installing .
Airbag Page 22 / 29

- Remove backrest 72-2, Backrest, removing and


installing

- Remove side trim 70-3, Side trim (2-door), removing


and installing

4-door only

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove 4-door side upholstery:

„ with rear side airbags 72-2, Side upholstery with


side airbag (4-door), removing and installing

„ without rear side airbags 72-2, Side upholstery (4-


door,), removing and installing

All vehicles

- Remove luggage compartment cover side compartment


70-5, Luggage compartment cover side storage
compartment, removing and installing

- Remove trim on C-pillars 70-3, C-pillar trim, removing


and installing

- Remove molded headliner 70-6, Headliner, removing


and installing

Warning!

Electrostatic discharges can lead to


an unintended deployment of the
airbag. Therefore the technician must
discharge static electricity from the
body before separating the ignition
and ground wiring. This is done e.g.
by briefly touching the body or the
door striker or pin.

- Disconnect wiring harness from side


curtain airbag

- Remove the four bolts - 1 - (4.5 Nm).

Note :

„ The four screws - 1 - must be replaced.

- Remove the two cap nuts - 2 - (9


Nm).
Airbag Page 23 / 29

- Remove all clips for curtain airbag from


body.

- Remove igniter - 3 - from threaded


pins - 4 - in body.

- Remove side curtain airbag from


vehicle via rear lid.

Installing

- Installation is performed in the reverse order of removal.

- After working on side curtain airbag,


ensure wiring harness - 1 - is routed as
shown.
Airbag Page 24 / 29

- Wiring harness - 1 - must be secured


with cable guide - 2 - in C-pillar area.

- Switch on ignition.

Warning!

Make sure that no persons are in the vehicle.

- Connect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

Front Passenger s Seat Occupied Sensor G128 ,


removing and installing

Warning!
Airbag Page 25 / 29

If Front Passenger s Seat Occupied Sensor G128 is


replaced, also the upholstery, front seat cushion must
always be replaced!

Removing

- Mount the fixture for seat repair VAS 6136 on the engine
and transmission holder VAS 6095 .

- Remove front seat 72-1, Front seat, removing and


installing

- Attach the seat to the fixture for seat repair VAS 6136 .

- Remove front right seat trim 72-1, Right seat trim,


removing and installing

Vehicles with manual seat adjustment

- Remove front left seat trim 72-1, Left seat trim,


removing and installing

- Remove bracket and front seat operating lever 72-1,


Front seat bracket and operating lever, removing and
installing

Vehicles with electric seat adjustment

- Remove left power seat trim 72-1, Left power seat


trim, removing and installing

- Remove retainer and power seat bracket 72-1,


Retainer and power seat bracket, removing and installing

All vehicles

- Remove front seat drawer mount 72-1, Seat drawer


mount, removing and installing

Note:

„ On vehicles with a luggage pass-through, it is


sufficient to fold the backrest forward, it does not
have to be removed.

- Remove front seat backrest 72-1, Front seat backrest,


removing and installing

- Remove cover and upholstery from front seat backrests


74-1, Front seat cushion cover and padding, removing
and installing

Warning!
Airbag Page 26 / 29

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


огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

Front Passenger s Seat Occupied


Sensor G128 - 1 - is secured with
seat cushion padding. It is not
possible to remove and install
separately, sensor must be replaced
with upholstery.

Installing

- Press wiring harness in positioning aid


area - 1 - in rear padding channel.

- Press wiring harness in area of -


arrows A and B - from padding.

- Align sensor positioning aid - 3 - with


padding positioning aid - 2 - .

Caution!

Ensure distance from sensor to


Airbag Page 27 / 29

positioning aids - 2 - is constant -


arrows - when doing this.

- Secure aligned sensor - 1 - with right


hand, remove adhesive tape strips - 2 -
and attach sensor to padding.

- Press wiring harness in rear area into


padding opening - arrow - .
Airbag Page 28 / 29

- Connect wiring harness with vehicle


electrical system.

Installing of remaining components is reverse of removal.

- After installing, perform a function check with ignition on.

Components, adapting
Airbag Page 29 / 29

„ Vehicle Diagnosis, Testing and Information System


VAS 5051

„ Diagnostic cable VAS 5051/1 or VAS 5051/3

Note:

„ VAS 5051 A version shown as example only.

Select "Guided Fault Finding" on vehicle diagnosis, testing


and information system VAS 5051 .

After all control modules have been interrogated:

- Press "Go to" button

- Select "Function/Component selection"

- Select "Body"

- "Body Repairs"

- Select "01 - On Board Diagnostic (OBD) capable


systems"

- Select "Airbag"

- Select "Functions"

- Select "Action"
Passenger Occupant Detection System (PODS) (USA only) Page 1 / 26

69 - 5

Passenger Occupant Detection System (PODS)


(USA only)
Note:

„ Passenger Occupant Detection System (PODS)


controls automatic passenger airbag deactivation.

„ This equipment is only installed on vehicles released


in the USA.

Safety measures when working on seat occupied


recognition

„ After every repair on the passenger seat in which the


seat and/or backrest cover was "disengaged" basic
setting on Seat Occupied Recognition Control
Module J706 must be performed. Perform basic
setting with a diagnostic tester that has "Guided
Fault Finding" .

„ The seat occupied recognition mat must not be


kinked.

„ A leaking mat must be replaced (repair kit).

„ The seat occupied recognition pressure hose must


not be kinked.

„ Seat occupied recognition (repair kit) components


must not fall on hard surfaces.

„ Seat occupied recognition components must not


come in contact with grease.

„ There is the danger that the pPassenger Occupant


Detection System (PODS) may be damaged by
sharp objects when working on the seat. It is
necessary to avoid this danger.

„ The mat, the crease and various covers must be


fitted to be free of folds.
Passenger Occupant Detection System (PODS) (USA only) Page 2 / 26

„ When installing, ensure upholstery and cover are


installed correctly.

„ Replace all upholstery clips and clip connectors from


cover, ensure it is positioned correctly on seat when
doing so.

„ System basic setting is only possible at


temperatures between 32 and 104 F (0 and
+40 C).

„ Make sure that no objects are placed on seat when


performing basic setting.

„ Use of seat covers, such as cushions or something


similar, impairs seat occupied recognition function
and airbag system effectiveness.

Procedure after an accident with belt pretensioner and/or


airbag deployment

„ Each time passenger airbag and/or belt pretensioner


on passenger side is deployed, Seat Occupied
Recognition Control Module J706 basic setting must
be performed. Perform basic setting with a
diagnostic tester that has "Guided Fault Finding" .

„ If the seat rails and/or seat pan must be replaced


after an accident due to deformation, seat occupied
recognition must also be replaced with "seat
occupied recognition repair kit" . Then, Seat
Occupied Recognition Control Module J706 basic
setting must be performed. Perform basic setting
with a diagnostic tester that has "Guided Fault
Finding" .

Passenger Occupant Detection System (PODS),


assembly overview (USA only)
Passenger Occupant Detection System (PODS) (USA only) Page 3 / 26

„ Front seat wiring harness

„ Seat frame

„ Seat Occupied Recognition


Control Module J706

„ Upholstery of front seat cushion

„ Must not be separated from


mat for seat occupied
recognition

„ Seat Occupied Recognition Mat

„ Must not be removed from


pressure hose and
upholstery of front seat
cushion

„ Insertion profile
Passenger Occupant Detection System (PODS) (USA only) Page 4 / 26

„ Note location

„ Bracket

„ White

Repair set components for Passenger Occupant


Detection System (PODS)

If there is a malfunction on a part of the


system, it must be replaced with
components from the repair kit. Repair
set is already matched to characteristics
of vehicle to be repaired and contains the
following components.

