BODY EXTERIOR

• HEADINGS
  • 50 Body, front
    • Body, front
      • Lock carrier, service position
        • Screw in special tool 3369
        • Secure lock carrier
      • Lock carrier with attachments, removing and installing
        • Disconnect upper coolant hose
        • Disconnect lower coolant hose
        • Disconnect hydraulic oil cooler
        • Disconnect hoses for charge air cooler
      • Cowl panel trim, removing and installing
      • Transverse support (dome brace), removing and installing
      • Fender, removing and installing
        • Removing and installing end plate
      • Noise insulation panel - assembly overview
  • 55 Hood, lids
    • Hood
      • Hood, removing, installing and adjusting
        • Gas-filled strut, removing and installing
        • Releasing gas from gas-filled strut
        • Buffer stop for height adjustment
        • Radiator grill, removing and installing
        • Removing and installing catch hook
        • Removing and installing lower part of hood lock
        • Adjusting lock carrier buffer stop
      • Hood gap dimensions
      • Hood lining, removing and installing
      • Hood seal, assembly overview
      • Impact guard, installing
      • Hood lock cable, removing and installing
    • Rear lid (Sedan)
      • Rear lid, removing and installing
        • Striker, removing and installing
        • Adjusting rear lid
      • Gap dimensions for rear lid
        • Gap dimensions for fuel filler flap
      • Lid lock and handle mechanism, removing and installing
      • Remote control motor, removing and installing (country versions)
      • Rear lid hinge, removing and installing
        • Gas-filled strut, removing and installing
      • Rear lid seal, installing
      • Adjusting buffer stops
      • Fuel filler flap
    • Rear lid (Avant)
      • Rear lid, removing and installing
      • Insulation mat to rear lid, adhering
      • Rear lid, adjusting
      • Rear lid hinge, removing and installing
      • Gas-filled strut for rear lid, removing and installing
      • Rear lid seal, removing and installing
      • Adjustment dimensions for rear lid
        • Panel gap dimensions
        • Gap dimensions for fuel filler flap
      • Lock cylinder for rear lid, removing and installing
      • Handle mechanism for rear lid, removing and installing
      • Rear lid lock, removing and installing
        • Removing lid lock
      • Rear lid lock actuator, removing and installing
      • Fuel filler flap
  • 57 Front doors/door components/central locking system
    • Front door
      • Window frame and window regulator, removing and installing
        • Window regulator motor, removing and installing
      • Door window, removing from window regulator
      • Motor for window regulator, removing and installing
      • Front door, adjusting
      • Adjusting using door adjustment template T40038/1
      • Panel gap dimensions
      • Window frame, adjusting
        • Adjustment for A-pillar region
        • Inclination adjustment at A-pillar
        • Adjustment for B-pillar region
        • Height adjustment at window frame
        • Front door adjustment
      • Window frame installation
      • Adjustment dimensions for front door window frame
      • Door handle and door lock - front, assembly overview
        • Locking cylinder, removing
      • Door handle, removing
        • Disengage mount for door handle
        • Removing trim
      • Door lock, removing
        • Engaging operating rod in door lock
    • Central locking system
      • Component overview (Sedan)
        • Removing Comfort System Central Control Module J393
        • Removing Fuel Tank Lid Unlock Motor V155
      • Component overview (Avant)
      • Repairing the central locking system
  • 58 Rear doors/door components
    • Rear doors
      • Window frame and window regulator, removing and installing
        • Window regulator motor, removing and installing
        • Manual window regulators, removing and installing
      • Window regulator and door window, separating
      • Motor for window regulator, removing and installing
      • Manual window regulators, removing and installing
      • Rear door, adjusting
      • Adjustment dimensions for rear door window frame
      • Adjusting using Door adjustment template T40038/1
      • Panel gap dimensions
      • Door handle and door lock - rear, assembly overview
        • Engaging operating rod in door lock
      • Door handle, removing
        • Disengage mount for door handle
        • Removing trim
      • Door lock, removing
        • Engaging Bowden cable in door lock
        • Engaging operating rod in door lock
  • 60 Sunroof
    • Sunroof, servicing
      • Assembly overview
      • Wind deflector, removing and installing
      • Sunroof panel, removing and installing (assembly overview)
      • Sunroof headliner, removing and installing
      • Trim, removing and installing
      • Boot, removing and installing (vehicles as of CW 27/2002 >)
      • Sunroof panel, removing
      • Sunroof panel, adjusting
      • Panel seal, replacing
      • "Zero" position (link guide), adjusting
      • "Zero" position of sunroof motor (link guide), checking and adjusting
    • Water drain hoses
      • Cleaning water drain hoses
  • 63 Bumper
    • Front bumper
      • Front bumper, removing and installing
        • Fender bolts
        • Adjusting support piece
        • Clamping pins for noise insulation
        • Removing guide piece
        • Brace for wheelhousing liner
        • Air intake grille for S4
      • Radiator grill, removing and installing
      • Centering holes for side impact moldings
        • Positioning centering holes
        • Adhering centering pins on side impact molding
        • Positioning license plate mounting holes
      • Front bumper, removing and installing
      • Bumper, mounting to shock absorber
      • Guide piece, removing and installing
      • Crossmember, removing from cover and installing
      • Two-piece bumper cover, separating
      • Shock absorber, removing and installing
    • Rear bumper (Sedan)
      • Bumper, removing and installing
        • Cap nuts
      • Side impact moldings, replacing
        • Centering holes for side impact moldings
        • Adhering centering pins on side impact molding
    • Rear bumper (Avant)
      • Bumper, removing and installing
      • Centering holes for side impact moldings
        • Disengaging support piece
      • Guide piece, removing and installing
      • Crossmember for bumper, removing and installing
      • Crossmember for bumper (vehicles with trailer hitch), removing and installing
        • Threaded plate for trailer hitch
  • 64 Glass
    • Flush-bonded windows
      • Flush-bonded windows, removing and installing - general information
      • Servicing windows using special tool
      • Materials
      • Minimum curing times!
    • Windshield, removing and installing
      • Assembly overview
      • Removing
      • Preparing for window installation
      • Windshield, installing
    • Side window (Sedan), removing and installing
      • Side window with molding - assembly overview
      • Side window with gloss package - assembly overview
      • Undamaged side window, removing
      • Preparing for window installation
      • Side window, installing
    • Side window (Avant), removing and installing
      • Side window (Avant), removing and installing - assembly overview
      • Undamaged side window, removing
      • Preparing for window installation
      • Side window, installing
    • Rear window (Sedan), removing and installing
      • Assembly overview
      • Undamaged rear window, removing
      • Damaged rear window, removing
      • Preparing for window installation
      • Installing rear window
    • Rear window (Avant), removing and installing
      • Assembly overview
      • Undamaged rear window, removing
      • Damaged rear window, removing
      • Preparing for window installation
      • Installing rear window
  • 66 Exterior equipment
    • Roof moldings
      • Roof joint strip (Sedan), removing and installing
      • Roof joint strip, removing and installing (Avant)
      • Roof trim molding (Sedan), removing and installing
      • Roof trim molding, removing and installing (Avant)
        • Disengaging roof trim molding from trim molding under side window
    • Roof rail
      • Roof rail, removing and installing
    • Protective moldings
      • Replacing side protective moldings
      • Trim cover for sill panel, removing and installing
      • Trim cover for sill panel, removing and installing S4
        • Front door
        • Rear doors
    • Face plates
      • B-pillar trim panel, removing and installing
    • Window weatherstrips
      • Window weatherstrips for front door (standard vehicle), removing and installing
      • Front window weatherstrips (vehicles with gloss package), removing and installing
      • Window weatherstrips for rear door (standard vehicle), removing and installing
      • Rear window weatherstrips (vehicles with gloss package), removing and installing
    • Outside rear view mirror
      • Outside rear view mirror, removing and installing
      • Outside rear view mirror lens, installing
      • Outside rear view mirror adjusting motor, removing and installing
      • Outside rear view mirror housing, removing and installing
        • Lower mirror locking tab
    • Outer sill panel trim
      • Outer sill panel trim, replacing
    • Sill panel cover, removing and installing
      • Sill panel cover, removing and installing
        • Removing bracket for sill panel cover
        • Rear sill panel cover
    • Underbody covers
      • Underbody covers
        • Removing and installing tunnel brace
    • Wheelhousing liner, removing and installing
      • Front wheelhousing liner
      • Rear wheelhousing liner
      • Wheel spoiler
    • Ornamental parts
      • Lettering on rear lid (Sedan)
      • Lettering on rear lid (Avant)
    • Ornamental parts, as of Vehicle Identification Number (VIN) 400 001
      • Lettering on rear lid (Sedan)
      • Lettering on rear lid (Avant)
    • Rear lid spoiler, removing and installing
      • Rear lid spoiler, removing and installing
        • Removing spoiler
        • Apply adhesive tape on spoiler
• FIGURES
  • Fig. 1: Lock Carrier Overview
  • Fig. 2: Screw In Special Tool 3369
  • Fig. 3: Secure Lock Carrier
  • Fig. 4: Lock Carrier Overview
  • Fig. 5: Disconnect Upper Coolant Hose
  • Fig. 6: Lock Carrier Overview
  • Fig. 7: Disconnecting Lower Coolant Hose
  • Fig. 8: Disconnecting Hydraulic Oil Cooler
  • Fig. 9: Disconnecting Hoses For Charge Air Cooler
  • Fig. 10: Cowl Panel Trim Overview
  • Fig. 11: Transverse Support (Dome Brace) Overview
  • Fig. 12: Fender Remove/Install Components (Up To Vehicle Identification Number (VIN) 400 000)
  • Fig. 13: Fender Remove/Install Components (As Of Vehicle Identification Number (VIN) 400 001)
  • Fig. 14: Removing And Installing End Plate
  • Fig. 15: Noise Insulation Panel - Assembly Overview
  • Fig. 16: Hood Remove/Install/Adjusting Components (Up To Vehicle Identification Number (VIN) 400 000)
  • Fig. 17: Hood Remove/Install/Adjusting Components (As Of Vehicle Identification Number (VIN) 400 001)
  • Fig. 18: Gas-Filled Strut, Removing And Installing
  • Fig. 19: Identifying Gas-filled Strut Area To be Clamped in Vice
  • Fig. 20: Buffer Stop For Height Adjustment
  • Fig. 21: Buffer Stop For Height Adjustment (As Of Vehicle Identification Number (VIN) 400 001)
  • Fig. 22: Radiator Grill, Removing And Installing
  • Fig. 23: Removing And Installing Catch Hook (Up To Vehicle Identification Number (VIN) 400 000)
  • Fig. 24: Removing And Installing Catch Hook (As Of Vehicle Identification Number (VIN) 400 001)
  • Fig. 25: Removing And Installing Lower Part Of Hood Lock
  • Fig. 26: Adjusting Lock Carrier Buffer Stop
  • Fig. 27: Identifying Adjustment Gauge 3371
  • Fig. 28: Hood Gap Dimensions
  • Fig. 29: Hood Lining, Removing And Installing
  • Fig. 30: Hood Seal, Assembly Overview
  • Fig. 31: Impact Guard, Installing
  • Fig. 32: Hood Lock Cable Remove/Install Components
  • Fig. 33: Rear Lid Remove/Install Components
  • Fig. 34: Striker, Removing And Installing
  • Fig. 35: Adjusting Rear Lid
  • Fig. 36: Identifying Adjustment Gauge 3371
  • Fig. 37: Gap Dimensions For Rear Lid
  • Fig. 38: Lid Lock And Handle Mechanism Remove/Install Components
  • Fig. 39: Remote Control Motor, Removing And Installing (Country Versions)
  • Fig. 40: Rear Lid Hinge Remove/Install Components
  • Fig. 41: Placing Electric Wiring Or Wiring For Central Locking System Into Lower Retainer Of Cable Guide At Cover
  • Fig. 42: Removing Rear Lid Hinges
  • Fig. 43: Removing As-Filled Strut
  • Fig. 44: Identifying Gas-filled Strut Area To be Clamped in Vice
  • Fig. 45: Rear Lid Seal, Installing
  • Fig. 46: Adjusting Buffer Stops
  • Fig. 47: Fuel Filler Flap Assembly Overview
  • Fig. 48: Using Screwdriver To Lift Retaining Spring And Remove Gas-Filled Strut From Upper Ball Stud
  • Fig. 49: Removing Cover For Rear Lid Hinge And Cable Guide From Rear Lid Hinge
  • Fig. 50: Removing Rear Lid Bolts At Left/Right
  • Fig. 51: Insulation Mat To Rear Lid, Adhering
  • Fig. 52: Removing/Installing Striker Combination Nuts
  • Fig. 53: Removing/Installing Cover & Adjustment Screw
  • Fig. 54: Removing/Installing Striker Combination Nuts
  • Fig. 55: Removing/Installing Cover & Adjustment Screw
  • Fig. 56: Removing Cover For Rear Lid Hinge And Cable Guide From Rear Lid Hinge
  • Fig. 57: Removing Outer Roof Frame Trim
  • Fig. 58: Removing Nuts
  • Fig. 59: Removing Rear Lid Bolts At Left/Right
  • Fig. 60: Using Screwdriver To Lift Retaining Spring And Remove Gas-Filled Strut From Upper Ball Stud
  • Fig. 61: Rear Lid Seal, Removing And Installing
  • Fig. 62: Identifying Adjustment Gauge 3371
  • Fig. 63: Adjustment dimensions for rear lid
  • Fig. 64: Positioning Rear Lid In Chassis Cut-Out Just So That Gap Measurement On Right Equals Gap Measurement On Left
  • Fig. 65: Lock Cylinder For Rear Lid, Removing And Installing
  • Fig. 66: Removing Nuts & Pressing Both Catches Down And Removing Grip Piece
  • Fig. 67: Rear Lid Lock Assembly Overview
  • Fig. 68: Lid Lock Remove/Install Components
  • Fig. 69: Rear Lid Lock Actuator, Removing And Installing
  • Fig. 70: Removing Bolts, Adapter Plate From Actuator
  • Fig. 71: Fuel Filler Flap Assembly Overview
  • Fig. 72: Window Frame And Window Regulator Remove/Install Components
  • Fig. 73: Window Regulator Motor Remove/Install Components
  • Fig. 74: Upper door hinge Remove/Install Components
  • Fig. 75: Lower Door Hinge Remove/Install Components
  • Fig. 76: Door Window, Removing From Window Regulator
  • Fig. 77: Removing Torx Bolts T30 And Motor
  • Fig. 78: T40038/01
  • Fig. 79: Panel Gap Dimensions
  • Fig. 80: Adjustment In Longitudinal Direction
  • Fig. 81: Adjustment In Longitudinal Direction
  • Fig. 82: Adjusting Via Striker
  • Fig. 83: Door Adjustment Template T40038/1
  • Fig. 84: Using Standard Bank Card To Drive Off Contact Area Of Sealing Lip To Roof Trim Molding With Light Pressure
  • Fig. 85: Identifying Template Has Points Of Different Lengths At So That Side Adjustment Of Door Can Be Tested
  • Fig. 86: Positioning Template With Cut-Out Facing Door Window
  • Fig. 87: Identifying Template Has Points Of Different Lengths At So That Side Adjustment Of Door Can Be Tested
  • Fig. 88: Making Sure Points Make Contact On Door Window
  • Fig. 89: Identifying Adjustment Gauge 3371
  • Fig. 90: Panel Gap Dimensions
  • Fig. 91: Loosening Mounting Bolts And Removing Or Adding Spacers At Bolt Point
  • Fig. 92: Removing/Installing Bolt
  • Fig. 93: Adjustment For B-Pillar Region
  • Fig. 94: Replacing Collared Shoulder Bolt
  • Fig. 95: Height Adjustment At Window Frame
  • Fig. 96: Front Door Adjustment
  • Fig. 97: Projection Of Front Door At Rear Door Must Be In Range Of Template Cut-Out
  • Fig. 98: Identifying Adjusting Element Is In Basic & End Position
  • Fig. 99: Applying Sealing Strip Along Window Shaft Strip Under
  • Fig. 100: Removing/Installing Door Seal Bolts
  • Fig. 101: Removing/Installing Bolt
  • Fig. 102: Removing/Installing Door Seal Bolts
  • Fig. 103: Removing/Installing Adjusting Element Out/In Of Door Shell
  • Fig. 104: Placing Finger On Window Frame And Door Plate As A Check
  • Fig. 105: Tightening Bolts Of Window Regulator Rails At Bottom
  • Fig. 106: Identifying Pins, Cable & Door Shell
  • Fig. 107: Securing Door Insulation Mat Using Water Resistant Webbed Band On Upper Side
  • Fig. 108: Function Of Adjusting Element
  • Fig. 109: Adjustment Dimensions For Front Door Window Frame
  • Fig. 110: Door Handle And Door Lock - Front, Assembly Overview
  • Fig. 111: Locking Cylinder, Removing
  • Fig. 112: Door Handle, Removing Overview
  • Fig. 113: Disengage Mount For Door Handle
  • Fig. 114: Removing Trim
  • Fig. 115: Door Lock, Removing Overview
  • Fig. 116: Engaging Operating Rod In Door Lock
  • Fig. 117: Central Locking System Component Overview (Sedan)
  • Fig. 118: Removing Comfort System Central Control Module J393
  • Fig. 119: Removing Fuel Tank Lid Unlock Motor V155
  • Fig. 120: Central Locking System Component Overview (Avant)
  • Fig. 121: Window Frame And Window Regulator Remove/Install Components
  • Fig. 122: Window Regulator Motor Remove/Install Components
  • Fig. 123: Unthreading Bolts And Removing Manual Window Regulator From Inner Door Plate
  • Fig. 124: Upper Door Hinge Remove/Install Components
  • Fig. 125: Removing/Installing Lower door hinge
  • Fig. 126: Window Regulator And Door Window, Separating Remove/Install Components
  • Fig. 127: Window Regulator Motor Remove/Install Components
  • Fig. 128: Unthreading Bolts And Removing Manual Window Regulator From Inner Door Plate
  • Fig. 129: Adjustment In Longitudinal Direction
  • Fig. 130: Adjustment In Longitudinal Direction
  • Fig. 131: Adjusting Via Striker
  • Fig. 132: Adjustment Dimensions For Rear Door Window Frame
  • Fig. 133: Template T40038
  • Fig. 134: Using Standard Bank Card To Drive Off Contact Area Of Sealing Lip To Roof Trim Molding With Light Pressure
  • Fig. 135: Identifying Template Has Points Of Different Lengths At So That Side Adjustment Of Door Can Be Tested
  • Fig. 136: Positioning Template With Cut-Out Facing Door Window
  • Fig. 137: Identifying Template Has Points Of Different Lengths At So That Side Adjustment Of Door Can Be Tested
  • Fig. 138: Making Sure Points Make Contact On Door Window
  • Fig. 139: Identifying Adjustment Gauge 3371
  • Fig. 140: Panel Gap Dimensions
  • Fig. 141: Door Handle And Door Lock - Rear, Assembly Overview
  • Fig. 142: Engaging Operating Rod In Door Lock
  • Fig. 143: Door Handle, Removing Components
  • Fig. 144: Disengage Mount For Door Handle
  • Fig. 145: Removing Trim
  • Fig. 146: Door Lock Remove/Install Components
  • Fig. 147: Engaging Bowden Cable In Door Lock
  • Fig. 148: Engaging Operating Rod In Door Lock
  • Fig. 149: Sunroof Assembly Overview
  • Fig. 150: Wind Deflector, Removing And Installing
  • Fig. 151: Laying Spring Around Retaining Pins On Wind Deflector
  • Fig. 152: Wind Deflector, Removing And Installing
  • Fig. 153: Sunroof Panel, Removing And Installing (Assembly Overview)
  • Fig. 154: Removing Bolt Of Spring Clip
  • Fig. 155: Sliding Headliner Back Slightly And Remove Spring Clip Toward Front
  • Fig. 156: Unclip Lower Panel At Rear From Locking Mechanism And Slide Toward Front
  • Fig. 157: Pressing On Lower Panel Onto Upper Edge Of Retaining Rail
  • Fig. 158: Sliding Lower Panel Toward Rear Until Hook Catches In Coupling Plate
  • Fig. 159: Pulling Off Boot Starting At Top From Glass Sunroof Panel And From Frame
  • Fig. 160: Removing Torx Bolts (T 25) On Both Sides And Lift Panel Upward And Out
  • Fig. 161: Sunroof Panel, Adjusting
  • Fig. 162: Identifying Sunroof panel,
  • Fig. 163: Pulling Sunroof Headliner Slightly Toward Rear In And Sliding In Headliner Toward Rear
  • Fig. 164: Guiding Pins In Center On Tilting Mechanism Must Align With Marking On Link Guide
  • Fig. 165: Coupling Plate Must Be Slid Into Guide On Sunroof Headliner At Rear
  • Fig. 166: Identifying Front/Rear Water Drain Hose
  • Fig. 167: Socket 40078
  • Fig. 168: Front Bumper Remove/Install Components (Up To Vehicle Identification Number (VIN) 400 000)
  • Fig. 169: Front Bumper Remove/Install Components (As Of Vehicle Identification Number (VIN) 400 001)
  • Fig. 170: Installing Fender Bolts
  • Fig. 171: Adjusting Support Piece
  • Fig. 172: Clamping Pins For Noise Insulation
  • Fig. 173: Removing Guide Piece
  • Fig. 174: Brace For Wheelhousing Liner
  • Fig. 175: Air Intake Grille For S4
  • Fig. 176: Radiator Grill, Assembly Overview
  • Fig. 177: Removing Radiator Grille
  • Fig. 178: Removing Panel For Fog Lights
  • Fig. 179: Disengaging Fog Lights Locking Mechanisms
  • Fig. 180: Disengaging Covers Locking Mechanisms
  • Fig. 181: Centering Holes For Side Impact Moldings
  • Fig. 182: Positioning Centering Holes
  • Fig. 183: Adhering Centering Pins On Side Impact Molding
  • Fig. 184: Positioning License Plate Mounting Holes
  • Fig. 185: Identifying Quick-Release Fasteners And Noise Insulation
  • Fig. 186: Loosening Left/Right Wheelhousing Liners In Front Area
  • Fig. 187: Pulling Back Wheelhousing Liner & Unclipping Bumper Rear Edge From Catch
  • Fig. 188: Releasing Catches Using Screwdriver And Removing Air Intake Grille On Left/Right On Bottom Part Of Bumper
  • Fig. 189: Unthreading Left/Right Retaining Bolts For Bumper
  • Fig. 190: Disconnecting Hose To Headlight Cleaning System & Harness Connector(s) To Bumper
  • Fig. 191: Removing/Installing Hose To Headlight Cleaning System & Harness Connector(s) To Bumper
  • Fig. 192: Pulling Back Wheelhousing Liner & Engaging Bumper Rear Edge Into Catch
  • Fig. 193: Removing/Installing Left/Right Retaining Bolts For Bumper
  • Fig. 194: Bumper, Mounting To Shock Absorber Overview
  • Fig. 195: Guide Piece Remove/Install Components
  • Fig. 196: Crossmember, removing from cover and installing
  • Fig. 197: Two-Piece Bumper Cover, Separating
  • Fig. 198: Shock Absorber Remove/Install Components
  • Fig. 199: Rear Bumper (Sedan) Remove/Install Components (Up to Vehicle Identification Number (VIN) 400 000)
  • Fig. 200: Rear Bumper (Sedan) Remove/Install Components (As Of Vehicle Identification Number (VIN) 400 001)
  • Fig. 201: Rear Bumper (Sedan) Remove/Install Components (Country Version)
  • Fig. 202: Cap Nuts
  • Fig. 203: Side Impact Moldings, Assembly Overview
  • Fig. 204: Centering Holes For Side Impact Moldings
  • Fig. 205: Adhering Centering Pins On Side Impact Molding
  • Fig. 206: Rear Bumper (Avant), Removing And Installing (Up To Vehicle Identification Number (VIN) 400 000)
  • Fig. 207: Rear Bumper (Avant), Removing And Installing (As Of Vehicle Identification Number (VIN) 400 001)
  • Fig. 208: Rear Bumper (Avant), Removing And Installing (Country Version)
  • Fig. 209: Centering Holes For Side Impact Moldings
  • Fig. 210: Adhering Centering Pins On Side Impact Molding
  • Fig. 211: Installing Support Piece
  • Fig. 212: Disengaging Support Piece
  • Fig. 213: Guide Piece Remove/Install Components (Up To Vehicle Identification Number (VIN) 400 000)
  • Fig. 214: Guide Piece Remove/Install Components (As Of Vehicle Identification Number (VIN) 400 001)
  • Fig. 215: Crossmember For Bumper Remove/Install Components
  • Fig. 216: Crossmember For Bumper Remove/Install Components (USA Version)
  • Fig. 217: Crossmember For Bumper (Vehicles With Trailer Hitch) Remove/Install Components
  • Fig. 218: Threaded Plate For Trailer Hitch
  • Fig. 219: Identifying Special Tools - Flush-Bonded Windows, Removing And Installing - General Information
  • Fig. 220: Spooling Tool V.A.G 1654 A
  • Fig. 221: Double Cartridge Gun VAS 5237
  • Fig. 222: Windshield, Assembly Overview
  • Fig. 223: Piercing Hole In Adhesive Sealing Material From Inside Of Vehicle Using Awl V.A.G 1755 Or Awl V.A.G 1351 At Bottom-Left Of Windshield
  • Fig. 224: Laying Cutting Cord Underneath And All Around Inside Of Windshield
  • Fig. 225: Securing End Of Cutting Cord At Bolt For Securing Window Wiper Frame
  • Fig. 226: Laying Cutting Cord Underneath And All Around Inside Of Windshield
  • Fig. 227: Moving Spooling Tool And Continue Cutting
  • Fig. 228: Moving Spooling Tool And Attaching Relay Pulley
  • Fig. 229: Removing Relay Pulley And Continue To Cut Adhesive
  • Fig. 230: Moving Spooling Tool And Attaching Relay Pulley In Upper Corner Of Window
  • Fig. 231: Applying Primer Evenly In One Pass Using Applicator
  • Fig. 232: Dimensions For Application Of Adhesive
  • Fig. 233: Positioning Complete Surface Of Nozzle Onto Window
  • Fig. 234: Applying Adhesive Sealing Material All Around
  • Fig. 235: Pressing Drip Rail Into Retaining Clips Until It Stops Only After Curing Time Has Elapsed
  • Fig. 236: Affixing Stickers On Windshield In Same Position On New Windshield
  • Fig. 237: Side Window With Molding - Assembly Overview
  • Fig. 238: Side Window With Gloss Package - Assembly Overview
  • Fig. 239: Undamaged Side Window, Removing
  • Fig. 240: Pulling Cutting Cord Toward Inside And Inserting Grab Handle Into Adhesive Bead At D-Pillar At Rear
  • Fig. 241: Pulling Cutting Cord Toward Inside And Inserting Grab Handle Into Adhesive Bead At D-Pillar At Top
  • Fig. 242: Removing/Installing Roof Trim Molding And Slide Trim
  • Fig. 243: Removing/Installing Roof Trim Molding
  • Fig. 244: Securing Ends X And Y In Two Pull Grips From Special Tool V.A.G 1351
  • Fig. 245: Dimensions For Application Of Adhesive
  • Fig. 246: Removing/Installing Roof Trim Molding
  • Fig. 247: Removing/Installing Roof Trim Molding And Slide Trim
  • Fig. 248: Side Window (Avant), Removing And Installing - Assembly Overview
  • Fig. 249: Removing C-Pillar Trim From Rear Side Window Toward Front
  • Fig. 250: Identifying Lower Trim Molding & Retaining Springs
  • Fig. 251: Piercing Through Adhesive Sealing Material Using Guide Needle With Handle From V.A.G 1755 Window Removing Kit
  • Fig. 252: Pulling Cutting Cord End Inward (Use Pliers And Protective Gloves) To Opposite Window Side With Guide Needle From V.A.G 1755 Window Removing Kit
  • Fig. 253: Pulling Cutting Cord With Small Tube From V.A.G 1755 Window Removing Kit Under Polyurethane Molding Of Side Window
  • Fig. 254: Inserting Cutting Cord Completely Around Window
  • Fig. 255: Attaching Spooling Tool V.A.G 1654 Together With Cutting Cord
  • Fig. 256: Cutting First Area At C-Pillar And Window Bottom
  • Fig. 257: Positioning V.A.G 1474/1 Roller
  • Fig. 258: Positioning V.A.G 1474/1 Roller, Moving Spooling Tool V.A.G 1654 & Continue Cutting (1 Of 2)
  • Fig. 259: Pressing Side Window Into Window Opening Using V.A.G 1344 Double Suction Cups
  • Fig. 260: Dimensions For Application Of Adhesive
  • Fig. 261: Identifying Lower Trim Molding & Retaining Springs
  • Fig. 262: Pressing Side Window Into Window Opening Using V.A.G 1344 Double Suction Cups
  • Fig. 263: Pressing It Into Retaining Clips At C-Pillar
  • Fig. 264: Rear Window (Sedan) Assembly Overview
  • Fig. 265: Pressing Awl Through Adhesive Sealing Material In Lower Window Corner, Until Eye Of Awl Is Visible Outside Of Vehicle
  • Fig. 266: Placing Cutting Cord Around Window
  • Fig. 267: Laying End Of Cutting Cord Around Buffer Stop
  • Fig. 268: Placing Cutting Cord Around Window
  • Fig. 269: Moving Winding Device And Attaching Relay Pulley In Lower Window Radius
  • Fig. 270: Removing Relay Pulley And Continue To Cut Adhesive
  • Fig. 271: Moving Winding Device And Attaching Relay Pulley In Lower Window Radius
  • Fig. 272: Removing Relay Pulley And Continuing To Cut Adhesive
  • Fig. 273: Disconnecting Connector For Antenna And Amplifier
  • Fig. 274: Removing Adhesive Sealing Material (With Glass Residue) From Window Opening Using Electric Cutter And Knife V.A.G 1561/11 (With Stopper Roll)
  • Fig. 275: Preparing For Window Installation
  • Fig. 276: Applying Primer Evenly In One Pass Using Applicator
  • Fig. 277: Dimensions For Application Of Adhesive
  • Fig. 278: Positioning Complete Surface Of Nozzle Onto Window
  • Fig. 279: Applying Adhesive Sealing Material All Around
  • Fig. 280: Rear Window (Avant), Assembly Overview
  • Fig. 281: Piercing Through Adhesive Sealing Material Using A Guide Needle With Handle From V.A.G 1755 Window Removing Kit
  • Fig. 282: Pulling Cutting Cord End Inward To Opposite Window Side With Guide Needle From V.A.G 1755 Window Removing Kit
  • Fig. 283: Inserting Cutting Cord End Around Rear Window Using Small Tube From V.A.G 1755 Window Removing Kit
  • Fig. 284: Using Needle And Handle To Pull Second Cutting Cord End
  • Fig. 285: Removing Cover For Rear Lid Hinge And Cable Guide From Rear Lid Hinge
  • Fig. 286: Fastening Cutting Cord End To Lid Hinge
  • Fig. 287: Cutting Glass Free At Bottom
  • Fig. 288: Cutting Glass Free At Side
  • Fig. 289: Cutting Glass Free At Top
  • Fig. 290: Cutting Window Away Completely And Lift Out From Rear Lid
  • Fig. 291: Applying Primer Evenly In One Pass Using Applicator
  • Fig. 292: Dimensions For Application Of Adhesive
  • Fig. 293: Positioning Complete Surface Of Nozzle Onto Window
  • Fig. 294: Applying Adhesive Sealing Material All Around
  • Fig. 295: Roof Joint Strip (Sedan) Remove/Install Components
  • Fig. 296: Roof Joint Strip (Avant) Remove/Install Components
  • Fig. 297: Roof Trim Molding (Sedan) Remove/Install Components
  • Fig. 298: Roof Trim Molding Remove/Install Components
  • Fig. 299: Disengaging Roof Trim Molding From Trim Molding Under Side Window
  • Fig. 300: Roof Rail Remove/Install Components
  • Fig. 301: Removing Protective Moldings, Heating Using A Hot Air Blower And Pulling Off From Door
  • Fig. 302: Trim Cover For Sill Panel Remove/Install Components
  • Fig. 303: Trim Cover For Sill Panel (S4) Remove/Install Components (Front Door)
  • Fig. 304: Trim Cover For Sill Panel (S4) Remove/Install Components (Rear Doors)
  • Fig. 305: B-Pillar Trim Panel Remove/Install Components
  • Fig. 306: Removing Clips & Window Shaft Strip
  • Fig. 307: Covering Area Below Window Weatherstrips With Adhesive Tape
  • Fig. 308: Carefully Bending Up Window Weatherstrip Slightly At Rear
  • Fig. 309: Using Plastic Wedge To Pry Off Window Weatherstrip From Carrier Part At Sides
  • Fig. 310: Widening Slightly The Lower Edge On Inside Of New Window Weatherstrip Using Plastic Wedge
  • Fig. 311: Inserting Window Weatherstrip From Above And Pressing Window Weatherstrip Completely Onto Carrier Part By Hand
  • Fig. 312: Removing Clips & Window Weatherstrips
  • Fig. 313: Covering Area Below Window Weatherstrips With Adhesive Tape
  • Fig. 314: Carefully Bending Up Window Weatherstrip Slightly At Rear
  • Fig. 315: Using Plastic Wedge To Pry Off Window Weatherstrip From Carrier Part At Sides
  • Fig. 316: Widening Slightly The Lower Edge On Inside Of New Window Weatherstrip Using Plastic Wedge
  • Fig. 317: Inserting Window Weatherstrip From Above And Pressing Window Weatherstrip Completely Onto Carrier Part By Hand
  • Fig. 318: Identifying Pry Lever 80-200
  • Fig. 319: Outside Rear View Mirror Remove/Install Components
  • Fig. 320: Outside Rear View Mirror Lens, Installing
  • Fig. 321: Outside Rear View Mirror Adjusting Motor, Removing And Installing
  • Fig. 322: Outside Rear View Mirror Housing Remove/Install Components
  • Fig. 323: Lower Mirror Locking Tab
  • Fig. 324: Removing/Installing Door Sill Panel Trim
  • Fig. 325: Removing/Installing Door Sill Panel Trim
  • Fig. 326: Sill Panel Cover Remove/Install Components
  • Fig. 327: Removing Bracket For Sill Panel Cover
  • Fig. 328: Rear Sill Panel Cover
  • Fig. 329: Underbody Covers (Front Underbody Cover)
  • Fig. 330: Underbody Covers (Rear Underbody Cover For Front Wheel Drive (FWD))
  • Fig. 331: Underbody Covers (Rear Underbody Cover For All Wheel Drive (AWD))
  • Fig. 332: Underbody Covers (Underbody Cover For Rough Terrain Package)
  • Fig. 333: Removing And Installing Tunnel Brace
  • Fig. 334: Front Wheelhousing Liner Remove/Install Components
  • Fig. 335: Rear Wheelhousing Liner Remove/Install Components
  • Fig. 336: Front Wheel Spoiler Remove/Install Components
  • Fig. 337: Rear Wheel Spoiler Remove/Install Components
  • Fig. 338: Dimensional Data For Front-Wheel Drive (FWD) Vehicles
  • Fig. 339: Dimensional Data For All Wheel Drive (AWD) Vehicles
  • Fig. 340: Dimensional Data For Front-Wheel Drive (FWD) Vehicles
  • Fig. 341: Dimensional Data For All Wheel Drive (AWD) Vehicles
  • Fig. 342: Dimensional Data For Front-Wheel Drive (FWD) Vehicles
  • Fig. 343: Dimensional Data For All Wheel Drive (AWD) Vehicles
  • Fig. 344: Dimensional Data For Front-Wheel Drive (FWD) Vehicles
  • Fig. 345: Dimensional Data For All Wheel Drive (AWD) Vehicles
  • Fig. 346: Identifying Heat Gun V.A.G 1416
  • Fig. 347: Rear Lid Spoiler - Assembly Overview S4 Sedan
  • Fig. 348: Heating Rear Lid In Adhesion Area For Spoiler Using Hot Air Gun V.A.G 1416
  • Fig. 349: Apply Adhesive Tape On Spoiler
  • Fig. 350: Removing/Installing Rear Lid Spoiler - S-Line Avant
• TABLES

ACCESSORIES & EQUIPMENT

Body Exterior

50 Body, front

Body, front

Lock carrier, service position

NOTE:

Do not remove noise insulation, only loosen front quick release screws --> Noise insulation panel - assembly overview. Bumper removed.