Warning!

Never use repair set components


separately.
Passenger Occupant Detection System (PODS) (USA only) Page 5 / 26

„ Upholstery of front seat


cushion

„ Pressure hose

„ Seat Occupied Recognition Mat

„ Seat Occupied Recognition


Pressure Sensor G452

„ Seat Occupied Recognition


Control Module J706

„ Front seat wiring harness

„ Bracket

„ White

Warning!

Read and follow instructions for use


on package of repair set.
Passenger Occupant Detection System (PODS) (USA only) Page 6 / 26

Misapplication may lead to


malfunction of system.

Components of Passenger Occupant Detection System


(PODS), removing (vehicles with manual seat
adjustment)

Warning!

Observe safety precautions when working on seat


occupied recognition 69-5, Safety measures when
working on seat occupied recognition .

Note:

„ Seat cushion, mat for seat occupied recognition,


control module and pressure sensor must only be
replaced together. Components are complementary
and must not be separated!

„ Only disconnect wiring harnesses mentioned in the


following description!

- Mount the fixture for seat repair VAS 6136 on the engine
and transmission holder VAS 6095 .

- Remove front seat 72-1, Front seat, removing and


installing .

- Attach the seat to the fixture for seat repair VAS 6136 .

- Remove front belt latch:

„ 2-door 69-1, Belt latch (2-door), removing and


installing

„ 4-door 69-1, Belt latch (4-door) removing and


installing

- Remove right trim on seat:

„ Seat without pass-through 72-1, Right seat trim,


removing and installing

„ Seat with pass-through 72-1, Right trim, removing


and installing (seat with pass-through)
Passenger Occupant Detection System (PODS) (USA only) Page 7 / 26

- Remove left trim on seat:

„ Seat without pass-through 72-1, Left seat trim,


removing and installing

„ Seat with pass-through 72-1, Left trim, removing


and installing (seat with pass-through)

- Remove bracket and front seat operating lever 72-1,


Front seat bracket and operating lever, removing and
installing .

- If present, remove mount for seat drawer 72-1, Seat


drawer mount, removing and installing .

- If present, remove connector - 1 - from


Front Passenger s Heated Seat Control
Module J132 .

- If equipped, remove retaining clip - 2 -


.

- Remove retaining clips - 3 - .

- If present, disconnect connector - 4 -


and remove connector from seat frame.

- Disconnect side airbag connector - 5 -


and remove connector from seat frame.
Passenger Occupant Detection System (PODS) (USA only) Page 8 / 26

- Remove line clip - 6 - and disconnect


backrest wiring harness from seat
frame.

- Remove front seat backrest 72-1, Front seat backrest,


removing and installing .

- Remove cover from upholstery of front seat cushion


(front seat cushion is not removed) 74-1, Front seat
cushion cover and padding, removing and installing .

- Unclip pressure hose - 6 - from


retainers.

- Unclip Seat Occupied Recognition


Pressure Sensor G452 - 5 - from
retainer, when doing this do not
disconnect harness connectors - 3 - or -
4 - at Seat Occupied Recognition
Pressure Sensor G452 and similarly at
Seat Occupied Recognition Control
Passenger Occupant Detection System (PODS) (USA only) Page 9 / 26

Module J706 - 2 - .

- Remove bolts - 1 - (1.5 Nm).

- If present, disconnect front seat heating


connector - 3 - .

- Disconnect black Seat Occupied


Recognition Safety Belt Force Sensor
G453 connector - 5 -

- Disconnect yellow Front Passenger s


Safety Belt Switch E25 connector - 4 - .

- If present, disconnect front seat


backrest heating connector - 6 - .

- Cut wiring harness cable ties - 2 - .

- Slide white bracket - 1 - left and


remove from seat frame.
Passenger Occupant Detection System (PODS) (USA only) Page 10 / 26

- Remove all connectors from bracket.

Caution!

Do not disconnect connector from


Seat Occupied Recognition Control
Module J706 .

- Lift upholstery of front seat cushion - 1


- , when doing this do not separate
upholstery of front seat cushion from mat
for seat occupied recognition - 4 - .

- Remove clip - 2 - from seat frame - 5 -


, clip - 3 - must not be removed.

Warning!

„ Do not damage seals when assembling or


disassembling.
Passenger Occupant Detection System (PODS) (USA only) Page 11 / 26

„ Seat cushion, mat for seat occupied recognition,


pressure hose, Seat Occupied Recognition
Pressure Sensor G452 and Seat Occupied
Recognition Control Module J706 must not be
separated!
Passenger Occupant Detection System (PODS) (USA only) Page 12 / 26

- Remove screws - 1 - (2.5 Nm) and


remove Seat Occupied Recognition
Control Module J706 bracket.

- Remove upholstery of front seat


cushion - 1 - together with mat for seat
occupied recognition - 4 - .
Passenger Occupant Detection System (PODS) (USA only) Page 13 / 26

- Thread pressure hose - 6 - , Seat


Occupied Recognition Pressure Sensor
G452 - 7 - , Seat Occupied Recognition
Control Module J706 - 9 - and seat
wiring harness - 8 - through opening -
arrow - on seat frame - 5 - .

Repair set for Passenger Occupant Detection System


(PODS), installing (vehicles with manual seat
adjustment)

Note:

„ When installing, there must be no wiring harness of


seat heater between upholstery and mat for seat
occupied recognition.

„ Pressure hose must be routed without kinking.

„ Stickers with notes on harness connectors must not


Passenger Occupant Detection System (PODS) (USA only) Page 14 / 26

be damaged.

„ After being connected to the vehicle electrical


system, verify that the replaced components can
move easily by moving the seat.

After replacing seat occupied recognition, basic setting of


seat occupied recognition must be performed using
diagnostic tester containing "Guided Fault Finding" .

Warning!

Basic setting must be performed when seat is not


occupied.

Installation is reverse of removal, noting the following:

- Secure insertion profile - 2 - with double-sided tape - 3 -


on seat frame - 1 - as shown.
Passenger Occupant Detection System (PODS) (USA only) Page 15 / 26

- Clip pressure hose - 6 - into bracket.


Begin clipping into bracket near Seat
Occupied Recognition Pressure Sensor
G452 - 5 - and end near connector - 3 -
.

- Switch on ignition.

Warning!

„ Make sure that no persons are in the vehicle.

„ Do not damage seals when assembling or


disassembling.

- Connect vehicle battery


Passenger Occupant Detection System (PODS) (USA only) Page 16 / 26

Repair Manual, Electrical Equipment, Repair Group 27,

Components of Passenger Occupant Detection System


(PODS), removing (vehicles with electric seat
adjustment)

Warning!

Observe safety precautions when working on seat


occupied recognition 69-5, Safety measures when
working on seat occupied recognition .

Note:

„ Seat cushion, mat for seat occupied recognition,


control module and pressure sensor must only be
replaced together. Components are complementary
and must not be separated!

„ Only disconnect wiring harnesses mentioned in the


following description!

- Mount the fixture for seat repair VAS 6136 on the engine
and transmission holder VAS 6095 .

- Remove front seat 72-1, Front seat, removing and


installing .

- Attach the seat to the fixture for seat repair VAS 6136 .

- Remove front belt latch:

„ 2-door 69-1, Belt latch (2-door), removing and


installing

„ 4-door 69-1, Belt latch (4-door) removing and


installing

- Remove right trim on seat 72-1, Right seat trim,


removing and installing .