Fig. 1: Lock Carrier Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Lock carrier

• Service position
• Unscrew intake air duct between lock carrier and air cleaner housing at lock carrier and remove.
• On the left side, screw in special tool 3369 in threaded hole Screw in special tool 3369
• On the right side, screw in special tool 3369.

• Unscrew mounting bolts - 5 - at left and right.
• Unscrew mounting bolts - 4 - and pull lock carrier - 1 - toward front.
• Secure lock carrier Secure lock carrier.

2 - Left engine cover

3 - Right engine cover

4 - Combination bolt

• 10 Nm

5 - Combination bolt

• 50 Nm
• For service position, screw in special tool 3369.

NOTE:

After assembly of lock carrier, check headlight positioning and adjust if necessary.

Screw in special tool 3369

Fig. 2: Screw In Special Tool 3369
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Screw in special tool 3369 left and right as shown.
• Pull lock carrier forward until rear hole in lock carrier aligns with front threaded hole in fender flange.

Secure lock carrier

Fig. 3: Secure Lock Carrier
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Secure lock carrier at left and right with bolts.

Lock carrier with attachments, removing and installing

Fig. 4: Lock Carrier Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Lock carrier

• Removing:
• Remove bumper --> Front bumper, removing and installing.
• Remove noise insulation --> Noise insulation panel - assembly overview.
• Disengage Bowden cable for hood lock --> Hood lock cable, removing and installing.

• Remove engine cover - 2 - and - 3 -.
• Remove intake air duct between lock carrier and air cleaner housing at lock carrier.
• Disconnect electrical connectors.
• Drain engine coolant and disconnect coolant pipes Disconnect upper coolant hose and Disconnect lower coolant hose.

• Remove condenser from water cooler only (do not disconnect lines)
• Secure A/C system condenser using wire e.g. to front wheel. Refer to 87 AIR CONDITIONING

NOTE:

Do not hang condenser on lines. Condenser lines should not be pinched under any circumstances. Disconnect hoses to hydraulic oil cooler. Remove hydraulic oil cooler --> Disconnect hydraulic oil cooler, 48 - STEERING

NOTE:

Hydraulic oil cooler line should not be pinched under any circumstances. For cars with automatic transmission, disconnect lines to ATF-cooler. Refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 CONTROLS, HOUSING for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J On vehicles with an intercooler, remove air conduction hose. Remove gasket for left and right front flap at juncture of fender at lock carrier - 1 -. Unscrew bolts - 5 -. A second mechanic is needed to hold the lock carrier - 1 -. Unscrew bolts - 4 -. Pull lock carrier toward front. Installation: Reverse order of removal. Headlights must be adjusted anew. Adjusting: Lock carrier - 1 - must be aligned between the fenders. If the fenders and the front flap are also to be changed, then adjust these to each other first.

2 - Left engine cover

3 - Right engine cover

4 - Combination bolt

• 10 Nm

5 - Combination bolt

• 50 Nm

Disconnect upper coolant hose

Fig. 5: Disconnect Upper Coolant Hose
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig. 6: Lock Carrier Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull out retainer for coolant line connecting flange at top of radiator and remove connecting flange.

Disconnect lower coolant hose

Fig. 7: Disconnecting Lower Coolant Hose
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull out retainer for coolant line connecting flange at bottom of radiator and remove connecting flange.
• Bleed cooling system. Refer to
  • 19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
  • 19 - ENGINE - COOLING SYSTEM for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
  • 19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
  • 19 - ENGINE - COOLING SYSTEM for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
  • 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
  • 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

Disconnect hydraulic oil cooler

Fig. 8: Disconnecting Hydraulic Oil Cooler
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect hoses from hydraulic oil line.
• Unscrew hydraulic line for power-assisted steering on lock carrier.

Disconnect hoses for charge air cooler

Fig. 9: Disconnecting Hoses For Charge Air Cooler
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• On vehicles with charge air cooler, loosen bolts on hose clamps - arrows -.
• Disconnect hoses.

Cowl panel trim, removing and installing

Fig. 10: Cowl Panel Trim Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Cowl trim

• Windshield wiper arms removed.
• Plenum chamber cover removed.
• Pull out securing pins - 4 -.
• Remove trim from retaining strip at windshield, bottom.

• Remove trim upward.
• When installing, make sure that the trim engages completely into retaining strip.

2 - Support

3 - Windshield

4 - Securing pin

5 - Plenum chamber cover

• Remove gasket - 6 - and remove cover from cowl panel trim

6 - Gasket

Transverse support (dome brace), removing and installing

Fig. 11: Transverse Support (Dome Brace) Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - 2 - and - 3 -.
• Remove transverse support - 1 - from mount - 4 -.
• Transverse support - 5 - only with Right Hand Drive

Fender, removing and installing

NOTE:

Bolts and washers are micro-encapsulated and must be replaced after loosening or after removing the fender.

Up to Vehicle Identification Number (VIN) 400 000

Fig. 12: Fender Remove/Install Components (Up To Vehicle Identification Number (VIN) 400 000)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Fender

• Remove bumper --> Front bumper, removing and installing.
• Remove wheelhousing liner --> Wheelhousing liner, removing and installing.
• Remove end plate --> Removing and installing end plate.
• Remove headlight. Refer to
  • 94 LIGHTS, SWITCHES - EXTERIOR
  • 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET
  ; Headlights, repairing

• Disconnect electrical connectors for the side blinkers.

2 - Combination bolt

• 8 Nm

3 - Combination bolt

• 10 Nm

4 - Combination bolt

• 10 Nm

5 - Combination bolt

• 10 Nm

6 - Combination bolt

• 10 Nm

7 - Bracket

8 - Combination bolt

• 10 Nm

As of Vehicle Identification Number (VIN) 400 001

Fig. 13: Fender Remove/Install Components (As Of Vehicle Identification Number (VIN) 400 001)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Brace for wheelhousing liner

2 - Combination bolt

• 10 Nm

3 - Brace for fender

4 - Combination bolt

• 10 Nm

5 - Torx screw

• 10 Nm

6 - Combination bolt

• 8 Nm

7 - Wheelhousing liner

• Removed

8 - Combination bolt

• 10 Nm

9 - Fender

• Remove bumper --> Front bumper, removing and installing.
• Remove wheelhousing liner --> Wheelhousing liner, removing and installing.
• Remove end plate --> Removing and installing end plate.
• Remove headlight. Refer to
  • 94 LIGHTS, SWITCHES - EXTERIOR
  • 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET
  ; Headlights, repairing

• Disconnect electrical connectors for the side blinkers.
• Remove bolts - 5 - ; - 6 - and - 8 - and remove fender.

Removing and installing end plate

Fig. 14: Removing And Installing End Plate
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Front wheel removed.
• Wheelhousing liner removed.
• Unscrew bolts - 1 - from expanding clip - 3 - and remove end plate - 2 - from fender - 4 -.
• Tightening torque 2 Nm

Noise insulation panel - assembly overview

Fig. 15: Noise Insulation Panel - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Quick release screw

• Remove only these quick release screws for service position of lock carrier.
• 3 pieces

2 - Noise insulation, front

3 - Wheel spoiler

4 - Quick release screw

• 3 pieces

5 - Noise insulation panel rear

• Only installed for certain motor types

6 - Quick release screw

• Two pieces

7 - Noise insulation panel mount

• Marking (recess) must point to left vehicle side.

8 - Bolt

• Two pieces
• 7 Nm

9 - Speed nut

• 3 pieces

10 - Speed nut

• Two pieces

11 - Clamping pin

• Six pieces

12 - Wheelhousing liner

13 - Bumper

14 - Lock carrier with attachments

55 Hood, lids

Hood

Hood, removing, installing and adjusting

Up to Vehicle Identification Number (VIN) 400 000

Fig. 16: Hood Remove/Install/Adjusting Components (Up To Vehicle Identification Number (VIN) 400 000)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Hood

• Removing:
• Disconnect line to windshield washer system and unclip line.
• Second technician is needed to support and lift hood during removal.
• Remove gas-filled strut - 5 - from hood - 1 - Gas-filled strut, removing and installing.

• Remove nuts - 4 -.
• Remove hood.
• Installing:
• Install in reverse order of removal.

• Adjusting:
• Align hood - 1 - between fenders.
• Adjust height of hood at hood lock Removing and installing lower part of hood lock.
• Hood can be adjusted for height relative to fenders by adjusting buffer stops --> Buffer stop for height adjustment.

• Panel gap dimensions --> Hood gap dimensions.

2 - Hood hinge

• Hood - 1 - must be removed or propped up securely.
• To remove, remove bolts - 3 - and nuts - 4 -.

3 - Combination bolt

• 21 Nm

4 - Hex nut

• 21 Nm

5 - Gas-filled strut

• Removing and installing Gas-filled strut, removing and installing

As of Vehicle Identification Number (VIN) 400 001

Fig. 17: Hood Remove/Install/Adjusting Components (As Of Vehicle Identification Number (VIN) 400 001)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Hood

• Removing:
• Disconnect line to windshield washer system and unclip line.
• Second technician is needed to support and lift hood during removal.
• Remove gas-filled strut - 5 - from hood - 1 - Gas-filled strut, removing and installing.

• Remove nuts - 4 -.
• Remove hood.
• Installing:
• Install in reverse order of removal.

• Adjusting:
• Align hood - 1 - between fenders.
• Adjust height of hood at hood lock Removing and installing lower part of hood lock.

2 - Hood hinge

• Hood - 1 - must be removed or propped up securely.
• To remove, remove bolts - 3 - and nuts - 4 -.

3 - Combination bolt

• 21 Nm

4 -

• 21 Nm

5 - Gas-filled strut

• Tube of gas-filled strut must be installed on body side

Gas-filled strut, removing and installing

Fig. 18: Gas-Filled Strut, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Support hood or secure it from falling down.
• Gently lift retaining springs at both ends of gas-filled strut using a screwdriver and unclip gas-filled strut.
• To install, press gas-filled strut onto ball stud and engage.
• Install with tube end of strut at body.

Releasing gas from gas-filled strut

Fig. 19: Identifying Gas-filled Strut Area To be Clamped in Vice
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Clamp gas-filled strut in vice area x. Dimension of - x - = 50 mm (2 in.).

CAUTION:

Clamping must only be done in this area, otherwise there is a risk of an accident. Always wear eye protection when performing this procedure.

• Cover area of sawn portion with a rag to absorb oil spraying out.

• 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).

Buffer stop for height adjustment

Fig. 20: Buffer Stop For Height Adjustment
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Buffer stops - 1 - and - 2 - must make contact lightly against lock carrier when hood is closed.

Fig. 21: Buffer Stop For Height Adjustment (As Of Vehicle Identification Number (VIN) 400 001)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

As of Vehicle Identification Number (VIN) 400 001

• Impact guard - 1 - for hood inserted
• During installation, screw buffer - 3 - for height adjustment into hood until it stops.
• For height adjustment, screw out far enough until contour aligns with fender.
• Buffer must make contact on lock carrier after adjustment.

• Buffers - 2 - for strike guard are inserted.

NOTE:

The buffer stops can be used for adjusting the height of the hood.

Radiator grill, removing and installing

Fig. 22: Radiator Grill, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To remove, disengage locking mechanisms - arrows -.
• Swivel out radiator grille at top, then pull off downward.

NOTE:

To ease installation, coat PU seal with lubricant.

• To install, insert centered at bottom (note middle centering) and swivel in - direction of arrow -.
• Dimension - a - = 1.5 ± 0.5 mm
• Dimension - b - =0.7 ± 0.5 mm
• When installing, make sure radiator grille engage completely (audibly).

Removing and installing catch hook

Fig. 23: Removing And Installing Catch Hook (Up To Vehicle Identification Number (VIN) 400 000)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Up to Vehicle Identification Number (VIN) 400 000

• To remove, unscrew cap nuts - 2 - and remove catch hook - 1 -.
• When installing, tighten cap nuts to 11 Nm.

Fig. 24: Removing And Installing Catch Hook (As Of Vehicle Identification Number (VIN) 400 001)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

As of Vehicle Identification Number (VIN) 400 001

• To remove, unscrew cap nuts - 2 - and remove catch hook - 1 - from hood - 3 -.
• When installing, tighten cap nuts to 11 Nm.

Removing and installing lower part of hood lock

Fig. 25: Removing And Installing Lower Part Of Hood Lock
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disengage Bowden cable for hood --> Hood lock cable, removing and installing.
• Remove bolts - 2 - (4x). Tightening torque: 14 Nm
• Remove lower part of lock - 1 -.
• To adjust hood, move lower section of lock up or down as required.

Adjusting lock carrier buffer stop

Fig. 26: Adjusting Lock Carrier Buffer Stop
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Buffer stop must make contact lightly on inner plate when hood is closed.
• When adjusting headlights, re-position buffer stop only for fine adjustment. Tightening torque: 15 Nm

Hood gap dimensions

Special tools, testers and auxiliary items required

Fig. 27: Identifying Adjustment Gauge 3371
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Adjusting gauge 3371

Fig. 28: Hood Gap Dimensions
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Dimension - A - = 4.5 mm ± 0.5 mm
• Dimension - B - = 4.5 mm ± 0.5 mm
• Dimension - C - = 4.5 mm ± 0.5 mm
• Dimension - D - = 3 mm ± 0.5 mm

Hood lining, removing and installing

Removing

Fig. 29: Hood Lining, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Unclip clips - 2 -.
• Remove cover - 1 -.

Installing

• Installation is reverse of removal.

Hood seal, assembly overview

Assembly overview

Fig. 30: Hood Seal, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Seal for lock carrier

• Apply gasket at left and right on foam piece.
• When doing this, make sure it is applied without gaps.
• Compress excess length of gasket along lock carrier.

2 - Left sealing profile

• Self-adhering, adhesion surfaces must be free of dust and grease.

3 - Seal for plenum chamber

• Apply gasket at left and right on foam piece.
• When doing this, make sure it is applied without gaps.
• Compress excess length of gasket along front panel of plenum chamber.

Impact guard, installing

NOTE:

When installing impact guard, drain holes must not be covered.

Fig. 31: Impact Guard, Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Insert profile and align at drain holes.
• Press on impact guard evenly.

Hood lock cable, removing and installing

Fig. 32: Hood Lock Cable Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Hood lock cable

• Removing:
• Raise vehicle.
• Remove front wheelhousing liner --> Wheelhousing liner, removing and installing.
• Remove drivers side storage compartment -->
  • 68 - INTERIOR EQUIPMENT
  • 68 - INTERIOR EQUIPMENT for BODY INTERIOR - CABRIOLET

• Remove retaining clamp - 4 -.
• Unclip cable for lower part of hood lock and disengage attachment lug arrow - A -.
• Installing:
• Install in reverse order of removal.

• Bring ball on cable for lower part of hood lock into installation position.

2 - Actuating lever

3 - Bolt

• 2.4 Nm

4 - Retaining clip

5 - Lower part of hood lock

• Removing and installing Removing and installing lower part of hood lock
• Can be used to adjust height of hood.

6 - Retaining clip

Rear lid (Sedan)

Rear lid, removing and installing

Fig. 33: Rear Lid Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear lid

• Removing:
• Remove warning triangle with bracket - 5 -
• Remove rear lid lining.
• Disconnect electrical harness connectors and pull out of lid.

• Remove the nuts that connect both lid hinges to rear lid.
• Second technician is needed to support and lift hood during removal.
• Installing:
• Install in reverse order of removal.

2 - Buffer stop

• Adjusting --> Adjusting buffer stops

3 - Expanding nut

4 - Bolt

5 - Bracket

6 - Striker

• Removing and installing Striker, removing and installing
• Adjusting Adjusting rear lid

7 - Nut

• 8 Nm

Striker, removing and installing

• Remove trim for rear panel. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

Fig. 34: Striker, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Unscrew nuts - 1 -. Tightening torque 8 Nm
• Installation is performed in the reverse order of removal.

Adjusting rear lid

Fig. 35: Adjusting Rear Lid
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove trim for rear panel. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

NOTE:

The gas-filled struts must be attached before installing a new rear lid.

• Loosen nuts - 1 - , striker - 2 - must be able to be moved.

• Carefully close rear lid until lid is flush with side panels.
• Carefully open lid and tighten nuts - 1 - to 8 Nm.

Gap dimensions for rear lid

Special tools, testers and auxiliary items required

Fig. 36: Identifying Adjustment Gauge 3371
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Adjusting gauge 3371

Fig. 37: Gap Dimensions For Rear Lid
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Dimension - A - = 4.0 mm ± 0.5 mm
• Dimension - B - = 2.0 mm ± 0.5 mm
• Dimension - C - = 2.0 mm ± 0.5 mm

Gap dimensions for fuel filler flap

• Removing and installing fuel filler flap --> Fuel filler flap

• Dimension - D - = 3 mm
• Dimension - E - = 3 mm
• Dimension - F - = 3.5 mm
• Dimension - G - = 3 mm

Lid lock and handle mechanism, removing and installing

Fig. 38: Lid Lock And Handle Mechanism Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear lid lock

• To remove, unclip operating rod from swivelling bush and disengage.
• Unscrew hex nuts - 3 - and remove rear lid lock.

2 - Swivelling bushing

• After installing rear lid lock, engage operating rod and secure.

3 - Nut

• 8 Nm

4 - Operating rod

5 - Bowden cable

6 - Lock cylinder

• Removing:
• Disconnect electrical harness connectors.
• Disengage Bowden cable - 6 - from lock cylinder.
• Remove combination bolt - 7 -.

• Twist lock cylinder 90°.
• Remove lock cylinder from handle mechanism.

7 - Combination bolt

• 8 Nm

8 - Engine

• Removing and installing --> Remote control motor, removing and installing (country versions)

9 - Grip piece

• Removing:
• Rear lid trim removed.
• Lock cylinder removed.
• Remove hex head collar nuts - 10 -.

• Press in catches - arrows -.
• Remove grip piece.

10 - Hex head collar nut

• 8 Nm

Remote control motor, removing and installing (country versions)

Fig. 39: Remote Control Motor, Removing And Installing (Country Versions)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Unclip operating rod - 3 - and disengage.
• Remove bolt - 2 - (Qty. 2). Tightening torque: 2 Nm
• Remove remote control motor.
• Disconnect connector from remote control motor - 1 -.

• Installation is performed in the reverse order of removal.

Rear lid hinge, removing and installing

Comfort hinge

Fig. 40: Rear Lid Hinge Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Gas-filled strut

• Engage tube end of strut at lid.
• Insert cover with angled retractors in hinge lever.
• Only then press cover at top over hinge lever until it engages audibly.
• Press stop into hinge eye.

2 - Cover

• Slide in cover from below between gas-filled strut and long hinge lever.

3 - Spring

• Before removing, remove gas-filled strut and cover.
• To remove, press off spring over ball stud.
• While installing, plastic shells of spring must engage cleanly over ball stud.

4 - Comfort hinge

5 - Ball stud

• No replacement part, belongs to delivery casing

• Gas-filled strut, removing and installing Gas-filled strut, removing and installing

Cover for rear lid hinge

Fig. 41: Placing Electric Wiring Or Wiring For Central Locking System Into Lower Retainer Of Cable Guide At Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Place electric wiring or wiring for central locking system - 2 - into lower retainer of cable guide at cover - 1 -.
• Insert trim - 1 - for lid hinge on long hinge lever at bottom and clip in audibly toward top onto hinge lever.
• Engage clip - 3 - on trim into hinge lever.

Removing and installing rear lid hinges

NOTE:

For easier adjustment of the rear lid hinges, use gradations marked on the hinges.

Removing

Fig. 42: Removing Rear Lid Hinges
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Loosen nut - 1 -. Tightening torque 21 Nm
• Unscrew nut - 2 -. Tightening torque: 21 Nm
• Lift off lid from hinge.
• Remove bolts - 3 - and - 4 -. Tightening torque: 21 Nm

• Only loosen center bolt - 5 -. Tightening torque: 21 Nm
• Remove hinge - 6 -.
• Installation is performed in the reverse order of removal.

Gas-filled strut, removing and installing

NOTE:

When removing or installing the gas-filled strut, push back the opened rear lid only slightly so as to avoid damaging components.

Fig. 43: Removing As-Filled Strut
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Lift retaining springs in succession on both ends using screwdriver and remove gas-filled strut.

Installation

• Clip in gas-filled strut at bottom first, then at top.
• Install with tube end of strut at rear lid.

Releasing gas from gas-filled strut

Fig. 44: Identifying Gas-filled Strut Area To be Clamped in Vice
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Clamp gas-filled strut in vice area x. Dimension of - x - = 50 mm (2 in.).

CAUTION:

Clamping must only be done in this area, otherwise there is a risk of an accident. Always wear eye protection when performing this procedure.

• Cover area of sawn portion with a rag to absorb oil spraying out.
• 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).

Rear lid seal, installing

Fig. 45: Rear Lid Seal, Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• The butt joint - position A - of the rear lid seal must be aligned with the ball socket of the left hinge.
• Press seal on.

Adjusting buffer stops

Fig. 46: Adjusting Buffer Stops
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Open lid.
• Remove rubber cap.
• Screw in buffer stops until they reach stop.
• Unscrew stop again in steps.

• Press rubber cap on.
• When adjusted correctly and with lid closed, buffer stops must make contact lightly on luggage compartment edge.

Fuel filler flap

Assembly overview

Fig. 47: Fuel Filler Flap Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Sheet-metal screw

• 1.5 Nm

2 - Fuel filler flap

• Panel gap dimensions Gap dimensions for fuel filler flap

3 - Fuel filler flap cup

• Coat with soap solution to assist assembly.

4 - Ring for fuel filler flap cup.

Rear lid (Avant)

Rear lid, removing and installing

Removing

• Remove rear lid trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• Disconnect or remove electrical harness connectors and hose for rear window washer system.
• Prop up and secure rear lid in open position.

Fig. 48: Using Screwdriver To Lift Retaining Spring And Remove Gas-Filled Strut From Upper Ball Stud
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Using screwdriver, lift retaining spring - 3 - as shown and remove gas-filled strut - 1 - from upper ball stud - 2 -.

Fig. 49: Removing Cover For Rear Lid Hinge And Cable Guide From Rear Lid Hinge
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove cover - 1 - for rear lid hinge and cable guide - 2 - from rear lid hinge - arrows -.

Fig. 50: Removing Rear Lid Bolts At Left/Right
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - arrows - at left and right.
• Second technician is needed to support and lift hood during removal.
• Remove rear lid.

Installing

Installation is the reverse of removal, noting the following:

• When installing, tightening torque 21 Nm.
• Adjusting rear lid --> Rear lid, adjusting.

Insulation mat to rear lid, adhering

Fig. 51: Insulation Mat To Rear Lid, Adhering
Courtesy of VOLKSWAGEN UNITED STATES, INC.

On a new rear lid, insulation mats must be adhered to surfaces depicted in the illustration after painting:

• Cut the insulation mats from self-adhering insulation Part No. 323 863 950 to the following dimensions:

1 - Insulation mat 100 x 150 mm (2x)

2 - Insulation mat 30 x 100 mm (2x)

Rear lid, adjusting

NOTE:

The gas-filled struts must be attached before installing a new rear lid.

• Remove rear cross panel trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

Fig. 52: Removing/Installing Striker Combination Nuts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Loosen combination nuts - 1 - and - 3 - , striker - 2 - must be adjustable.

NOTE:

When installing a striker, make sure it is in the proper installation position, for this the tab - arrow - must point to the rear.

Fig. 53: Removing/Installing Cover & Adjustment Screw
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Unclip cover - 1 - at rear lid stop.
• Screw the adjustment screw - 2 - counterclockwise into position "0".

Fig. 54: Removing/Installing Striker Combination Nuts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Tighten nuts - 1 - and - 3 - hand tight.
• Close rear lid.
• Press lid by hand into chassis approx. 2 mm.
• Open rear lid in this position and tighten nuts - 1 - and - 3 - to 21 Nm.

• Check whether rear lid closes easily and without play at lock. Repeat adjustment if necessary.
• Check whether lid sits without play by pressing on the side edge of rear lid below rear window.

Fig. 55: Removing/Installing Cover & Adjustment Screw
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pre-tension stop by turning adjustment screw - 2 - clockwise if necessary.
• Check whether rear lid still closes easily, repeat adjustment if necessary.
• Checking adjustment dimensions --> Adjustment dimensions for rear lid.

Rear lid hinge, removing and installing

Removing

Fig. 56: Removing Cover For Rear Lid Hinge And Cable Guide From Rear Lid Hinge
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove cover - 1 - for rear lid hinge and cable guide - 2 - from rear lid hinge - arrows -.

Fig. 57: Removing Outer Roof Frame Trim
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove outer roof frame trim - 1 - , for this purpose lift trim from retaining clips - 2 - after unclipping and guide tabs - arrows - around the hinge.
• Remove D-pillar trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

NOTE:

To prevent damage to paint, support and secure rear lid.

Fig. 58: Removing Nuts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove nuts - arrows -.

Fig. 59: Removing Rear Lid Bolts At Left/Right
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - arrows - at left and right.
• Remove hinge.

Installing

Installation is the reverse of removal, noting the following:

• When installing, tightening torque 21 Nm.
• Adjusting rear lid --> Rear lid, adjusting.

Gas-filled strut for rear lid, removing and installing

Removing

• Prop up and secure rear lid in open position.

Fig. 60: Using Screwdriver To Lift Retaining Spring And Remove Gas-Filled Strut From Upper Ball Stud
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Using screwdriver, lift retaining spring - 3 - as shown and remove gas-filled strut - 1 - from upper ball stud - 2 -.

NOTE:

Following complete removal of the gas-filled strut, check for correct positioning during installation. Sound insulation component must be installed on the body side.

NOTE:

Installing

Installation is the reverse of removal, noting the following:

• To install, press gas-filled strut onto ball studs so that it engages in position.
• Ball stud tightening torque: 15 Nm^{-1 Nm}

Rear lid seal, removing and installing

Fig. 61: Rear Lid Seal, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Open rear lid and pull out seal.
• When installing, insert seal in lower left and right corners first.
• Press seal - 1 - onto body as shown.

Adjustment dimensions for rear lid

Special tools, testers and auxiliary items required

Fig. 62: Identifying Adjustment Gauge 3371
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Adjusting gauge 3371

Panel gap dimensions

Fig. 63: Adjustment dimensions for rear lid
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Dimension - A - = 4 mm
• Dimension - B - = 4.5 mm
• Dimension - C - = 1.75 mm

Gap dimensions for fuel filler flap

• Dimension - D - = 3 mm
• Dimension - E - = 3 mm
• Dimension - F - = 3.5 mm
• Dimension - G - = 3 mm

Fig. 64: Positioning Rear Lid In Chassis Cut-Out Just So That Gap Measurement On Right Equals Gap Measurement On Left
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Position rear lid in chassis cut-out just so that the gap measurement on the right equals the gap measurement on the left.
• Check whether chassis surface below rear window stands flush with chassis surface of lower side panel - arrows a -.
• Check whether rear lid is flush with roof (and projects slightly upward).

• Dimension - b - = 0 to 0.5 mm

Lock cylinder for rear lid, removing and installing

Removing

• Remove rear lid trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

Fig. 65: Lock Cylinder For Rear Lid, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical harness connector - 2 -.
• Disengage actuating link - 3 - to rear lid lock.
• Remove bolt - 1 -.
• Tightening torque: 8 Nm

• Turn lock cylinder 90° around its own shaft and remove lock cylinder.

Installing

Installation is performed in the reverse order of removal.

Handle mechanism for rear lid, removing and installing

Removing

• Remove lock cylinder for rear lid --> Lock cylinder for rear lid, removing and installing.
• Disconnect inner electrical harness connector at grip piece.

Fig. 66: Removing Nuts & Pressing Both Catches Down And Removing Grip Piece
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove nuts (Qty. 4) - 1 - and - 2 - (different versions; mark for re-installation).
• Tightening torque: 8 Nm
• Press both catches - arrows - down and remove grip piece - 3 -.

Installing

Installation is performed in the reverse order of removal.

Rear lid lock, removing and installing

Assembly overview

As of Vehicle Identification Number (VIN) 400 001

Fig. 67: Rear Lid Lock Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear lid

2 - Lid lock

• Removing Removing lid lock

3 - Hex nut

• 21 Nm

4 - Cover

• Connected to lid lock as anti-theft device.

5 - Cover for lid lock

• Slide on lid lock before installing rear lid trim.

Removing lid lock

• Remove lower rear lid trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

Fig. 68: Lid Lock Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disengage actuating link - 6 - , for this purpose press expanding clip - 5 - from operating lever.
• Disengage operating rod - 1 - to actuator, for this purpose turn hinge arm - 7 - clockwise and remove operating rod.
• Remove nuts - 2 - and - 4 - and remove rear lid lock - 3 -.
• Tightening torque: 21 Nm

Installing

Installation is performed in the reverse order of removal.

Rear lid lock actuator, removing and installing

Removing

• Remove lower rear lid trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

Fig. 69: Rear Lid Lock Actuator, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disengage operating rod - 3 - at rear lid lock, for this purpose turn hinge arm - 4 - clockwise and remove operating rod.
• Disengage operating rod at actuator - 1 - , for this purpose slide operating rod to actuator and turn approx. 90° out of mount - arrow -.
• Loosen bolts - 2 - approx. 2 rotations and disengage actuator at rear lid.
• Disconnect electrical harness connector.

Fig. 70: Removing Bolts, Adapter Plate From Actuator
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - 3 -.
• Tightening torque 2 Nm
• Remove adapter plate - 2 - from actuator - 1 -.

Installing

Installation is performed in the reverse order of removal.

Fuel filler flap

Assembly overview

Fig. 71: Fuel Filler Flap Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Sheet-metal screw

• 1.5 Nm

2 - Fuel filler flap

• Panel gap dimensions Gap dimensions for fuel filler flap

3 - Fuel filler flap cup

• Coat with soap solution to assist assembly.

4 - Ring for fuel filler flap cup

57 Front doors/door components/central locking system

Front door

Window frame and window regulator, removing and installing

Fig. 72: Window Frame And Window Regulator Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Window frame

• Removing:
• Remove door trim. Refer to
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
  ; front door trim
• Disconnect electrical harness connectors.
• Remove window regulator motor Window regulator motor, removing and installing.

• Remove bolts - 7 -.
• Remove bolts - 4 - , - 8 - and - 10 -.
• Remove bolts - 6 - and - 9 - and lift window frame with window regulator upward and out of door.
• Installation:

• Drive window into window frame half way before installing.
• Insert window frame and window regulator into door from above.
• Knock in the upper profile halves of door-side gasket into window frame at top.
• Loosely screw in mounting bolts in the sequence - 6 - ; - 9 - ; - 3 - ; - 8 - and - 10 -.

• Tighten collared shoulder bolts - 6 - and - 9 - hand tight.
• Lightly press window frame - 1 - inward at top.
• Tighten bolts - 4 - and - 8 - to 32 Nm.
• Tighten collared shoulder bolts - 6 - and - 9 - to 32 Nm.

• Tighten bolt - 10 - to 10 Nm.
• Tighten locating bolt - arrows - in window frame to 32 Nm.

2 - Window regulator

• Bolted to window frame for installing in door.

3 - Front door

4 - Torx screw

• 32Nm

5 - Concealment cap

6 - Collared shoulder bolt

• 32Nm

7 - Collar bolt

• 6Nm

8 - Torx screw

• 10Nm

9 - Collared shoulder bolt

• 32Nm

Window regulator motor, removing and installing

Fig. 73: Window Regulator Motor Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To remove, unscrew bolts - 2 - and remove window regulator motor.
• Install window regulator motor --> Motor for window regulator, removing and installing.

Fig. 74: Upper door hinge Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Upper door hinge

• Torx bolt T45 - 1 - (installed from inside of vehicle) 32 Nm.
• Top door hinge - 2 -.
• Cover cap - 3 -.
• Torx bolt T45 - 4 - 32 Nm.

• Install bolt - 5 - T45 32 Nm.

Fig. 75: Lower Door Hinge Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lower door hinge

• Torx bolt T45 - 1 - 32Nm bolted to B-pillar from interior of vehicle.
• Lower door hinge - 2 -.
• Cover cap - 3 -.
• Torx bolt T45 - 4 - 32Nm.