- Remove left power seat trim 72-1, Left power seat


trim, removing and installing .

- If present, remove seat drawer mount 72-1, Seat


drawer mount, removing and installing

- Remove retainer and power seat bracket 72-1,


Retainer and power seat bracket, removing and installing
Passenger Occupant Detection System (PODS) (USA only) Page 17 / 26

- Disconnect connector - 1 - from backrest adjustment


motor.

- Disconnect connector - 1 - from seat


adjustment motor.

- Remove cable brackets - 2 - and - 3 -


.

- Disconnect backrest adjustment


connector - 4 - and remove connector
from seat frame.

- Remove cable bracket - 5 - .

- If present, remove connector - 6 - from


Front Passenger s Heated Seat Control
Module J132 .

- If equipped, remove retaining clip - 7 -


.

- Disconnect side airbag connector - 8 -


.

- Remove cable bracket - 9 - .

- If present, disconnect front backrest


heating connector - 10 - and remove
yellow connector.

Note :

„ Do not remove white bracket.


Passenger Occupant Detection System (PODS) (USA only) Page 18 / 26

- Remove cable bracket - 11 - .

- Remove front seat backrest 72-1, Front seat backrest,


removing and installing .

- Remove cover from upholstery of front seat cushion


(front seat cushion is not removed) 74-1, Front seat
cushion cover and padding, removing and installing .

Caution!

Do not disconnect connector from


Seat Occupied Recognition Control
Module J706 .

- Unclip pressure hose - 6 - from


retainers.

- Unclip Seat Occupied Recognition


Pressure Sensor G452 - 5 - from
retainer, when doing this do not
disconnect harness connectors - 3 - or -
Passenger Occupant Detection System (PODS) (USA only) Page 19 / 26

4 - at Seat Occupied Recognition


Pressure Sensor G452 and similarly at
Seat Occupied Recognition Control
Module J706 - 2 - .

- Remove bolts - 1 - (1.5 Nm).

- Disconnect black Seat Occupied


Recognition Safety Belt Force Sensor
G453 connector - 1 -

- Disconnect yellow Front Passenger s


Safety Belt Switch E25 connector - 2 - .
Passenger Occupant Detection System (PODS) (USA only) Page 20 / 26

- Remove white bracket - 3 - from seat


frame.

- If present, disconnect front seat heating


connector - 3 - .

- If present, disconnect front seat


backrest heating connector - 4 - .

- Cut wiring harness cable ties - 2 - .

- Slide white bracket - 1 - left and


remove from seat frame.
Passenger Occupant Detection System (PODS) (USA only) Page 21 / 26

- Remove all connectors from bracket.

- Lift upholstery of front seat cushion - 1


- , when doing this do not separate
upholstery of front seat cushion from mat
for seat occupied recognition - 4 - .

- Remove clip - 2 - from seat frame - 5 -


, clip - 3 - must not be removed.

Warning!

Seat cushion, mat for seat occupied


recognition, pressure hose, Seat
Occupied Recognition Pressure
Sensor G452 and Seat Occupied
Recognition Control Module J706
must not be separated!
Passenger Occupant Detection System (PODS) (USA only) Page 22 / 26

- Remove upholstery of front seat


cushion - 1 - together with mat for seat
occupied recognition - 4 - .
Passenger Occupant Detection System (PODS) (USA only) Page 23 / 26
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огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

- Thread pressure hose - 6 - , Seat


Occupied Recognition Pressure Sensor
G452 - 7 - , Seat Occupied Recognition
Control Module J706 - 9 - and seat
wiring harness - 8 - through opening -
arrow - on seat frame - 5 - .

Repair set for Passenger Occupant Detection System


(PODS), installing (vehicles with electric seat
adjustment)

Note:

„ When installing, there must be no wiring harness of


seat heater between upholstery and mat for seat
occupied recognition.

„ Pressure hose must be routed without kinking.

„ Stickers with notes on harness connectors must not


Passenger Occupant Detection System (PODS) (USA only) Page 24 / 26

be damaged.

„ After being connected to the vehicle electrical


system, verify that the replaced components can
move easily by moving the seat.

After replacing seat occupied recognition, basic setting of


seat occupied recognition must be performed using
diagnostic tester containing "Guided Fault Finding" .

Warning!

Basic setting must be performed when seat is not


occupied.

Installation is reverse of removal, noting the following:

- Secure insertion profile - 2 - with double-sided tape - 3 -


on seat frame - 1 - as shown.
Passenger Occupant Detection System (PODS) (USA only) Page 25 / 26

- Connect pressure hose - 6 - . Brackets


must be reinstalled, from Seat Occupied
Recognition Pressure Sensor G452 - 5 -
to wiring harness connector - 3 - .

- Switch on ignition.

Warning!

„ Do not damage seals when assembling or


disassembling.

„ Make sure that no persons are in the vehicle.

- Connect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,


Passenger Occupant Detection System (PODS) (USA only) Page 26 / 26

.
Crash sensors Page 1 / 6

69 - 6

Crash sensors
Front door crash sensors, removing and installing

Note:

„ Removal and installation is described for the right-


hand side of the vehicle. Removal and installation for
the left-hand side is performed in the same manner.

Removing

Warning!

Observe safety precautions for working on airbags.

- Disconnect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

- Remove outer door panel

Repair Manual, Body Exterior, Repair Group 57,

- Separate wiring harness - 1 - from


crash sensor - 3 - .
Crash sensors Page 2 / 6

- Remove the two bolts - 2 - (2.5 Nm).

Installing

- Installation is performed in the reverse order of removal.

- Switch on ignition.

Warning!

Make sure that no persons are in the vehicle.

- Connect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

Rear wheel housing crash sensors (2-door), removing


Crash sensors Page 3 / 6

and installing

Note:

„ Removal and installation is described for the right-


hand side of the vehicle. Removal and installation for
the left-hand side is performed in the same manner.

Removing

Warning!

Observe safety precautions for working on airbags.

- Disconnect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove backrest 72-2, Backrest, removing and


installing

- Remove upper B-pillar trim 70-3, Upper B-pillar trim,


removing and installing

- Remove side trim 70-3, Side trim (2-door), removing


and installing

- Press connector lock - 1 - toward rear -


arrow - and disconnect connector - 2 -
from crash sensor - 4 - .
Crash sensors Page 4 / 6

- Remove the two bolts - 3 - (9 Nm).

Installing

- Installation is performed in the reverse order of removal.

- Switch on ignition.

Warning!

Make sure that no persons are in the vehicle.

- Connect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

Rear wheel housing crash sensors (4-door), removing


Crash sensors Page 5 / 6

and installing

Note:

„ Removal and installation is described for the right-


hand side of the vehicle. Removal and installation for
the left-hand side is performed in the same manner.

Removing

Warning!

Observe safety precautions for working on airbags.

- Disconnect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove 4-door side upholstery:

„ with rear side airbags 72-2, Side upholstery with


side airbag (4-door), removing and installing

„ without rear side airbags 72-2, Side upholstery (4-


door,), removing and installing

- Wheel housing trim, 4-door, removing 68-3, Wheel


housing trim (4-door), removing and installing

- Remove 4-door sill panel trim 68-3, Sill panel trim (4-
door), removing and installing

- Press connector lock - 1 - toward rear -


arrow - and disconnect connector - 2 -
from crash sensor - 4 - .
Crash sensors Page 6 / 6

- Remove the two bolts - 3 - (9 Nm).