• Collared shoulder bolt T45 - 5 - 32Nm.
• Re-grease lubrication points - arrows - in service interval.
• Front door - 6 -.

Door window, removing from window regulator

Fig. 76: Door Window, Removing From Window Regulator
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Window frame

• Removing:
• Remove door trim.
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
  ; front door trim
• Window frame with window regulator removed from front door --> Window frame and window regulator, removing and installing.
• Door window - 4 - removed

• To remove, unscrew countersunk screws - 3 - and remove window regulator from window frame.
• Installation:
• When installing, make sure that both guide rails, - arrows A - , run parallel to guide - arrow B -.
• Tighten bolts - 3 - to 6 Nm.

2 - Window regulator

• Window frame with window regulator removed from front door --> Window frame and window regulator, removing and installing.
• Door window removed.
• To remove, unscrew countersunk screws - 3 - and remove window regulator from window frame.

3 - Countersunk screw

• 6Nm

4 - Window

• Removing:
• Drive down door window fully.
• Unscrew bolts - 5 - and remove door windows from window regulator.
• Installing:

• Insert window into window regulator.
• Screw bolts - 5 - into window regulator, but do not tighten yet.
• Drive door window upward into window frame.
• Pull door window toward rear into window guide on window frame at B-pillar and tighten bolts - 5 - to 4Nm.

5 - Socket head bolt

• 4 Nm

Motor for window regulator, removing and installing

Removing

• Door trim removed. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

NOTE:

Motor for window regulator can be removed or installed in every position of motor or side window. Before removing motor, disconnect electrical harness connectors.

Fig. 77: Removing Torx Bolts T30 And Motor
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove Torx bolts - 2 - T30 and remove motor.

Installing

• When installing, make sure that threaded pins - arrows - are engaged in inner door plate.
• Slide on window regulator motor -1- and secure with bolts - 2 -.
• Tightening torque 3.5 Nm

NOTE:

Only switch ignition on and off after installing motor and connected wires. Then move door window upward to stop and keep pressing switch for window regulator for approx. 2 seconds longer. This position is the base position and the high- and low-running function is activated.

Front door, adjusting

Special tools and equipment

Special tools, testers and auxiliary items required

Fig. 78: T40038/01
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• T40038/01

NOTE:

To adjust door exactly in relation to height, inclination and door recess, use the special tool T40 038/1 as described on --> Adjusting using door adjustment template T40038/1.

Fig. 79: Panel Gap Dimensions
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Panel gap dimensions

NOTE:

Rear door must be adjusted. Panel gap dimensions can be checked using 3371 adjustment gauge.

• Dimension - A - = 3.5 mm ± ^{* .5mm} .
• Dimension - B - = 4.5 mm ± ^{* .5mm} .
• Flush dimension - C - =approx.^{* mm+1mm} in parallel position to chassis.

Adjustment in longitudinal direction

Fig. 80: Adjustment In Longitudinal Direction
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Adjustment in longitudinal direction is performed by loosening hinge bolts - arrow A - of A-pillar at top of door hinge or/and bottom and sliding doors - 2 - (over-sized holes in hinge or in A-pillar)
• Tightening torque 32 Nm
• Door hinge - 1 -.
• - A - pillar - 3 -

• Door - 2 -

NOTE:

Illustration shows lower door hinge.

Adjustment to center of vehicle

NOTE:

A collared shoulder bolt is installed at each upper and lower door hinge (door side). When repairing, an adjustment is therefore not necessary under normal circumstances. If an adjustment should become necessary anyway, bolts can be replaced with bolts of the same size, length and toughness .

Fig. 81: Adjustment In Longitudinal Direction
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• The adjustment to vehicle center occurs by loosening hinge bolts - arrow B - at top and/or at bottom of door and shifting the doors (elongated holes in hinge).
• Tightening torque 32 Nm

NOTE:

In rear portion of door, adjust door depth (relative to vehicle center) via striker.

Adjusting via striker

Fig. 82: Adjusting Via Striker
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Loosen bolts - 2 -.
• Use the markings (- arrows a - and - arrows c -) for side adjustment.
• Slide striker - 1 - until the door is flush with the contour of the chassis.

NOTE:

Door may only be adjusted for depth (towards car interior) and not for height.

• Use the markings (- arrows b - and - arrows d -) for height adjustment.
• Striker must align in door lock center for correct adjustment.
• Tighten bolts to 25 Nm.

Adjusting using door adjustment template T40038/1

Fig. 83: Door Adjustment Template T40038/1
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Use the door adjustment template T40 038/1 as described in the following for testing (e.g. for wind noises) and for adjusting door.
• For testing contact pressure of sealing lips on roof trim molding, use a standard bank card - 1 - or similar means.

Fig. 84: Using Standard Bank Card To Drive Off Contact Area Of Sealing Lip To Roof Trim Molding With Light Pressure
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Testing sealing lip/roof trim molding contact

• Using a standard bank card, drive off contact area of sealing lip to roof trim molding with light pressure.
• When doing this, card must not sink in between sealing lip - 1 - and roof trim molding - 2 -.

Fig. 85: Identifying Template Has Points Of Different Lengths At So That Side Adjustment Of Door Can Be Tested
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Template has points of different lengths at - arrows a - and - arrows b - so that side adjustment of door can be tested.
• The upper point - arrow a - on the side with the cut-out - arrow c - at bottom is the longer side (max. marking).
• This side is used to check whether the window frame is located too far outward in relation to the chassis.

Fig. 86: Positioning Template With Cut-Out Facing Door Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Position template at dimension - a - = 200mm and with cut-out - arrow - facing door window
• Make sure that points - 1 - and - 3 - make contact.
• At point - 2 - of template, there must be a gap.
• In this position (max), doors are adjusted to farthest outward point within tolerance range.

• If there is no gap at point - 2 - , or there is a gap at point - 1 - , the window frame is set too far outward and must be adjusted --> Window frame, adjusting.

Fig. 87: Identifying Template Has Points Of Different Lengths At So That Side Adjustment Of Door Can Be Tested
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• The upper point - arrow b - opposite the side with cut-out - arrow c - at bottom is the shorter side (min. marking).
• This side is used to check whether the window frame is located too far inward in relation to the chassis.
• Position template at dimension - a - = 200mm and with cut-out - arrow - turned away from door window as depicted in magnified areas of illustration.

Fig. 88: Making Sure Points Make Contact On Door Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Make sure that points - 2 - and - 3 - make contact on door window.
• At point - 1 - of template, there must be a gap.
• In this position (min), doors are adjusted to farthest inward point within tolerance range.
• If point - 1 - has no gap, or if template cannot be brought into contact at point - 2 - , window frame is set too far inward and must be adjusted.

Panel gap dimensions

Special tools, testers and auxiliary items required

Fig. 89: Identifying Adjustment Gauge 3371
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Adjusting gauge 3371

Fig. 90: Panel Gap Dimensions
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Dimension - E - = 3.5 mm ± 0.5 mm
• Dimension - F - = 4.5 mm ± 0.5 mm
• Flush adjustment of front door to fender must be in the range of 0 mm to 1 mm recess.
• Flush adjustment of front door to rear door must be in the range of 0 mm to 1 mm projection.

Window frame, adjusting

Adjustment for A-pillar region

Fig. 91: Loosening Mounting Bolts And Removing Or Adding Spacers At Bolt Point
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Insulation for door trim

• Must not be removed for the adjustment.

2 - Front door

• For correct adjustment of window frame, door trim and loudspeaker must be removed.

3 - Spacer

• Place underneath at bolt point - B - if necessary.
• By loosening mounting bolts - arrow A - and removing or adding spacers at bolt point - B - , --> Inclination adjustment at A-pillar, the position (inclination) of window frame in A-pillar region can be adapted to roof molding.
• Different sizes (0.5 mm and 1 mm thick) are available.

Inclination adjustment at A-pillar

Fig. 92: Removing/Installing Bolt
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• By loosening bolt - arrow - and placing underneath or removing spacers, the contact pressure of seal in A-pillar region can be adjusted.
• Spacers up to a maximum of 3 mm can be inserted underneath, depending on technical assessment.
• Spacers in sizes of 0.5 mm and 1 mm are available.

Adjustment for B-pillar region

NOTE:

If height adjustment dimensions are not within tolerance range of the adjusting template, collared shoulder bolts must be replaced by two standard-type bolts. After that, the window frame height can be adjusted.

Fig. 93: Adjustment For B-Pillar Region
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Front collared shoulder bolt

• Replace with standard-type bolt for height adjustment if necessary.
• 32 Nm.

2 - Rear collared shoulder bolt

• Replace with standard-type bolt for height adjustment if necessary.
• 32 Nm.

3 - Bolt for longitudinal compensation (X compensation)

• 32 Nm.

4 - Rear mounting bolt

• 32 Nm.

5 - Front mounting bolt

• 32 Nm.

6 - Door seal

NOTE:

After installing or adjusting window frame, mounting bolts must be screwed in and tightened in the sequence described in the following. Door window must be lowered to half-way before installing window frame. Insert door frame into door base carrier. Screw in bolts - 1 - and - 2 - "hand tight". Loosen bolt - 3 -. Install door seal - 6 - in window frame. Screw in bolt - 4 - and tighten it to 32 Nm. Close door and check inclination of window frame using adjusting template --> Adjusting using door adjustment template T40038/1. If necessary, the inclination can be adjusted further by loosening bolt - 4 -. Check contact area of seal in A-pillar region Inclination adjustment at A-pillar Tighten bolt - 5 - to 32 Nm.

Height adjustment at window frame

Fig. 94: Replacing Collared Shoulder Bolt
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• If height of window frame must be adjusted, then the corresponding collared shoulder bolt -arrow- must be replaced with a standard bolt.
• Now, the window frame height can be adjusted.
• Position adjusting template as shown on roof, or on upper edge of rain channel.

Fig. 95: Height Adjustment At Window Frame
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• For a correct adjustment, lower edge of window frame must be located between markings - a - , (line on template - arrow -) or - b -.
• Check/adjust inclination of window frame --> Adjusting using door adjustment template T40038/1.

Front door adjustment

Fig. 96: Front Door Adjustment
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Door position can be assessed using lower side of template T40038.
• No recess of front door - 1 - at rear door - 2 - is permitted.
• Recess of front door - 1 - at rear door - 2 - is not permitted (wind noise).

Fig. 97: Projection Of Front Door At Rear Door Must Be In Range Of Template Cut-Out
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Projection (maximum 0.8 mm) of front door at rear door must be in range of template cut-out - arrow -.

Window frame installation

NOTE:

If window frame must be removed or installed for a repair, observe the following points and the bolting sequence described afterward. The adjusting element is self-adjusting, meaning it can compensate bearing tolerances.

Fig. 98: Identifying Adjusting Element Is In Basic & End Position
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• First check basic setting of adjusting element.
• Before installing window frame, adjusting element must always be in the basic position.
• Adjusting element is in basic position in position - a -.
• Adjusting element is in end position in position - b -.

Fig. 99: Applying Sealing Strip Along Window Shaft Strip Under
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• In area of mirror base on A-pillar, a sealing strip is applied flush along window shaft strip under trim as shown.
• When removing mirror base, sealing strip must always be replaced.
• Pull off protective foil from sealing strip.
• Affix sealing strip starting from - arrow b - up to cut at front and shorten strip using scissors - arrow a -.

• Insert window frame with door window lowered to half-way into door shell.

Fig. 100: Removing/Installing Door Seal Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Screw in bolts - arrow 1 - and - arrow 2 - by hand.
• Loosen bolt - arrow 3 -.
• Install door seal into window frame.
• Screw in rear bolt through door shell and secure window frame.

• Tighten bolt to 32 Nm.
• Close door and check inclination of window frame using adjusting template in B- pillar region and adjust if necessary.

Fig. 101: Removing/Installing Bolt
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Screw in bolt - arrow - and check adjustment in A-pillar region.
• If necessary, adjust window frame at A-pillar Inclination adjustment at A-pillar
• Spacers can be slid in between window frame and door shell up to a maximum of 3mm, depending on technical assessment.
• Tighten bolt - arrow - to 32 Nm.

Fig. 102: Removing/Installing Door Seal Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Tighten collared shoulder bolts - arrow 2 - and - arrow 3 - to 32Nm.
• Also tighten bolt - arrow 3 - to 32 Nm.
• Insert bolt into adjusting element as shown in magnified area of illustration.
• Slowly screw bolt into adjusting element.

• While doing this, upper part of adjusting element unscrews and fits automatically

NOTE:

If upper part of adjusting element does not unscrew on its own, adjusting element must be replaced.

Fig. 103: Removing/Installing Adjusting Element Out/In Of Door Shell
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Replacing adjusting element

• To remove, pull adjusting element - 2 - out of door shell - 1 -.
• To install, press adjusting element in basic position with retaining pins completely into door shell at top.

Fig. 104: Placing Finger On Window Frame And Door Plate As A Check
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• While screwing the adjusting element, place a finger on window frame and door plate as a check.
• The reason for this is the distance must not change while screwing the adjusting element.

Fig. 105: Tightening Bolts Of Window Regulator Rails At Bottom
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Tighten bolts of window regulator rails at bottom to 6Nm.

Fig. 106: Identifying Pins, Cable & Door Shell
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Clip pins - arrows a - for window regulator cable reel completely into door shell.
• Clip cable - 1 - into door shell - arrow b - , otherwise rattling noises will result.

Fig. 107: Securing Door Insulation Mat Using Water Resistant Webbed Band On Upper Side
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Also secure door insulation mat using water resistant webbed band (e.g. D 004 350 A2) - arrow - on upper side as shown.
• This measure can prevent insulation mat from loosening from door during periods of operation and thus preventing drafts.

Fig. 108: Function Of Adjusting Element
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Function of adjusting element

• While screwing in bolt - 5 - , the upper part - 3 - of adjusting element screws itself out of the lower part - 2 - and compensates a gap between window frame - 4 - and door shell - 1 -.

Adjustment dimensions for front door window frame

Fig. 109: Adjustment Dimensions For Front Door Window Frame
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Window frame

• For correct door adjustment, sealing lip must make clean contact to contours at roof frame and at B- pillar, see - arrows -.

2 - Window

• Adjust door until the result is dimension - d - = 4 mm in area - c - = 365 mm.
• Dimension - d - can be checked further using door adjusting template T40038.
• Dimension - b - of rear door edge starting at B- pillar = 200 mm.

3 - Window frame

• Door window - 2 - must drive as far as dimension - a - = 7.5 mm^-1mm into window frame at B- pillar.

Door handle and door lock - front, assembly overview

Fig. 110: Door Handle And Door Lock - Front, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Mount for door handle.

• Releasing Disengage mount for door handle.

2 - Door lock

• Removing:
• Door trim removed.
• Window frame and window regulator removed --> Window frame and window regulator, removing and installing.
• To remove, unscrew multi-point bolts - 4 - and remove door lock downward.

3 - Operating rod

• Clip into door lock Engaging operating rod in door lock

4 - Socket-head bolt

• 20 Nm

5 - Lock cylinder cover

• Lock cylinder removed and cover unclipped

6 - Lock cylinder

• Removal Locking cylinder, removing

7 - Door handle

• Before disassembling, remove window frame and window regulator.
• Removal --> Door handle, removing.

8 - Actuating lever

9 - Clip

• Engage operating rod in clip, swivel clip 90° and engage at operating rod.

Locking cylinder, removing

Fig. 111: Locking Cylinder, Removing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Open driver-side door.
• Remove cover cap - 2 -.
• Turn Torx bolt arrow counter-clockwise until it stops.
• This moves the arm - 1 - toward rear and releases lock cylinder.

• Remove lock cylinder from door handle.

Door handle, removing

Fig. 112: Door Handle, Removing Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Door handle

2 - Clip

• When disassembling door handle - 1 - , unclip operating rod - 3 - here.

3 - Operating rod

• Before removing door handle, disengage at clip - 2 -.
• After installing a new door lock, first insert operating rod into casing and engage.
• Only then pull securing pin - 5 - from door lock.

4 - Casing

• To engage operating rod - 3 - , slide casing - 4 - upward.

5 - Securing pin

• Only available as replacement part.
• Pull out after installing operating rod - 3 -.

6 - Door lock

• Removal --> Door handle and door lock - front, assembly overview.

Disengage mount for door handle

Fig. 113: Disengage Mount For Door Handle
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Door trim as well as window frame and window regulator removed.
• Insert screwdriver through door plate and release slider - 2 - from door handle - 1 - in direction of arrow.

Removing trim

Fig. 114: Removing Trim
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To remove, pull up door handle - 1 - , slide out locking mechanism - 3 - in longitudinal direction using small screwdriver.
• Disengage trim - 2 - at top on the sides and remove downward from door handle.
• Installation is the reverse order of removal.

Door lock, removing

Fig. 115: Door Lock, Removing Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Socket head bolt M8

• 20 Nm

2 - Base plate

3 - Door lock

• Door trim removed.
• Window frame and window regulator removed.
• Disconnect electrical harness connector at door lock.
• If the same door lock is installed again, disengage operating rod at door handle.

• If door lock is being replaced, disengage operating rod at door lock Engaging operating rod in door lock.
• Unclip operating rod at casing from door lock.
• Unscrew multi-point bolts - 1 - and remove door lock.