Installing

- Installation is performed in the reverse order of removal.

- Switch on ignition.

Warning!

Make sure that no persons are in the vehicle.

- Connect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

.
Volkswagen Golf 5 2004-> VW Rabbit GTI 2006->
(A5)

Instrument panel
Tools

Required special tools, workshop equipment, testing and


measuring equipment, and aids

„ Trim removal wedge 3409

Instrument panel, removing and installing

Removing

- Disconnect vehicle battery

Repair Manual, Electrical Equipment, Repair Group 27,

- Remove driver-side airbag unit 69-4, Driver airbag


module, removing and installing

- Remove steering wheel 69-4, Steering wheel,


removing and installing

- Remove side instrument panel covers 68-2, Instrument


panel side covers, removing and installing

- Remove upper trim on A-pillars 70-3, Upper A-pillar


trim, removing and installing

- Remove center cover 68-2, Center cover, removing


and installing

- Remove glove compartment 68-2, Glove


compartment, removing and installing

- Remove center console:


Instrument panel Page 2 / 13

„ Front center console without adjustable/folding


armrest with storage compartment 68-2, Front
center console without adjustable/folding armrest
with storage compartment, removing and installing

„ Front center console with adjustable/folding armrest


with storage compartment 68-2, Front center
armrest adjustable/folding with storage
compartment, removing and installing

- Remove instrument panel center vent 68-2, Instrument


panel center vent, removing and installing (vehicles with
Climatronic)

„ Vehicles without Climatronic 68-2, Instrument


panel center vent (vehicles without Climatronic),
removing and installing

„ Vehicles with Climatronic 68-2, Instrument panel


center vent, removing and installing (vehicles with
Climatronic)

- Remove instrument panel center trim: 68-2, Center


instrument panel trim, removing and installing

Vehicles with radio system

- Remove radio

Repair Manual, Electrical Equipment, Repair Group 91,

Vehicles with Navigation

- Remove Navigation display and control head

Repair Manual, Electrical Equipment, Repair Group 91,

Vehicles with Climatic or Climatronic

- Remove Climatic or Climatronic mechanism

Repair Manual, Heating Air Conditioning, Repair Group


87,
Instrument panel Page 3 / 13

Vehicles with heating

- Remove heating mechanism

Repair Manual, Heating Air Conditioning, Repair Group


80,

- Remove steering column trim 68-2, Steering column


trim, removing and installing

- Remove Steering Column Electronic Systems Control


Module J527

Repair Manual, Electrical Equipment, Repair Group 94,

- Remove Airbag Spiral Spring/Return Spring With Slip


Ring F138

Repair Manual, Electrical Equipment, Repair Group 94,

- Remove Steering Angle Sensor G85

Repair Manual, Electrical Equipment, Repair Group 94,

- Remove Turn Signal Switch E2

Repair Manual, Electrical Equipment, Repair Group 94,

- Remove Windshield Wiper Switch E

Repair Manual, Electrical Equipment, Repair Group 94,

- Remove right trim panel on drivers side 68-2, Drivers


side left trim, removing and installing

- Remove left trim panel on drivers side 68-2, Drivers


side right trim, removing and installing

- Remove instrument cluster


Instrument panel Page 4 / 13

Repair Manual, Electrical Equipment, Repair Group 91,

- Remove drivers side footwell cover 68-2, Drivers side


footwell cover, removing and installing

- Remove two bolts - 1 - (9 Nm) from


front passenger airbag.

- Disconnect wiring harness from front


passengers side airbag.

- Remove bolt - 2 - (3 Nm).

- Remove bolts - 3 - and - 4 - (3 Nm).

- Remove bolt - 1 - (3 Nm).


Instrument panel Page 5 / 13

- Remove two screws - 2 - (8 Nm)


above tunnel.
Instrument panel Page 6 / 13

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огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

- Remove bolts - 1 - , - 2 - and - 3 - (3


Nm).

- Pull instrument panel out of mounts - 1


- in area of juncture to front windshield.

- Depending on vehicle equipment,


disconnect the corresponding wiring
harnesses and remove instrument panel
from vehicle with a second technician.

Note :

„ When installing instrument panel, make sure that


instrument panel is placed with exact fit into mounts
- 1 - .
Instrument panel Page 7 / 13

Installing

- Installation is performed in the reverse order of removal.

Instrument panel, aligning in vehicle


Instrument panel Page 8 / 13

Instrument panel height is adjusted correctly when there is


no offset between door trim seam - arrow A - and
instrument panel seam - arrow B - .

Height difference between upper edge of door trim - 1 -


and upper edge of instrument panel - 2 - is 3 mm 1 mm.

It is not necessary to change instrument panel position to


increase horizontal gap between door trim and instrument
panel - arrow C - .

- Open door and remove screw - 1 - (2 Nm).

- Hold an appropriately thick cloth at left edge of


instrument panel and close door.
Instrument panel Page 9 / 13

In this way, door trim engages closer to door and the gap
between door trim and instrument panel increases
appropriately. Thus, it is not necessary to align instrument
panel.

Note:

„ Perform work on passenger side in the same way.

Instrument panel, aligning

Instrument panel can be aligned in height and diagonally to


direction of travel.

- Remove wiper arm

Repair Manual, Electrical Equipment, Repair Group 92,

- Remove plenum chamber cover

Repair Manual, Body Exterior, Repair Group 64,

- Remove side instrument panel covers 68-2, Instrument


panel side covers, removing and installing

- Pry cover - 1 - out of mounts using trim removal wedge


3409 .

- Unclip cover - 1 - from trim using a


small screw driver.

- Remove bolt - 2 - (1.5 Nm).

- Pull left footwell trim - 3 - out of


mounts.

Note :
Instrument panel Page 10 / 13

„ Removal of right footwell trim is identical.

- Loosen screw - 1 - in plenum chamber 2-3 turns.

- Loosen two screws - 1 - below heating


or A/C mechanism 2-3 turns (9 Nm).
Instrument panel Page 11 / 13

Note :

„ Additional screws in this area do not need to be


loosened.

- Loosen four screws - 2 - in tunnel area


2-3 turns (20 Nm).

- Loosen nut - 1 - on right side 2-3 turns


(18 Nm).

- Loosen fuse holder screw - 3 - on left


side (2 Nm).

- Loosen two nuts - 4 - 2-3 turns (18


Nm).

Instrument panel, aligning height

Note :
Instrument panel Page 12 / 13

„ Instrument panel height is set using eccentric screws


- 2 - and - 5 - .

„ In the zero position, the longer eccentric surface


faces toward outside of vehicle.

„ Eccentric must not be turned more than 90 out


of zero position.

- Adjust desired instrument panel height


using eccentric screws - 2 - and - 5 - .

Instrument panel, aligning width

- Slide instrument panel into desired


position.

- After aligning in vehicle, secure instrument panel with


Instrument panel Page 13 / 13

specified torque.

Installation of removed components is reverse of removal.


Door trim Page 1 / 9

70 - 2

Door trim
Tools

Required special tools, workshop equipment, testing and


measuring equipment, and aids

„ Trim removal wedge 3409

„ Pliers 3392

Driver side front door trim, removing and installing

Removing

- Switch off ignition.

- Pry upper section of grip shell - 1 -


upward out of mounts in door trim using
trim removal wedge 3409 .

- Depending on vehicle equipment,


disconnect wiring harnesses from upper
section of grip shell.
Door trim Page 2 / 9

- Remove two screws - 2 - (1.5 Nm) in


area handle molding area.

- Remove bolt - 3 - and three bolts - 4 -


(2 Nm).

- Disengage door trim from mounts in


lower area using disassembly pliers
3392 .

- Disengage door trim from mounts on


the sides using disassembly pliers
3392 .

- Pull door trim vertically upward out of


window shaft.

- In vehicles with radio system,


disconnect wiring harness from speaker.

- Disconnect door trim wiring harness


from door control module.

- Detach release cable - 5 - from inside


door release mechanism - 6 - .

- Remove screw - 7 - (2 Nm) and pry


mirror triangle cover - 8 - out of mounts
using trim removal wedge 3409 .
Door trim Page 3 / 9

- In vehicles with radio system,


disconnect wiring harness from speaker
in cover.

Installing

- Installation is performed in the reverse order of removal.

Note:

„ Before installing, inspect the securing clips for


damage and replace if necessary.

Passenger side front door trim, removing and installing

Removing

- Switch off ignition.

- Pry upper section of grip shell - 1 - out


Door trim Page 4 / 9

of pull handle in door trim using wedge


3409 .

- Remove bolts - 2 - and - 3 - (1.5


Nm).

- Remove screw - 3 - and three screws -


4 - (2 Nm).

- Disengage door trim from mounts in


lower area using disassembly pliers
3392 .

- Disengage door trim from mounts on


the sides using disassembly pliers
3392 .

- Pull door trim vertically upward out of


window shaft.

- In vehicles with radio system,


disconnect wiring harness from speaker.

- Disconnect door trim wiring harness


from door control module.

- Disengage release cable - 6 - from


interior door mechanism - 7 - .

- Remove screw - 8 - (2 Nm) and pry


mirror triangle cover - 9 - out of mounts
using trim removal wedge 3409 .
Door trim Page 5 / 9

- In vehicles with radio system,


disconnect wiring harness from speaker
in cover.

Installing

- Installation is performed in the reverse order of removal.

Note:

„ Before installing, inspect the securing clips for


damage and replace if necessary.

Rear door trim, removing and installing

Note:

„ Removal and installation is described for the right


rear door trim panel. Removal and installation of the
left rear door trim panel is performed in the same
Door trim Page 6 / 9

manner.

Removing

- Switch off ignition.

Only vehicles with manual window regulators

- Remove window crank 70-2, Manual window crank,


removing and installing

- Pry upper section of grip shell - 1 - out


of pull handle in door trim using wedge
3409 .

- Remove bolts - 2 - and - 3 - (1.5


Nm).

- Remove bolt - 4 - (2 Nm).

- Disengage door trim from mounts in


lower area using disassembly pliers
3392 .

- Disengage door trim from mounts on


the sides using disassembly pliers
3392 .

- Pull door trim vertically upward out of


window shaft.

- Depending on vehicle equipment,


disconnect wiring harnesses from door
trim.
Door trim Page 7 / 9

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огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

- Detach release cable - 5 - from inside


door release mechanism - 6 - .

Installing

- Installation is performed in the reverse order of removal.

Note:

„ Before installing, inspect the securing clips for


damage and replace if necessary.

Manual window crank, removing and installing

Removing
Door trim Page 8 / 9

- Press circlip - 1 - forward in direction of


travel - arrow - and remove window
crank - 2 - from drive mechanism - 3 - .

Installing

- Installation is performed in the reverse order of removal.

Note :

„ After installation, window crank on right side of


vehicle must stand at "5:00" position when window is
closed.

„ After installation, window crank on left side of vehicle


must stand at "7:00" position when window is
closed.

„ This corresponds to a - 30 angle - position.


Door trim Page 9 / 9

„ Deviation of window cranks to each other must be 6


max.
Pillar and side trim Page 1 / 13

70 - 3

Pillar and side trim


Upper A-pillar trim, removing and installing

Note:

„ Removal and installation is described for the left-


hand side of the vehicle. Removal and installation for
the right-hand side is performed in the same
manner.

Removing

- Remove airbag emblem - 1 - and


remove screw - 2 - (4 Nm).

- Remove trim in area of mounting clip -


3 - from mounts - arrow A - .

- Remove trim from door seal tubing.

- Pull trim out of front mount - arrow B -


.

- Remove trim in rear area from


instrument panel - arrow C - .

Note :

„ When re-installing, airbag emblem - 1 - must be


replaced.

„ Before installing, inspect the securing clips for


damage and replace if necessary.
Pillar and side trim Page 2 / 13

Installing

- Installation is performed in the reverse order of removal.

Driver side lower A-pillar trim, removing and installing

Removing

- Disengage sill panel trim from body in area of juncture to


lower A-pillar trim.

„ 2-door 68-3, Sill panel trim (2-door), removing and


installing

„ 4-door 68-3, Sill panel trim (4-door), removing and


installing

- Remove side instrument panel covers 68-2, Instrument


panel side covers, removing and installing
Pillar and side trim Page 3 / 13

- Remove hood operating lever - 1 -

Repair Manual, Body Exterior, Repair


Group 55,

- Remove clip - 2 - .

- Remove trim from body - arrow A - .

- Remove trim from door seal tubing.

- Pull trim out of mount - arrow B - .

Note :

„ Before installation, clip - 2 - must be checked for


damage and replaced if necessary.

Installing
Pillar and side trim Page 4 / 13

- Installation is performed in the reverse order of removal.

Passenger side lower A-pillar trim, removing and


installing

Removing

- Disengage sill panel trim from body in area of juncture to


lower A-pillar trim.

„ 2-door 68-3, Sill panel trim (2-door), removing and


installing

„ 4-door 68-3, Sill panel trim (4-door), removing and


installing

- Remove side instrument panel cover on front passengers


side 68-2, Instrument panel side covers, removing and
installing

Note :

„ For the sake of illustration, instrument panel is not


depicted in the illustration.

- Remove trim from body - arrow A - .

- Remove trim from door seal tubing.


Pillar and side trim Page 5 / 13

- Pull trim out of mount - arrow B - .

Installing

- Installation is performed in the reverse order of removal.

Upper B-pillar trim, removing and installing

Note:

„ Removal and installation is described for the left-


hand side of the vehicle. Removal and installation for
the right-hand side is performed in the same
manner.

Removing

- Remove airbag emblem - 1 - and


remove screw - 2 - (4 Nm).
Pillar and side trim Page 6 / 13

Note :

„ When re-installing, airbag emblem - 1 - must be


replaced.

- Pull trim in lower area out of mounts in


body - arrow A - .

- Remove trim from door seal tubing.

- Pull trim out of top mount - arrow B - .

4-door vehicles

- Remove lower B-pillar trim 70-3, Lower B-pillar trim,


removing and installing

- Remove belt anchor from front seatbelt 69-1, Front


seat belts (4-door), removing and installing

2-door vehicles
Pillar and side trim Page 7 / 13

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove 2-door sill panel trim 68-3, Sill panel trim (2-
door), removing and installing

- Remove anchor rail from seat belt 69-1, Front seat


belts (2-door), removing and installing

All vehicles

- Pull seat belt through trim opening.

Installing

Note :

„ When installing, driver for belt height adjuster - 4 -


and button in trim - 3 - must be located in the same
position.

„ Before installation, clip must be checked for damage


and replaced if necessary.
Pillar and side trim Page 8 / 13

- Installation is performed in the reverse


order of removal.

Lower B-pillar trim, removing and installing

Note:

„ Removal and installation is described for the left-


hand side of the vehicle. Removal and installation for
the right-hand side is performed in the same
manner.

Removing

- In vehicles with interior monitoring system, switch ignition


off.