4 - Release lever

5 - Bowden cable for interior door mechanism

• To install, first insert vertically into release lever as shown in the magnified area of illustration, then swivel 90° and clip into door lock to secure.

Engaging operating rod in door lock

Fig. 116: Engaging Operating Rod In Door Lock
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• When installing a new door lock, clip operating rod - 1 - into casing.
• Move slide - 2 - of casing upward to engage operating rod.
• Pull securing pin - 3 - out of door lock.

Central locking system

Component overview (Sedan)

Fig. 117: Central Locking System Component Overview (Sedan)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Front Passengers Door Control Module J387

• Integrated in window regulator.

2 - Right Rear Door Control Module J389

• Integrated in window regulator.

3 - Fuel Tank Lid Unlock Motor V155

• Removal Removing Fuel Tank Lid Unlock Motor V155

4 - Rear Lid Unlock Motor V139

5 - Left Rear Door Control Module J388

• Integrated in window regulator.

6 - Drivers Door Control Module J386

• Integrated in window regulator.

7 - Comfort System Central Control Module J393

• Before removing, disassemble left front seat
• Remove lower A-pillar trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• Remove lower A-pillar trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• Removal Removing Comfort System Central Control Module J393

8 - Front Hood Switch F266

• Component location in lock carrier

Removing Comfort System Central Control Module J393

Fig. 118: Removing Comfort System Central Control Module J393
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Left front seat and lower A- pillar trim removed.
• Ignition switched off.
• Open box - 1 - for control module.
• Disconnect harness connector from control module - 2 - and remove it.

Removing Fuel Tank Lid Unlock Motor V155

Fig. 119: Removing Fuel Tank Lid Unlock Motor V155
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical connector.
• Loosen bolts - arrows - using special tool T10010, slide actuator - 1 - toward front and remove.
• Before installing actuator, emergency release - 3 - must be slid over the locking pin.
• Locking pin of actuator must move cleanly into closed fuel filler flap - 2 -.

Component overview (Avant)

Fig. 120: Central Locking System Component Overview (Avant)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Front Passengers Door Control Module J387

• Integrated in window regulator.

2 - Right Rear Door Control Module J389

• Integrated in window regulator.

3 - Fuel Tank Lid Unlock Motor V155

• Removal Removing Fuel Tank Lid Unlock Motor V155

4 - Rear Lid Unlock Motor V139

5 - Left Rear Door Control Module J388

• Integrated in window regulator.

6 - Drivers Door Control Module J386

• Integrated in window regulator.

7 - Comfort System Central Control Module J393

• Before removing, disassemble left front seat
• Remove lower A-pillar trim. -->
  • 72 - SEAT - FRAMES
  • 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
• Remove lower A-pillar trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• Removal Removing Comfort System Central Control Module J393

8 - Front Hood Switch F266

• Component location in lock carrier

Repairing the central locking system

• Central locking system in the A4 operates electrically instead of pneumatically as before.
• Actuators in doors are integrated in the door lock and have 2 motors.
• Actuators cannot be replaced separately.
• The first motor locks the door and the second motor locks the interior door mechanism (Safe function).

• Now, doors also can no longer be opened from the interior.
• Actuators of fuel filler flap and rear lid have one motor each and cannot be replaced individually.
• After an accident in which the airbag deploys, the central locking system control module opens any doors which were locked.
• Central locking system control module is located in front of drivers seat, at left, under floor mat.

58 Rear doors/door components

Rear doors

Window frame and window regulator, removing and installing

Fig. 121: Window Frame And Window Regulator Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Window frame

• Removing:
• Remove door trim.
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
  ; front door trim
• Remove window regulator motor Window regulator motor, removing and installing or manual window regulator Manual window regulators, removing and installing.
• Disconnect electrical harness connectors.

• Remove bolts - 7 - and - 8 -.
• Remove bolts - 3 - - 4 - ; - 6 - and - 10 - and lift window frame with window regulator upward and out of door.
• Installation:
• Insert window frame and window regulator into door from above.

• Knock in the upper profile halves of door-side gasket into window frame at top.
• Loosely screw in mounting bolts - 4 - at front and rear.
• Then, loosely screw in bolts in the sequence - 3 - ; - 10 - ; - 8 -.
• Tighten collared shoulder bolts - 4 - hand tight.

• Lightly press window frame - 1 - inward at top.
• Tighten bolts - 3 - and - 10 - to 32 Nm.
• Tighten collared shoulder bolts - 4 - to 32 Nm.
• Tighten bolt - 8 - to 10 Nm.

• Tighten locating bolt - arrows - in window frame to 32 Nm.
• Knock in lower half of door seal into inner door plate.
• Secure window regulator rail with bolt - 7 - to inner door plate.
• Press threaded pin of window regulator reel through inner door plate until it engages Window regulator motor, removing and installing.

Window regulator motor, removing and installing

Fig. 122: Window Regulator Motor Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To remove, unscrew bolts - 2 - and remove window regulator motor.
• Install window regulator motor --> Motor for window regulator, removing and installing.

Manual window regulators, removing and installing

Fig. 123: Unthreading Bolts And Removing Manual Window Regulator From Inner Door Plate
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Unthread bolts - 2 - and remove manual window regulator from inner door plate.
• Install manual window regulator --> Manual window regulators, removing and installing.

Fig. 124: Upper Door Hinge Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Upper door hinge

• Torx bolt T45 - 1 - (installed from interior of vehicle) 32 Nm.
• Top door hinge - 2 -.
• Cover cap - 3 -.
• Torx bolt T45 - 4 - 32 Nm.

• Fitting bolt - 5 - T45 32 Nm.

Fig. 125: Removing/Installing Lower door hinge
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lower door hinge

• B-pillar trim removed.
• Torx bolts T45 - 1 - 32Nm bolted to B-pillar from interior of vehicle.
• Lower door hinge - 2 -.
• Cover cap - 3 -.

• Torx bolt T45 - 4 - 32Nm.
• Fitting bolt T45 - 5 - 32Nm.
• Re-grease lubrication points - arrows - in service interval.
• Front door - 6 -.

Window regulator and door window, separating

Fig. 126: Window Regulator And Door Window, Separating Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Window frame

• Removing:
• Remove door trim.
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
  ; front door trim
• Window frame removed together with window regulator from door --> Window frame and window regulator, removing and installing.
• Door window - 4 - removed

• To remove, unscrew countersunk screw - 7 - and remove window regulator from window frame.
• Installation:
• When installing, make sure that guide rail, arrow - A - , runs parallel to guide arrow - B -.
• Tighten bolts - 7 - to 6 Nm.

2 - Triangular panel

• Before removing, disassemble window frame and window regulator.
• Unscrew bolt - 3 - and remove panel sideways.

3 - Countersunk screw

• 5Nm

4 - Window

• Removing:
• Drive down door window fully.
• Unscrew bolts - 5 - and remove door windows from window regulator.
• Installation:

• Insert window into window regulator.
• Screw bolts - 5 - into window regulator, but do not tighten yet.
• Drive door window upward into window frame.
• Pull door window toward front into window guide on window frame at B-pillar and tighten bolts - 5 - to 4Nm.

5 - Socket head bolt

• 4Nm^-0.5Nm

6 - Window regulator

• Window frame removed together with window regulator from door --> Window frame and window regulator, removing and installing.
• Door window removed.
• To remove, unscrew countersunk screw - 7 - and remove window regulator from window frame.

Motor for window regulator, removing and installing

Removing

• Door trim removed. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

NOTE:

Motor for window regulator can be removed or installed in every position of motor or side window. Before removing motor, disconnect electrical harness connectors.

Fig. 127: Window Regulator Motor Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove Torx bolts - 2 - T30 and remove motor.

Installing

• When installing, make sure that threaded pins - arrows - are engaged in inner door plate.
• Slide on window regulator motor -1- and secure with bolts - 2 -.
• Tightening torque 3.5 Nm

NOTE:

Only switch ignition on and off after installing motor and connected wires. Then move door window upward to stop and keep pressing switch for window regulator for approx. 2 seconds longer. This position is the base position and the high- and low-running function is activated.

Manual window regulators, removing and installing

• Door trim removed. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

Fig. 128: Unthreading Bolts And Removing Manual Window Regulator From Inner Door Plate
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Unthread bolts - 2 - and remove manual window regulator from inner door plate.
• When installing, tighten bolts to 3.5 Nm.

Rear door, adjusting

Adjustment in longitudinal direction

Fig. 129: Adjustment In Longitudinal Direction
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Adjustment in longitudinal direction is performed by loosening hinge bolts - arrow A - of B-pillar at top of door hinge or/and bottom and sliding doors - 2 - (over-sized holes in hinge or in B-pillar).
• Tightening torque: 32 Nm
• Door hinge - 1 -.
• A-pillar - 3 -.

• Door - 2 -.

NOTE:

Illustration shows lower door hinge.

Adjustment to center of vehicle

NOTE:

A fitting bolt is installed at each upper and lower door hinge (door side). When repairing, an adjustment is therefore not necessary under normal circumstances. If an adjustment should become necessary anyway, fitting bolts can be replaced with bolts of the same size, length and toughness .

Fig. 130: Adjustment In Longitudinal Direction
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• The adjustment to vehicle center occurs by loosening hinge bolts (arrow -B-) at top and/or at bottom of door and shifting the doors (elongated holes in hinge).
• Tightening torque: 32 Nm

NOTE:

In rear portion of door, adjust door depth (relative to vehicle center) via striker.

Adjusting via striker

Fig. 131: Adjusting Via Striker
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Loosen bolts - 2 -.
• Use the markings (- arrows a - and - arrows c -) for side adjustment.
• Slide striker - 1 - until the door is flush with the contour of the chassis.

NOTE:

Door may only be adjusted for depth (towards car interior) and not for height.

• Use the markings (- arrows b - and - arrows d -) for height adjustment.
• Striker must align in door lock center for correct adjustment.
• Tighten bolts to 25 Nm.

Adjustment dimensions for rear door window frame

Fig. 132: Adjustment Dimensions For Rear Door Window Frame
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Window frame

• For correct door adjustment, sealing lip must make clean contact to contours at roof frame and at A-pillar, see - arrows -.

2 - Window

• Adjust door until the result is dimension - c - = 4 mm in area - b - = 300 mm.
• Dimension - c - can be tested further using a gauge.
• Dimension - a - of front door edge starting at B-pillar = 200 mm.

3 - Window frame

• Door window - 2 - must drive as far as dimension - d - = 7.5mm^-1mm into window frame at B-pillar.

Adjusting using Door adjustment template T40038/1

Special tools, testers and auxiliary items required

Fig. 133: Template T40038
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Template T40038

• Use the door adjustment Template T40038 as described in the following for testing (e.g. for wind noises) and for adjusting door.

Fig. 134: Using Standard Bank Card To Drive Off Contact Area Of Sealing Lip To Roof Trim Molding With Light Pressure
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Testing sealing lip/roof trim molding contact

• Using a standard bank card, drive off contact area of sealing lip to roof trim molding with light pressure.
• When doing this, card must not sink in between sealing lip - 1 - and roof trim molding - 2 -.

Fig. 135: Identifying Template Has Points Of Different Lengths At So That Side Adjustment Of Door Can Be Tested
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Template has points of different lengths at - arrows a - and - arrows b - so that side adjustment of door can be tested.
• The upper point - arrow a - on the side with the cut-out - arrow c - at bottom is the longer side (max. marking).
• This side is used to check whether the window frame is located too far outward in relation to the chassis.

Fig. 136: Positioning Template With Cut-Out Facing Door Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Position template at dimension - a - = 200 mm and with cut-out - arrow - facing door window
• Make sure that points - 1 - and - 3 - make contact.
• At point - 2 - of template, there must be a gap.
• In this position (max), doors are adjusted to farthest outward point within tolerance range.

• If there is no gap at point - 2 - , or there is a gap at point - 1 - , the window frame is set too far outward and must be adjusted.

Fig. 137: Identifying Template Has Points Of Different Lengths At So That Side Adjustment Of Door Can Be Tested
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• The upper point - arrow b - opposite the side with cut-out - arrow c - at bottom is the shorter side (min. marking).
• This side is used to check whether the window frame is located too far inward in relation to the chassis.
• Position template at dimension - a - = 200 mm and with cut-out - arrow - turned away from door window as depicted in magnified areas of illustration.

Fig. 138: Making Sure Points Make Contact On Door Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Make sure that points - 2 - and - 3 - make contact on door window.
• At point - 1 - of template, there must be a gap.
• In this position (min), doors are adjusted to farthest inward point within tolerance range.
• If point - 1 - has no gap, or if template cannot be brought into contact at point - 2 - , window frame is set too far inward and must be adjusted.

Panel gap dimensions

Special tools, testers and auxiliary items required

Fig. 139: Identifying Adjustment Gauge 3371
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Adjusting gauge 3371

Fig. 140: Panel Gap Dimensions
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Dimension - E - = 3.5 mm ± 0.5 mm
• Dimension - F - = 4.5 mm ± 0.5 mm
• Flush adjustment of rear door to front door must be in the range of 0 mm to 1 mm recess
• Flush adjustment of rear door to side panel must be in the range of 0 mm to 1 mm projection

Door handle and door lock - rear, assembly overview

Fig. 141: Door Handle And Door Lock - Rear, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Mount for door handle

• Releasing Disengage mount for door handle.

2 - Door handle

• Before disassembling, remove window frame and window regulator.
• Removal --> Window frame and window regulator, removing and installing.

3 - Operating rod

• Clip into door lock Engaging operating rod in door lock.

4 - Clip

• Engage operating rod in clip, swivel clip 90° and engage at operating rod.

5 - Socket-head bolt

• 20 Nm

6 - Door lock

• Removing:
• Door trim removed.
• Window frame and window regulator removed --> Window frame and window regulator, removing and installing.
• To remove, unscrew multi-point bolts - 5 - and remove door lock downward.

Engaging operating rod in door lock

Fig. 142: Engaging Operating Rod In Door Lock
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• When installing a new door lock, clip operating rod - 1 - into casing - 2 -.
• Move slide - 3 - of casing - 2 - upward to engage operating rod.
• Pull securing pin - 4 - out of door lock.

Door handle, removing

Fig. 143: Door Handle, Removing Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Door handle

2 - Clip

• When disassembling door handle - 1 - , unclip operating rod - 3 - here.

3 - Operating rod

• Before removing door handle, disengage at clip - 2 -.
• After installing a new door lock, first insert operating rod into casing and engage.
• Only then pull securing pin - 5 - from door lock.

4 - Casing

• To engage operating rod - 3 - , slide casing - 4 - upward.

5 - Securing pin

• Only available as replacement part.
• Pull out after installing operating rod - 3 -.

6 - Door lock

• Removal --> Door handle and door lock - rear, assembly overview.

Disengage mount for door handle

Fig. 144: Disengage Mount For Door Handle
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Door trim as well as window frame and window regulator removed.
• Insert screwdriver through door plate and release slider - 2 - from door handle - 1 - in direction of arrow.

Removing trim

Fig. 145: Removing Trim
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To remove, pull up door handle - 1 - , slide out locking mechanism - 3 - in longitudinal direction using small screwdriver.
• Disengage trim - 2 - at top on the sides and remove downward from door handle.
• Installation is the reverse order of removal.

Door lock, removing

Fig. 146: Door Lock Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear doors

2 - Grommet

3 - Base plate

4 - Door lock

• Door trim removed.
• Window frame and window regulator removed.
• Disconnect electrical harness connector at door lock.
• If the same door lock is installed again, disengage operating rod at door handle.

• If door lock is being replaced, disengage operating rod at door lock Engaging operating rod in door lock.
• Unscrew multi-point bolts - 6 - and remove door lock.

5 - Bowden cable for interior door mechanism

• Installing Engaging Bowden cable in door lock

6 - Socket head bolt M8

• 20 Nm

Engaging Bowden cable in door lock

Fig. 147: Engaging Bowden Cable In Door Lock
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To install, first insert Bowden cable - 2 - vertically into release lever - 3 - as shown in the magnified area of illustration, then swivel 90° and clip into door lock - 1 - to secure.

Engaging operating rod in door lock

Fig. 148: Engaging Operating Rod In Door Lock
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• When installing a new door lock, clip operating rod - 1 - into casing.
• Move slide - 2 - of casing upward to engage operating rod.
• Pull securing pin - 3 - out of door lock.

60 Sunroof

Sunroof, servicing

Assembly overview

Fig. 149: Sunroof Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Combination bolt (T 25)

• 3Nm

2 - Sunroof motor

• The sunroof motor casing must be removed at molded headliner before removing motor -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

3 - Frame

• Detach headliner before removing
• Removing and installing is described in -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

4 - Wind deflector

• Removal --> Wind deflector, removing and installing

5 - Extension spring for wind deflector

Wind deflector, removing and installing

Removing:

• Slide sunroof completely open

Fig. 150: Wind Deflector, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Press wind deflector - 2 - out of bracket - 3 - in - direction of arrow -.
• Lift wind deflector towards rear and out of sunroof opening.

Installation:

Fig. 151: Laying Spring Around Retaining Pins On Wind Deflector
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Lay spring - 3 - around retaining pins on wind deflector - 2 -.
• Also place spring in groove on wind deflector.

NOTE:

Bracket - 1 - is shown in detached condition for the sake of diagram clarity.