- Remove upper B-pillar trim. Belt anchor or belt anchor


rail do not need to be removed from front seat belt 70-3,
Upper B-pillar trim, removing and installing .
Pillar and side trim Page 9 / 13

- Remove the two bolts - 1 - (4 Nm).

- Remove trim - 3 - from door seal


tubing.

- Remove trim from mounts in body in


area of guide - 2 - .

- In vehicles with interior monitoring


system, disconnect wiring harness from
sensor.

Installing

- Installation is performed in the reverse order of removal.

C-pillar trim, removing and installing

Note:

„ Removal and installation is described for the left-


hand side of the vehicle. Removal and installation for
Pillar and side trim Page 10 / 13

the right-hand side is performed in the same


manner.

Removing

- Switch off ignition.

4-door vehicles

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove 4-door side upholstery:

„ with rear side airbags 72-2, Side upholstery with


side airbag (4-door), removing and installing

„ without rear side airbags 72-2, Side upholstery (4-


door,), removing and installing

2-door vehicles

- Remove upper B-pillar trim. Belt anchor or belt anchor


rail do not need to be removed from front seat belt 70-3,
Upper B-pillar trim, removing and installing

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove backrest 72-2, Backrest, removing and


installing

- Remove side trim 70-3, Side trim (2-door), removing


and installing

All vehicles

- Remove luggage compartment cover side compartment


70-5, Luggage compartment cover side storage
compartment, removing and installing .

- Remove roof end strip 70-6, Roof end strip, removing


and installing

- Remove airbag emblem - 1 - and


remove screw - 2 - (4 Nm).

Note :

„ When re-installing, airbag emblem - 1 - must be


replaced.
Pillar and side trim Page 11 / 13

- Remove nut - 3 - (1.5 Nm).

- Loosen trim from threaded pins in nut -


3 - - arrow A - .

- Remove trim from mounts - arrow B -


and door seal tubing.

- Remove trim upward out of mounts in


body - arrow C - .

Installing

- Installation is performed in the reverse order of removal.

Note:

„ Before installing, inspect the securing clips for


damage and replace if necessary.

Side trim (2-door), removing and installing


Pillar and side trim Page 12 / 13

Note:

„ Removal and installation is described for the right-


hand side of the vehicle. Removal and installation for
the left-hand side is performed in the same manner.

Removing

- Remove upper B-pillar trim. Belt anchor rail does not


need to be removed from front seat belt 70-3, Upper B-
pillar trim, removing and installing .

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove backrest 72-2, Backrest, removing and


installing

- Remove cover cap - 1 - from mounts


and remove screw - 2 - (2 Nm).

- Remove sill panel trim from mounts in


side trim in lower area.

- Remove side trim from mounts in body.

- In vehicles with radio system,


disconnect wiring harness from speaker -
3- .
Pillar and side trim Page 13 / 13

- In vehicles with interior monitoring


system, disconnect wiring harness from
sensor.

Installing

- Installation is performed in the reverse order of removal.

Note:

„ Before installing, check securing clips for damage


and replace if necessary.
Rear lid trim Page 1 / 3

70 - 4

Rear lid trim


Tools

Required special tools, workshop equipment, testing and


measuring equipment, and aids

„ Pliers 3392

Rear lid trim, removing and installing

Removing

- Remove two screws - 1 - from handle


recess (2 Nm).

- Remove trim from mounts in rear lid


using disassembly pliers 3392 . Start
from lower edge of rear lid.

- Remove rear lid trim - 2 - on both sides


from window frame trim - 3 - .
Rear lid trim Page 2 / 3

- Remove trim in centering pin area - 4 -


and - 5 - from mounts in rear lid.

Installing

- Installation is performed in the reverse order of removal.

Note:

„ Before installing, check securing clips for damage


and replace if necessary.

Window frame trim, removing and installing

Removing

- Remove rear lid trim 70-4, Rear lid trim, removing and
installing

- Using pliers 3392 , remove trim at


Rear lid trim Page 3 / 3

sides from mounts in lid.

- Pull trim on upper edge out of mounts.

- Remove trim in centering pin area - 1 -


and - 2 - from mounts in rear lid.

Installing

- Installation is performed in the reverse order of removal.

Note:

„ Before installing, check securing clips for damage


and replace if necessary.
Luggage compartment trim Page 1 / 5

70 - 5

Luggage compartment trim


Luggage compartment cover side storage compartment,
removing and installing

Note:

„ Removal and installation is described for the right-


hand side of the vehicle. Removal and installation for
the left-hand side is performed in the same manner.

Removing

- Switch off ignition.

2-door vehicles

- Remove upper B-pillar trim. Belt anchor rail does not


need to be removed from front seat belt 70-3, Upper B-
pillar trim, removing and installing

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove backrest 72-2, Backrest, removing and


installing

- Remove side trim 70-3, Side trim (2-door), removing


and installing

4-door vehicles

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove 4-door side upholstery:

„ with rear side airbags 72-2, Side upholstery with


side airbag (4-door), removing and installing

„ without rear side airbags 72-2, Side upholstery (4-


door,), removing and installing

All vehicles

- Remove lock carrier cover from catches


in compartment transition area.

- Remove bolts - 1 - and - 2 - (1.5


Nm).
Luggage compartment trim Page 2 / 5

- Remove compartment - 3 - from


mounts.

- Depending on vehicle equipment,


disconnect wiring harnesses from
compartment.

Installing

- Installation is performed in the reverse order of removal.

Note:

„ Before installing, check securing clips for damage


and replace if necessary.

Luggage compartment side trim, removing and installing

Note:

„ Removal and installation is described for the right-


Luggage compartment trim Page 3 / 5

hand side of the vehicle. Removal and installation for


the left-hand side is performed in the same manner.

Removing

- Switch off ignition.

- Remove floor covering from vehicle.

2-door vehicles

- Remove upper B-pillar trim. Belt anchor or belt anchor


rail do not need to be removed from front seat belt 70-3,
Upper B-pillar trim, removing and installing .

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove backrest 72-2, Backrest, removing and


installing

- Remove side trim 70-3, Side trim (2-door), removing


and installing

4-door vehicles

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove 4-door side upholstery:

„ with rear side airbags 72-2, Side upholstery with


side airbag (4-door), removing and installing

„ without rear side airbags 72-2, Side upholstery (4-


door,), removing and installing

All vehicles

- Remove rear lock carrier cover 70-5, Rear lock carrier


cover, removing and installing

- Remove luggage compartment cover side compartment


70-5, Luggage compartment cover side storage
compartment, removing and installing

- Remove the two bolts - 1 - (8 Nm) and


remove the anchor point - 2 - .
Luggage compartment trim Page 4 / 5

- Remove five press buttons - 3 - and


remove trim from vehicle.

Rear lock carrier cover, removing and installing

Removing

- Remove floor covering from vehicle.

- Disengage cover from body in lower


area - arrow A - .

- Remove cover from side mounts - 1 -


and - 2 - in body.
Luggage compartment trim Page 5 / 5

- Pull cover upward from lock carrier -


arrows B - .

Installing

- Installation is performed in the reverse order of removal.

Note:

„ Before installing, inspect the securing clips for


damage and replace if necessary.
Roof trim Page 1 / 9

70 - 6

Roof trim
Tools

„ Electric cutter V.A.G 1561 A

„ Cutting blade V.A.G 1561/20

„ Cartridge gun V.A.G 1628

„ Release lever T10039

Roof end strip, removing and installing


Roof trim Page 2 / 9

Removing

- Open rear lid.

- Remove roof end strip - 1 - down out


of mounts in roof crossmember and rear
lid seal molding.

Note :

„ Before installing, check securing clips for damage


and replace if necessary.

Installing

- Installation is performed in the reverse order of removal.

Headliner, removing and installing

Removing
Roof trim Page 3 / 9

- If present, open sunroof.

- Switch off ignition.

- Remove lights and switch in molded headliner

Repair Manual, Electrical Equipment, Repair Group 96.,

- Remove roof end strip 70-6, Roof end strip, removing


and installing

- Remove upper a-pillar trim 70-3, Upper A-pillar trim,


removing and installing

- Remove upper B-pillar trim. Belt anchors or front belt


anchor rails do not have to be removed 70-3, Upper B-
pillar trim, removing and installing

2-door only

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove backrest 72-2, Backrest, removing and


installing

- Remove side trim 70-3, Side trim (2-door), removing


and installing

4-door only

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove 4-door side upholstery:

„ with rear side airbags 72-2, Side upholstery with


side airbag (4-door), removing and installing

„ without rear side airbags 72-2, Side upholstery (4-


door,), removing and installing

All vehicles

- Remove luggage compartment cover side compartment


70-5, Luggage compartment cover side storage
compartment, removing and installing

- Remove C-pillar trim 70-3, C-pillar trim, removing and


installing

Vehicles with sunroof


Roof trim Page 4 / 9

- Push the wedge T10039/1 between


frame - 1 - and headliner - 2 - .

- Using the release lever T10039/1 ,


separate the frame in - direction of the
arrow - from the headliner, the whole
way around.

All vehicles

- Remove right and left sun visors - 1 -


68-2, Sun visor, removing and
installing

- Remove right and left roof grab handles


- 2 - and - 3 - 68-4, Grab handles
(roof), removing and installing

- Remove the two bolts - 4 - (2 Nm).

- Lower molded headliner slightly and


(depending on vehicle equipment)
Roof trim Page 5 / 9

disconnect wiring harnesses from molded


headliner.

- Remove molded headliner from vehicle


through rear lid.

Installing

- Installation is performed in the reverse order of removal.

Roof insulation/reinforcement, removing and installing

Removing

Warning!

Observe safety precautions for working on airbags


69-4, Safety precautions for work on airbags .

- If present, open sunroof.

- Disconnect vehicle battery


Roof trim Page 6 / 9

Repair Manual, Electrical Equipment, Repair Group 27,

- Remove sun visors 68-2, Sun visor, removing and


installing

- Remove roof grab handle 68-4, Grab handles (roof),


removing and installing

- Remove lights and switch in molded headliner

Repair Manual, Electrical Equipment, Repair Group 96.,

- Remove roof end strip 70-6, Roof end strip, removing


and installing

- Remove upper a-pillar trim 70-3, Upper A-pillar trim,


removing and installing

- Remove upper B-pillar trim. Belt anchors or front belt


anchor rails do not have to be removed 70-3, Upper B-
pillar trim, removing and installing

2-door only

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove backrest 72-2, Backrest, removing and


installing

- Remove side trim 70-3, Side trim (2-door), removing


and installing

4-door only

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove 4-door side upholstery:

„ with rear side airbags 72-2, Side upholstery with


side airbag (4-door), removing and installing

„ without rear side airbags 72-2, Side upholstery (4-


door,), removing and installing

All vehicles

- Remove luggage compartment cover side compartment


Roof trim Page 7 / 9

70-5, Luggage compartment cover side storage


compartment, removing and installing

- Remove trim on C-pillars 70-3, C-pillar trim, removing


and installing

- Remove molded headliner 70-6, Headliner, removing


and installing

Note:

„ A Lupo is shown as an example in the following


illustrations. Removal and installation of
insulation/reinforcements is same in Golf.

- Cut roof insulation/reinforcements - 1 -


in direction of travel in strips approx. 6
cm wide - 2 - using a carpet knife.

- Pull off strips - 2 - from roof.

- Cut back adhesive residue - 3 - using


electric cutter V.A.G 1561 A and cutting
blade V.A.G 1561/20 - 4 - .

Note :

„ If paint structure was damaged while removing roof


insulation/reinforcements, paint damage must be
repaired in accordance with specifications in
Repair Manual Paint .
Roof trim Page 8 / 9

Installing

Note:

„ Processing instructions of adhesive must be


observed when installing roof
insulation/reinforcements.

- Apply adhesive D 190 MKD A3 to


insulation/reinforcements using cartridge
gun V.A.G 1628 .

- Apply adhesive in beads on


insulation/roof reinforcement.

- Dimension - a - = 58 2 mm

- Dimension - b - =25 5 mm
Roof trim Page 9 / 9

- Transport roof insulation/reinforcements


into vehicle through rear lid and press on
to roof over the entire surface.
Volkswagen Golf 5 2004-> VW Rabbit GTI 2006->
(A5)

Front seat covers and padding


Tools

Special tools, testers and auxiliary items required

„ Pliers 3392

„ Engine and transmission holder VAS 6095

„ Fixture for seat repair VAS 6136


Front seat covers and padding Page 2 / 14

Front seat cushion cover and padding, removing and


installing

Note:

„ Removal and installation of the components is


described for the left-hand seat. The same
instructions apply for removal and installation of
components for right seat.

Warning!

If the upholstery, front seat cushion on front


passengers side is replaced, Front Passengers Seat
Occupied Sensor G128 also must always be replaced
69-4, Front Passenger s Seat Occupied Sensor
G128 , removing and installing

Removing

- Mount the fixture for seat repair VAS 6136 on the engine
and transmission holder VAS 6095 .

- Remove front seat 72-1, Front seat, removing and


installing

- Attach the seat to the fixture for seat repair VAS 6136 .

- Remove front belt latch:

„ 2door 69-1, Belt latch (2-door), removing and


installing

„ 4door 69-1, Belt latch (4-door) removing and


installing

- Remove front right seat trim 72-1, Right seat trim,


removing and installing

Vehicles with manual seat adjustment

- Remove front left seat trim 72-1, Left seat trim,


removing and installing

- Remove bracket and front seat operating lever 72-1,


Front seat bracket and operating lever, removing and
installing

Vehicles with electric seat adjustment

- Remove left power seat trim 72-1, Left power seat


trim, removing and installing
Front seat covers and padding Page 3 / 14

- Remove retainer and power seat bracket 72-1,


Retainer and power seat bracket, removing and installing

All vehicles

- Remove front seat drawer mount 72-1, Seat drawer


mount, removing and installing

- Remove front seat backrest 72-1, Front seat backrest,


removing and installing

- Remove profile - 1 - from receptacle.

- Disengage retaining straps - 2 - from


seat on both sides.

- Disengage profiles - 3 - from mounts


on both sides of seat.

- Disengage profile - 4 - from mount on


front side of seat.

- Roll cover upward on outer sides


Front seat covers and padding Page 4 / 14

around circumference.

- Using a small screwdriver, unclip


profiles - 1 - for cover out of mounts - 2
- in upholstery.

- In vehicles with seat heater, disconnect


wiring harness - 3 - from seat frame.

- Remove the cover - 4 - and padding -


5 - from the seat frame - 6 - .

Installing

- Installation is performed in the reverse order of removal.

Front bucket seat cushion cover and padding, removing


and installing

Note:
Front seat covers and padding Page 5 / 14

„ Removal and installation of the components is


described for the left-hand seat. The same
instructions apply for removal and installation of
components for right seat.