Fig. 152: Wind Deflector, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Slide in stop - 1 - of wind deflector - 2 - toward front under roof cut-out.
• Insert a wind deflector retaining pin into bracket - 3 -.
• Push opposite side of wind deflector slightly towards center of vehicle to snap second retaining pin into bracket.

Sunroof panel, removing and installing (assembly overview)

Fig. 153: Sunroof Panel, Removing And Installing (Assembly Overview)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Sliding headliner

• Only for vehicles with glass panel
• For vehicles with solar panel, slide into sunroof toward rear
• Detach headliner before removing
• Removal --> Sunroof headliner, removing and installing.

2 - Spring for sliding headliner

• Detach cover frame for molded headliner before removal. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• To remove, remove countersunk screw - 7 - at front and rear.
• Push front spring - 2 - forward and rear spring rearward, remove both from sliding headliner.
• Pull sliding headliner on opposite guide track out of side and lift out.

3 - Lower trim

• Removal --> Trim, removing and installing.

4 - Upper trim

• Removal --> Trim, removing and installing.

NOTE:

For vehicles as of calendar week 27/2002, a boot is installed in place of upper/lower panel. Removal and installation is described on --> Boot, removing and installing (vehicles as of CW 27/2002 >).

5 - Sunroof panel

• To remove, detach headliner
• Remove left and right panels --> Trim, removing and installing.
• Remove Torx bolts (T 25) left and right at sunroof panel and lift out panel --> Sunroof panel, removing.
• Adjusting --> Sunroof panel, adjusting.

6 - Panel seal

• Removal --> Panel seal, replacing.

7 - Countersunk screw

• 1.5Nm.

Sunroof headliner, removing and installing

• Sunroof panel removed

Fig. 154: Removing Bolt Of Spring Clip
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolt of spring clip - 1 -.
• In vehicles with solar sunroof, unscrew bolt and remove guide.

Fig. 155: Sliding Headliner Back Slightly And Remove Spring Clip Toward Front
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Slide headliner back slightly and remove spring clip - 1 - toward front.
• Slide out rear spring clip toward rear.
• Remove headliner upward.

Trim, removing and installing

Removing

• Tilt sunroof open
• Push sliding headliner fully back

Fig. 156: Unclip Lower Panel At Rear From Locking Mechanism And Slide Toward Front
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Unclip lower panel -1- at rear in direction of arrow - A - from locking mechanism and slide toward front - arrow B -.
• Remove lower trim from guide track by pulling towards center of vehicle.
• Unclip front and center of trim - 2 - and remove in direction of arrow.

Installing

Fig. 157: Pressing On Lower Panel Onto Upper Edge Of Retaining Rail
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Press on lower panel - 1 - onto upper edge - arrows - of retaining rail - 2 -.

Fig. 158: Sliding Lower Panel Toward Rear Until Hook Catches In Coupling Plate
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Slide lower panel - 1 - toward rear in - direction of arrow - far enough until hook catches in coupling plate - 2 -.
• Press in upper trim in link guide.

Boot, removing and installing (vehicles as of CW 27/2002 >)

Removing

• Tilt sunroof open
• Slide sunroof headliner completely toward rear.

Fig. 159: Pulling Off Boot Starting At Top From Glass Sunroof Panel And From Frame
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull off boot starting at top from glass sunroof panel and from frame - arrows -.

Installing

Installation is the reverse of removal, noting the following:

• Press on lower panel - 1 - onto upper edge - arrows - of retaining rail - 2 -.
• Press on lower panel - 1 - onto upper edge - arrows - of retaining rail - 2 -.

NOTE:

Make sure especially that boot is seated correctly in rear mounts on glass sunroof panel.

Sunroof panel, removing

• Trims removed

Fig. 160: Removing Torx Bolts (T 25) On Both Sides And Lift Panel Upward And Out
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove Torx bolts (T 25) - arrows - on both sides and lift panel upward and out.
• When installing, tightening torque 4.5) 0.5 Nm.

Sunroof panel, adjusting

Fig. 161: Sunroof Panel, Adjusting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Perform height adjustment at front and rear according to illustration to prevent wind noise.
• Check height adjustment at each point, left and right, where rounded portion of roof cut-out merges with straight portion.
• Sunroof panel should not be higher than roof at any point at front or lower than roof at any point at rear.
• When adjusting sunroof panel height, start by running sunroof from open position (not tilted open) into closed position.

Panel seal, replacing

• Sunroof panel - 3 - removed.
• Remove panel seal - 2 - from sunroof panel - 3 -.

Fig. 162: Identifying Sunroof panel,
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Push new panel seal into sunroof panel - 3 - starting at rear of panel edge in center.

NOTE:

Coat edge of panel with soapy water to facilitate installation of seal.

"Zero" position (link guide), adjusting

• Motor is removed, electrical harness connections connected.
• Move rotary control to "roof closed" position.
• Sunroof motor runs to "zero" position and cuts out automatically
• Install motor in this position with sunroof closed

"Zero" position of sunroof motor (link guide), checking and adjusting

Checking

Zero position can only be checked when sunroof panel is installed.

• Trims removed
• Slide sunroof back and into closed position.
• On vehicles with glass panel, slide sliding headliner completely toward rear.
• In vehicles with solar panel, drive back sunroof panel.

Fig. 163: Pulling Sunroof Headliner Slightly Toward Rear In And Sliding In Headliner Toward Rear
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull sunroof headliner slightly toward rear in - direction of arrow - and slide in headliner toward rear.
• Close sunroof.

Fig. 164: Guiding Pins In Center On Tilting Mechanism Must Align With Marking On Link Guide
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• For a correct "zero" position, guide pins - 1 - in center on tilting mechanism must align with marking - arrow - on link guide - 2 -.
• In vehicles with solar panel, slide headliner with panel closed from rear toward front until it engages.

Fig. 165: Coupling Plate Must Be Slid Into Guide On Sunroof Headliner At Rear
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• When doing this, coupling plate must be slid into guide on sunroof headliner at rear.
• When sunroof is tilted open, headliner is also tilted open.

Water drain hoses

Cleaning water drain hoses

NOTE:

For cleaning, it is recommended that you create your own assisting tool out of a speedometer inner cable, approx. 2300 mm (90.5 in.) long.

Fig. 166: Identifying Front/Rear Water Drain Hose
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Front water drain hose

• Front water drain hoses - 1 - are routed in A-pillar and end between door and A-pillar. Cleaning is performed at cut out for sunroof.

2 - Rear water drain hose

• Rear water drain hoses - 2 - are routed in C-pillars and end at sides behind bumper cover. Cleaning is performed from lower hose end. To do this, bumper cover must be removed --> Bumper, removing and installing.

63 Bumper

Front bumper

Front bumper, removing and installing

Special tools, testers and auxiliary items required

Fig. 167: Socket 40078
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Socket 40078
• Use socket 40078 to screw in cap nuts on fender bolts.

Up to Vehicle Identification Number (VIN) 400 000

Fig. 168: Front Bumper Remove/Install Components (Up To Vehicle Identification Number (VIN) 400 000)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Socket head bolt

• 26 Nm

2 - Air intake grille

• S4, removing Air intake grille for S4.

3 - Clamping pin

• To disassemble, rotate 180°.

4 - Side impact molding

• Replace
• Side impact moldings are secured to bumper with double-sided adhesive tape.
• It is not possible to remove without destroying.
• To remove, pull side impact molding away from bumper.

• Remove any residual adhesive on bumper.
• Installation on same bumper
• Bumper must be free of dust and grease in adhesion area
• Clean bumper using petroleum spirits or cleaning solution D 009 401 04.

NOTE:

Centering holes for centering pins for the exact installation of side impact moldings are already present in bumper Position centering pins with double-sided adhesive tape onto markings of side impact molding Adhering centering pins on side impact molding. Remove protective foil from double-sided adhesive tape for side impact molding. Press side impact molding with attached centering pins firmly onto bumper over the entire surface. Installing on new bumper

NOTE:

Centering holes for side impact molding must be drilled on the new bumper before painting. Position centering holes for side impact moldings on bumper --> Centering holes for side impact moldings. Apply side impact moldings to bumper as described above.

5 - Bumper

• With crossmember
• Bumper, removing and installing --> Front bumper, removing and installing
• Removing and installing crossmember --> Crossmember, removing from cover and installing
• Separating two-piece bumper cover --> Two-piece bumper cover, separating

• Positioning license plate mounting holes Positioning license plate mounting holes

6 - Guide piece

• Removing and installing --> Guide piece, removing and installing

7 - Expanding clip

• 6x
• Must be inserted into fender before installing bumper cover

8 - Grommet

• 2x
• Must be inserted into fender before installing bumper cover

9 - Shock absorber

• self-aligns to correct height in crossmember --> Bumper, mounting to shock absorber

10 - Fender

11 - Special nut

• 4 Nm

12 - Wheelhousing liner

13 - Bolt

• 1 Nm
• 2x

As of Vehicle Identification Number (VIN) 400 001

Fig. 169: Front Bumper Remove/Install Components (As Of Vehicle Identification Number (VIN) 400 001)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Combination bolt

• 6 Nm

2 - Socket head bolt

• 23 Nm

3 - Bumper

• Bumper cover removed.
• To remove, unscrew socket head bolts - 2 -.
• Disconnect harness connectors to signal horns and remove bumper from shock absorbers toward front.

4 - Pop rivet

5 - Signal horn

• To remove, drill off rivet heads.

6 - Support piece

• Before assembling bumper cover, adjustment screw for support piece must be adjusted Adjusting support piece
• To disassemble, drill off pop rivet heads.

7 - Pop rivet

8 - Signal horn

9 - Brace for fender

10 - Guide piece

• Side piece of bumper cover must be clipped in between fender and guide piece Removing guide piece

11 - Torx screw

• 1 Nm

12 - Bumper cover

NOTE:

While installing, the following sequence described for assembling/bolting must be observed for correct assembly.

• Set cover onto vehicle and first clip the left and right side piece into guide parts - 10 -.
• Tighten cap nuts on fender bolts to 4 Nm Fender bolts.
• Tighten bolts - 12 - to wheelhousing liner.
• Loosely thread in bolts - 1 -.

• Close hood and check cover for projection and recess.
• If necessary, correct the cover position and tighten bolts - 12 - to 6 Nm.
• Tighten bolt on support piece to 2 Nm.
• Bumper, removing and installing --> Front bumper, removing and installing

• Removing and installing crossmember --> Crossmember, removing from cover and installing

Fender bolts

Fig. 170: Installing Fender Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Make sure when installing that the clips - 2 - are inserted onto threaded pins.
• Tighten cap nuts - 4 - to 4 Nm after inserting bumper cover - 1 - into fender - 3 -.

Adjusting support piece

Fig. 171: Adjusting Support Piece
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Before installing bumper cover - 1 - , adjust adjustment screw - 3 - for support piece - 5 - to dimension - a - = 21 mm +1 mm.
• Mounting bracket - 4 - must be screwed on completely (left-hand thread) for this.
• Adjustment screw - 3 - and mounting bracket - 4 - belong to delivery casing for support piece - 5 - , there are no replacement parts.
• While screwing in bolt - 3 - , mounting bracket - 4 - screws out and holds the carrier part - 2 - of bumper cover - 1 - in the designated position.

• Support piece - 5 - is secured to bumper - 6 - with pop rivets.

Clamping pins for noise insulation

Fig. 172: Clamping Pins For Noise Insulation
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• When removing bumper cover - 1 - , rotate clamping pins - 2 - 180° and pull out of speed nuts - 4 - of noise insulation - 3 -.

Removing guide piece

Fig. 173: Removing Guide Piece
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Bumper cover removed
• Unscrew bolts - 3 - and pull guide piece - 2 - downward out of fender - 1 -.
• When installing, cover - 4 - for bumper must engage cleanly in guide piece.

Brace for wheelhousing liner

Fig. 174: Brace For Wheelhousing Liner
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• For mounting front wheelhousing liner - 3 -.
• When installing brace - 1 - , tighten bolt - 2 - to 10 Nm.

Air intake grille for S4

Fig. 175: Air Intake Grille For S4
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove phillips head bolt - arrow -.
• Press air intake grille - 2 - on the inside of bumper cover - 2 - as shown toward rear out of locking mechanism.
• Remove air intake grille toward front out of bumper cover.

Radiator grill, removing and installing

Assembly overview

Fig. 176: Radiator Grill, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Bumper cover

2 - Radiator grille

• Bumper cover removed

3 - Trim for radiator grille

4 - License plate holder

• To disassemble from rear side, unclip from radiator grille

Fig. 177: Removing Radiator Grille
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing radiator grille

• Bumper cover removed
• Unscrew bolts - arrows - around edge and pull radiator grille from bumper cover.
• When installing, tighten bolts to 1.5 Nm.

Fig. 178: Removing Panel For Fog Lights
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing panel for fog lights

• Disengage locking mechanisms - arrows - and pull off panel toward vehicle interior.

Fig. 179: Disengaging Fog Lights Locking Mechanisms
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fog lights removed.

• Disengage locking mechanisms - arrows - and pull off panel toward outside.

Fig. 180: Disengaging Covers Locking Mechanisms
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Covers are divided into two parts.

Disengage locking mechanisms - arrows - and pull off cover toward outside.

Centering holes for side impact moldings

Up to Vehicle Identification Number (VIN) 400 000

Fig. 181: Centering Holes For Side Impact Moldings
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Front bumper

• Position hole to vehicle outside - arrow B - according to marking on bumper.

NOTE:

If there is no marking in this position, the long hole (as depicted in illustration) must be manufactured at upper/outer edge, according to the lines on bumper Positioning centering holes. Position hole to vehicle center - arrow A - according to marking on bumper.

Positioning centering holes

Fig. 182: Positioning Centering Holes
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Position of long holes is indicated by markings on bumper.
• Long hole must be aligned to dimensions - a - = 8.5 mm and b = 15.5 mm as shown
• If there is no marking in this area, the long hole must be aligned according to the indicated lines on bumper as shown, with upper edge to horizontal line and with outer edge to vertical line.
• Dimension - a - = 8.5 mm.

• Dimension - b - = 15.5 mm.

Adhering centering pins on side impact molding

Fig. 183: Adhering Centering Pins On Side Impact Molding
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Adhesive and centering pin are in delivery casing of side impact molding.

• Remove protective foil from the double-sided adhesive - 3 - and adhere it onto centering pin - 4 -.
• Remove second protective foil and position centering pin onto marking - arrow - on side impact molding.
• Remove protective foils from double-sided adhesive strips - 2 - and press side impact molding - 1 - onto bumper.

Positioning license plate mounting holes

Fig. 184: Positioning License Plate Mounting Holes
Courtesy of VOLKSWAGEN UNITED STATES, INC.

There are four centering punch marks on license plate area of bumper cover which must be drilled through for securing a license plate (dimensions 115 x 520 mm).

If centering punch marks are not visible, proceed as follows:

• Determine vertical bisecting line from Audi emblem to center of grill on bumper.
• Determine horizontal bisecting line:

• Dimension - a - = dimension - a -

• Determine mounting points for license plate symmetrically as follows:

• Dimension - x - = 139 mm
• Dimension - y - = 62 mm

Front bumper, removing and installing

Removing

• To ease repair work, remove front noise insulation completely.

Fig. 185: Identifying Quick-Release Fasteners And Noise Insulation
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• For this purpose, remove bolts and quick release screws - 1 - and - 2 -. Rear noise insulation (quick release screws - 3 -) remains installed.
• Remove left and right front wheels.

Fig. 186: Loosening Left/Right Wheelhousing Liners In Front Area
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Loosen left and right wheelhousing liners in front area - arrows -.

Fig. 187: Pulling Back Wheelhousing Liner & Unclipping Bumper Rear Edge From Catch
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull back wheelhousing liner - arrow A -.
• Remove bolt - 2 - and nuts - 1 -.
• Unclip bumper rear edge from catch - arrow B -.
• Repeat procedure on opposite side of the vehicle.

Fig. 188: Releasing Catches Using Screwdriver And Removing Air Intake Grille On Left/Right On Bottom Part Of Bumper
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Release catches - 1 - to - 4 - using a screwdriver - arrow - and remove air intake grille on left and right on bottom part of bumper.

Fig. 189: Unthreading Left/Right Retaining Bolts For Bumper
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Unthread left and right retaining bolts for bumper approx. 15 rotations - arrow -.
• Pull lock carrier slightly toward front.

Fig. 190: Disconnecting Hose To Headlight Cleaning System & Harness Connector(s) To Bumper
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• If installed, disconnect hose - 1 - to headlight cleaning system and reserve washer fluid in a clean container for re-use.
• Disconnect harness connector(s) - 2 - to bumper.

Installing

Installation is the reverse of removal, noting the following:

NOTE:

Before installing bumper, check for the presence of threaded pins at bumper rear edge as well as expanding clips and sleeves in the fenders.

Fig. 191: Removing/Installing Hose To Headlight Cleaning System & Harness Connector(s) To Bumper
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Slide bumper onto shock absorber and re-connect hose - 1 - of headlight cleaning system and electrical harness connectors - 2 -.
• Move bumper into installation position. Make sure that the threaded pins in bumper side edges engage into holes at the fenders.

Fig. 192: Pulling Back Wheelhousing Liner & Engaging Bumper Rear Edge Into Catch
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull back wheelhousing liner - arrow A -.
• Engage bumper rear edge into catch - arrow B -.
• Tighten nuts - 1 - to 4 Nm and bolt - 2 - to 1 Nm.
• Repeat procedure on opposite side of the vehicle.