Removing

- Mount the fixture for seat repair VAS 6136 on the engine
and transmission holder VAS 6095 .

- Remove front seat 72-1, Front seat, removing and


installing

- Attach the seat to the fixture for seat repair VAS 6136 .

- Remove front left bucket seat trim 72-1, Left bucket


seat trim, removing and installing

- Remove front belt latch:

„ 2door 69-1, Belt latch (2-door), removing and


installing

„ 4door 69-1, Belt latch (4-door) removing and


installing

- Remove front right bucket seat trim 72-1, Right bucket


seat trim, removing and installing

- Remove front bucket seat backrest 72-1, Front bucket


seat backrest, removing and installing
Front seat covers and padding Page 6 / 14

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


огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

- Loosen profile - 1 - from mount - 2 - in rear area of seat


base .

- Loosen Velcro strip on both sides - 1 - .

- Loosen surrounding profile - 2 - on seat pan - 3 - .


Front seat covers and padding Page 7 / 14

- Loosen all Velcro strips - 1 - on cover from depression in


upholstery - 2 - .

- Remove upholstery from bucket seat.

Installing

- Installation is performed in the reverse order of removal.

Front seat backrest cover and padding, removing and


installing

Note:

„ Removal and installation of the components is


described for the left-hand seat. The same
instructions apply for removal and installation of
components for right seat.

Removing

- Mount the fixture for seat repair VAS 6136 on the engine
and transmission holder VAS 6095 .

- Remove front seat 72-1, Front seat, removing and


installing

- Attach the seat to the fixture for seat repair VAS 6136 .

- Remove front right seat trim 72-1, Right seat trim,


removing and installing

Vehicles with manual seat adjustment

- Remove front left seat trim 72-1, Left seat trim,


removing and installing

Vehicles with electric seat adjustment

- Remove left power seat trim 72-1, Left power seat


trim, removing and installing
Front seat covers and padding Page 8 / 14

All vehicles

- Remove front seat backrest 72-1, Front seat backrest,


removing and installing

- Attach the backrest to the fixture for seat repair VAS


6136 .

- Press corresponding button in headrest


guide and pull headrest - 1 - out of
backrest.

2-door only

- Remove operating knob - 2 - .

- Position a screwdriver in - direction of


arrow - and pry trim - 3 - out of mount.

Note :

„ When installing, securing spring - 4 - must be


removed from lever - 5 - and replaced.

Only vehicles with manual lumbar


adjustment

- Remove lumbar support adjusting


wheel - 6 - using disassembly pliers
3392 .

All vehicles

- Disengage backrest profile - 7 - on


both sides.
Front seat covers and padding Page 9 / 14

- Release profile - 8 - from mount - 9 -


.

- Loosen side profile - 1 - and - 2 - from


mounts and fold back side of cover
upward.

- Remove plate - 3 - from backrest.

- Open side profile - 4 - and disengage


tension wire - 5 - .
Front seat covers and padding Page 10 / 14

- Open side profile - 7 - and disengage


tension wire - 6 - .

- Fold cover - 5 - upward.

- Using a small screwdriver, unclip


profiles - 1 - for cover out of mounts - 2
- in upholstery.

- Disengage tension wire - 4 - on both


sides from upholstery wire - 3 - .

- Remove headrest guides 72-1,


Headrest guides, removing
Front seat covers and padding Page 11 / 14

- Remove the cover - 5 - and padding -


6 - from the seat frame - 7 - .

Installing

- Installation is performed in the reverse order of removal.

Front bucket seat backrest, removing and installing

Note:

„ Removal and installation of the components is


described for the left-hand seat. The same
instructions apply for removal and installation of
components for right seat.

Removing

- Mount the fixture for seat repair VAS 6136 on the engine
and transmission holder VAS 6095 .
Front seat covers and padding Page 12 / 14

- Remove front seat 72-1, Front seat, removing and


installing

- Attach the seat to the fixture for seat repair VAS 6136 .

- Remove front left bucket seat trim 72-1, Left bucket


seat trim, removing and installing

- Remove front belt latch:

„ 2door 69-1, Belt latch (2-door), removing and


installing

„ 4door 69-1, Belt latch (4-door) removing and


installing

- Remove front right bucket seat trim 72-1, Right bucket


seat trim, removing and installing

- Remove front bucket seat backrest 72-1, Front bucket


seat backrest, removing and installing

- Press left trim - 1 - on upper edge


downward.

- Then remove trim from mounts in area


of the two catches - arrows - .

- Remove right trim - 2 - in the same


way.

- Remove surrounding cover profile - 3 -


in side area of backrest from mount - 4 -
.
Front seat covers and padding Page 13 / 14

- In lower area of backrest, remove


profile - 5 - from mount.

- Loosen all Velcro strips - 1 - on cover


from depression in upholstery - 2 - .
Front seat covers and padding Page 14 / 14

- Remove upholstery from backrest


frame.

Installing

- Installation is performed in the reverse order of removal.


Cover and upholstery for rear seats Page 1 / 6

74 - 2

Cover and upholstery for rear seats


Seat bench cover and upholstery, removing and
installing

Removing

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- On the underside of the seat bench,


detach all cover profiles - arrows - seat
frame.

- Release respective Velcro strap - 1 - in


area of belt latches.

- Roll up cover on the sides.


Cover and upholstery for rear seats Page 2 / 6

- Using a small screwdriver, press apart


side ribs of mounts - 1 - and pull out grip
channels - 2 - .

- Release cover - 3 - and upholstery - 4


- from seat frame - 5 - .

Installing

- Installation is performed in the reverse order of removal.

Cover and cushion for backrest, removing and installing

Note:

„ Removal and installation of components is described


for right backrest. The same instructions apply for
removal and installation of components for left
backrest.
Cover and upholstery for rear seats Page 3 / 6

Removing

Only vehicles with pass-through

- Remove storage unit with center armrest 74-2,


Storage unit with center arm rest, removing and installing

All vehicles

- Remove seat bench 72-2, Rear seat bench, removing


and installing .

- Remove backrest 72-2, Backrest, removing and


installing

Headrest removal

- To remove headrest - 1 - , depress tab


on headrest mount.

- Locate small hole on opposite headrest


mount and insert a small screwdriver to
release headrest from guide.

- Remove headrest - 1 - completely.

Continued removal of cover and


cushion for backrest

- Press corresponding button in headrest


guide and pull headrest - 1 - out of
backrest.

- Press side locking mechanisms -


arrows - and release belt extraction
panel - 2 - from mounts.

Note :

„ Belt extraction panel - 2 - has a one-time locking


mechanism and therefore must be replaced when
installing.

- Press side locking mechanisms inward


and pull cover - 3 - out of backrest.
Cover and upholstery for rear seats Page 4 / 6

- Using a screwdriver, pry all profiles - 4


- out of mounts - 5 - on rear side of
backrest along the circumference.

- Roll up cover on the sides.

- Using a small screwdriver, press apart


side ribs of mounts - 1 - and pull out grip
channels - 2 - .
Cover and upholstery for rear seats Page 5 / 6

- Release cover - 3 - and upholstery - 4


- from backrest frame - 5 - .

Installing

- Installation is performed in the reverse order of removal.

Storage unit with center arm rest, removing and


installing

Removing

- Remove upholstery insert - 1 - beneath


center armrest.
Cover and upholstery for rear seats Page 6 / 6

- Open storage unit - 2 - and remove


two bolts - 3 - (9 Nm).

Installing

- Installation is performed in the reverse order of removal.