Fig. 193: Removing/Installing Left/Right Retaining Bolts For Bumper
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Tighten left and right retaining bolts for bumper to 23 Nm - arrow -.
• Install left and right air intake grille on bumper.

Rest of installation is performed in the reverse order of removal.

Bumper, mounting to shock absorber

Up to Vehicle Identification Number (VIN) 400 000

NOTE:

Shock absorber is self-adjusting, meaning it can compensate bearing tolerances in height between bumper and shock absorber when screwing in the socket head bolt. This holds and secures the front bumper automatically in the previously adjusted position when screwing in the socket head bolt - 1 -. In vehicles as of Vehicle Identification Number (VIN) 400 001, the self-adjusting height compensation has been discontinued.

Fig. 194: Bumper, Mounting To Shock Absorber Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Socket head bolt

• 23 Nm

2 - Lower carrier bushing

• Plastic part pressed into adjusting screw.
• No replacement part available

3 - Lower adjusting screw

• Before assembling bumper, screw in completely but do not tighten.
• Left-hand thread
• No replacement part available

4 - Lower threaded bushing

• Secured against falling out with securing pin.
• No replacement part available

5 - Securing pin

• No replacement part available

6 - Shock absorber

• Removing and installing --> Shock absorber, removing and installing.

7 - Upper threaded bushing

• Secured against falling out with securing pin.
• No replacement part available

8 - Upper adjusting screw

• Screw in completely before assembling bumper.
• Right-hand thread
• No replacement part available

9 - Cover

• Removing and installing --> Front bumper, removing and installing.

10 - Nut

• Belongs to crossmember delivery casing.

11 - Upper carrier bushing

• Plastic part pressed into adjusting screw.
• No replacement part available

12 - Cross member

• Removing from cover and installing --> Crossmember, removing from cover and installing

Guide piece, removing and installing

Up to Vehicle Identification Number (VIN) 400 000

Fig. 195: Guide Piece Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Guide piece

• Bumper removed.
• To remove, remove bolts - 2 -.

2 - Bolt

• 1.5 Nm

3 - Clip

4 - Cover

• Removal --> Front bumper, removing and installing
• When installing, cover must engage cleanly in guide piece - 1 -.

5 - Special nut

• 4 Nm
• Only accessible after loosening front half of wheelhousing liner.

Crossmember, removing from cover and installing

• Bumper removed.
• Remove signal horn - 4 -.

Fig. 196: Crossmember, removing from cover and installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect hose - 5 - of headlamp cleaning system on both sides (press release buttons).
• Unscrew bolts - 3 - of right spray jet for headlamp cleaning system - spray jet remains installed.
• Remove bolts - 1 - (qty. 5).
• Pry off retaining clips - 2 - (qty. 3).

• Swivel spray jet for headlamp cleaning system to the side and remove crossmember from bumper cover.

Two-piece bumper cover, separating

• Bumper removed.

Fig. 197: Two-Piece Bumper Cover, Separating
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Unscrew bolt - 2 - on both sides.
• Release catches for center part of air intake grille and remove it.
• Release catches - arrows - and remove lower part - 1 - of bumper cover.

Shock absorber, removing and installing

• Bumper removed.

Fig. 198: Shock Absorber Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove combination bolts - 2 -.
• Unscrew nut - 3 - and pull shock absorber - 1 - from longmember.
• When installing, tighten combination bolts - 2 - to 50 Nm and hex nut - 3 - to 4 Nm.

Rear bumper (Sedan)

Bumper, removing and installing

Up to Vehicle Identification Number (VIN) 400 000

Fig. 199: Rear Bumper (Sedan) Remove/Install Components (Up to Vehicle Identification Number (VIN) 400 000)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Combination bolt

• 18 Nm

2 - Bumper

• Bumper cover removed.

Remove combination bolts - 1 - and pull out bumper toward rear.

3 - Cover

• Two-piece version
• One-piece version (for USA)
• Removing:
• Remove side luggage compartment trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

• Disconnect electrical harness connectors to parking aid sensors at control module (under tail light, left side).
• Remove cap nuts - 9 - and - 10 -.
• Remove combination bolts - 4 -.
• Unscrew wheel housing liners - 8 - in rear area.

• Remove bolts left and right on guide piece - 6 -
• Unscrew bolts - 7 - from wheelhousing liner
• Unclip cover side-pieces on guide piece.
• Remove cover.

• Separating two-piece cover:
• Drill off rivet heads from pop rivets at left and right.
• Disengage locking tabs and pull spoiler out of cover.

4 - Combination bolts

• 4 Nm

5 - Grommet

• Grommets must be pressed in before assembling cover.

6 - Guide piece

• Removing and installing --> Guide piece, removing and installing

7 - Sheet-metal screw

• 2 Nm

8 - Wheelhousing liner

9 - Cap nut

• 4 Nm

10 - Cap nuts

• 4 Nm

As of Vehicle Identification Number (VIN) 400 001

Fig. 200: Rear Bumper (Sedan) Remove/Install Components (As Of Vehicle Identification Number (VIN) 400 001)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Cover

• Removing:

• Remove side luggage compartment trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• Disconnect electrical harness connectors to parking aid sensors at control module (under tail light, left side).
• Remove special nuts - (accessible from luggage compartment).
• Remove special nuts - Cap nuts- (accessible from luggage compartment).

• Unscrew wheel housing liners in rear area.
• Remove bolts left and right on guide piece - 3 -
• Unclip cover side-pieces on guide piece.
• Remove cover.

• Separating two-piece cover:
• Drill off rivet heads from pop rivets at left and right.
• Disengage locking tabs and separate both pieces of cover.

2 - Grommet

• Grommets must be installed before assembling cover.

3 - Guide piece

4 - Combination bolts

• 1.5 Nm

5 - Expanding rivet

• Pressed into side panel at bottom

6 - Combination bolt

• 18 Nm

7 - Base plate

• Must always be installed.

8 - Combination bolt

• 18 Nm

9 - Right holder for bumper

• Bumper removed
• Remove combination bolt - 8 - and pull shock absorber out of bumper.

10 - Hex nut

• 18 Nm
• Counterhold when tightening combination bolt - 8 -.

11 - Bracket

• Riveted to bumper.

12 - Pop rivet

13 - Left holder for bumper

• Bumper removed
• Remove combination bolt - 8 - and pull shock absorber out of bumper.

14 - Bumper

• Cover - 1 - removed.
• Remove combination bolts - 6 - and pull bumper toward rear out of longmembers.

Country version

Fig. 201: Rear Bumper (Sedan) Remove/Install Components (Country Version)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Cover

• Removing:

• Remove side luggage compartment trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• Disconnect electrical harness connectors to parking aid sensors at control module (under tail light, left side).
• Remove special nuts - (accessible from luggage compartment).
• Remove special nuts - Cap nuts- (accessible from luggage compartment).

• Unscrew wheel housing liners in rear area.
• Remove bolts left and right on guide piece - 3 -
• Unclip cover side-pieces on guide piece.
• Remove cover.

• Separating two-piece cover:
• Drill off rivet heads from pop rivets at left and right.
• Disengage locking tabs and separate both pieces of cover.

2 - Special nut

• 4 Nm

3 - Guide piece

4 - Combination bolts

• 1.5 Nm

5 - Expanding rivet

• Pressed into side panel at bottom

6 - Combination bolt

• 18 Nm

7 - Base plate

• Must always be installed.

8 - Combination bolt

• 30 Nm

9 - Right shock absorber

• Bumper removed
• Remove combination bolt - 8 - and pull shock absorber out of bumper.

10 - Hex nut

• 30 Nm
• Counterhold when tightening combination bolt - 8 -.

11 - Bracket

• Riveted to bumper.

12 - Pop rivet

13 - Left shock absorber

• Remove combination bolt - 8 - and pull shock absorber out of bumper.

14 - Bumper

• Cover - 1 - removed.
• Remove combination bolts - 6 - and pull bumper toward rear out of longmembers.

Cap nuts

Fig. 202: Cap Nuts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove cap nuts - 1 - and - 2 - for bumper cover disassembly.
• Cap nut - 2 - only installed in Avant models.
• When installing, tighten cap nuts to 4 Nm.

Side impact moldings, replacing

Assembly overview

Fig. 203: Side Impact Moldings, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Bolt

• 1 Nm

2 - Wheelhousing liner

3 - Cap nut

• 4 Nm

4 - Cap nut

• 4 Nm

5 - Guide piece

6 - Grommet

• Must be pressed in before assembling cover - 9 -.

7 - Trim molding

8 - Bolt

• 2 Nm

9 - Cover

• Removal Bumper, removing and installing

10 - Side impact molding

• Replace
• Side impact moldings are secured to bumper with double-sided adhesive tape.
• It is not possible to remove without destroying.
• To remove, pull side impact molding away from bumper.

• Remove any residual adhesive on bumper.
• Installation on same bumper
• Bumper must be free of dust and grease in adhesion area
• Clean bumper using petroleum spirits or cleaning solution D 009 401 04.

• Position centering pins with double-sided adhesive tape onto markings of side impact molding Adhering centering pins on side impact molding.
• Remove protective foil from double-sided adhesive tape for side impact molding.
• Press side impact molding with attached centering pins firmly onto bumper over the entire surface.

Centering holes for side impact moldings

NOTE:

Centering holes for side impact molding must be drilled on a new bumper before painting.

Fig. 204: Centering Holes For Side Impact Moldings
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear bumper

• Markings for centering holes are positioned on the inside of the cover - arrows - as shown.
• Drill through cover at these locations (3x) using a drill bit 8.5mm before painting.

Adhering centering pins on side impact molding

Fig. 205: Adhering Centering Pins On Side Impact Molding
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Adhesive - 3 - and centering pin - 4 - (3x each) are in delivery casing of side impact molding - 1 -.

• Remove protective foil from the double-sided adhesive - 3 - and adhere it onto centering pin - 4 -.
• Remove second protective foil and position centering pin onto marking - arrow - on side impact molding.
• Remove protective foils from double-sided adhesive strips - 2 - and press side impact molding - 1 - onto bumper.

Rear bumper (Avant)

Bumper, removing and installing

Up to Vehicle Identification Number (VIN) 400 000

Fig. 206: Rear Bumper (Avant), Removing And Installing (Up To Vehicle Identification Number (VIN) 400 000)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Bolt

• 1 Nm

2 - Wheelhousing liner

3 - Combination nut

• 4 Nm

4 - Cap nut

• 4 Nm

5 - Guide piece

• Removing and installing --> Guide piece, removing and installing

6 - Grommet

• Grommets must be pressed in before assembling cover.

7 - Supporting strip

8 - Sheet-metal screw

• 2 Nm

9 - Sealing strip

• Clipped in cover - 12 -

10 - Trim molding

• Clipped in cover - 12 -

11 - Side sealing strip

• Clipped in cover - 12 -

12 - Cover

• Two-piece version
• One-piece version (for USA)
• Removing:
• Remove side luggage compartment trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

• Remove bass loudspeaker. -->
  • 91 - COMMUNICATION
  • 91 RADIO, TELEPHONE, NAVIGATION, TRIP COMPUTER for COMMUNICATION, CABRIOLET
• Disconnect electrical harness connectors to parking aid sensors at control module (under tail light, left side).
• Remove combination nuts - 3 - and special nuts - 4 - (accessible from luggage compartment).
• Unscrew bolts - 13 -.

• Unscrew wheel housing liners - 2 - in rear area.
• Remove bolts - 1 - at left and right on guide piece - 6 -
• Unclip cover side-pieces on guide piece.
• Remove cover.

• Separating two-piece cover:
• Drill off rivet heads from pop rivets at left and right.
• Disengage locking tabs and separate both pieces of cover.
• Installing:

• Install in reverse order of removal.
• When installing a new bumper cover, insert a new support piece - 14 - into cover.
• Disengage support piece only when bumper cover is completely installed Disengaging support piece.

13 - Bolt

14 - Support piece

• Replace when installing a new bumper cover
• Disengage only when bumper cover is completely installed Disengaging support piece

15 - Side impact molding

• Replace
• Side impact moldings are secured to bumper with double-sided adhesive tape.
• It is not possible to remove without destroying.
• To remove, pull side impact molding away from bumper.

• Remove any residual adhesive on bumper.
• Installing on new bumper

NOTE:

Centering holes for side impact molding must be drilled on a new bumper before painting. Position centering holes for side impact moldings on bumper --> Centering holes for side impact moldings.

As of Vehicle Identification Number (VIN) 400 001

Fig. 207: Rear Bumper (Avant), Removing And Installing (As Of Vehicle Identification Number (VIN) 400 001)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Cover

• Removing:

• Remove side luggage compartment trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• Disconnect electrical harness connectors to parking aid sensors at control module (under tail light, left side).
• Remove special nuts - (accessible from luggage compartment).
• Remove special nuts - Cap nuts- (accessible from luggage compartment).

• Unscrew wheel housing liners in rear area.
• Remove bolts left and right on guide piece - 3 -
• Unclip cover side-pieces on guide piece.
• Remove cover.

• Separating two-piece cover:
• Disengage locking tabs and separate both pieces of cover.

2 - Guide piece

3 - Combination bolts

4 - Expanding rivet

• Pressed into side panel at bottom

5 - Cap nut

• 4 Nm

6 - Base plate

• Must always be installed.

7 - Combination bolt

• 18 Nm

8 - Base plate

• Must always be installed.

9 - Expanding clip

• Qty. 5 inserted in rear cross panel.

10 - Supporting strip

11 - Sheet-metal screw

• 2.5 Nm

12 - Combination bolt

• 18 Nm

13 - Right holder for bumper

• Bumper removed
• Remove combination bolt - 12 - and pull shock absorber out of bumper.

14 - Hex nut

• 18 Nm
• Counterhold when tightening combination bolt - 8 -.

15 - Bracket

• Riveted to bumper.

16 - Pop rivet

17 - Left holder for bumper

• Remove combination bolt - 8 - and pull shock absorber out of bumper.

18 - Bumper

• Cover - 1 - removed.
• Remove combination bolts - 6 - at left and right and pull out bumper toward rear.

19 - Support piece

• Replace when installing a new bumper cover
• Disengage only when bumper cover is completely installed Disengaging support piece

Country version

Fig. 208: Rear Bumper (Avant), Removing And Installing (Country Version)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Cover

• Removing:

• Remove side luggage compartment trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• Disconnect electrical harness connectors to parking aid sensors at control module (under tail light, left side).
• Remove special nuts - (accessible from luggage compartment).
• Remove special nuts - Cap nuts- (accessible from luggage compartment).

• Unscrew wheel housing liners in rear area.
• Remove bolts left and right on guide piece - 3 -
• Unclip cover side-pieces on guide piece.
• Remove cover.

• Separating two-piece cover:
• Disengage locking tabs and separate both pieces of cover.

2 - Guide piece

3 - Combination bolts

4 - Expanding rivet

• Pressed into side panel at bottom

5 - Cap nut

• 4 Nm

6 - Base plate

• Must always be installed.

7 - Combination bolt

• 18 Nm

8 - Base plate

• Must always be installed.

9 - Expanding clip

• Qty. 5 inserted in rear cross panel.

10 - Supporting strip

11 - Sheet-metal screw

• 2.5 Nm

12 - Combination bolt

• 30 Nm

13 - Right shock absorber for bumper

• Bumper removed
• Remove combination bolt - 12 - and pull shock absorber out of bumper.

14 - Hex nut

• 30 Nm
• Counterhold when tightening combination bolt - 8 -.

15 - Bracket

• Riveted to bumper.

16 - Pop rivet

17 - Left shock absorber for bumper

• Remove combination bolt - 8 - and pull shock absorber out of bumper.

18 - Bumper

• Cover - 1 - removed.
• Remove combination bolts - 6 - at left and right and pull out bumper toward rear.

19 - Support piece

• Replace when installing a new bumper cover
• Disengage only when bumper cover is completely installed Disengaging support piece

Centering holes for side impact moldings

Up to Vehicle Identification Number (VIN) 400 000

NOTE:

Centering holes for side impact molding must be drilled on a new bumper before painting.

Fig. 209: Centering Holes For Side Impact Moldings
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear bumper

• Markings for centering holes are positioned on the inside of the cover - arrows - as shown.
• Drill through cover at these locations (3x) using a drill bit 8.5 mm before painting.

Fig. 210: Adhering Centering Pins On Side Impact Molding
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Adhering centering pins on side impact molding

NOTE:

Adhesive - 3 - and centering pin - 4 - (3x each) are in delivery casing of side impact molding - 1 -.

• Remove protective foil from the double-sided adhesive - 3 - and adhere it onto centering pin - 4 -.
• Remove second protective foil and position centering pin onto marking - arrow - on side impact molding.
• Remove protective foils from double-sided adhesive strips - 2 - and press side impact molding - 1 - onto bumper.

Fig. 211: Installing Support Piece
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing support piece

NOTE:

Support piece must be installed only with a new bumper cover.

• To remove, press catch - arrow - to the side and pull support piece downward out of cover - 1 -.
• Insert support piece - 2 - into cover as shown and let engage inside.
• Disengaging cord must be removed only when the cover is installed completely.

Disengaging support piece

Fig. 212: Disengaging Support Piece
Courtesy of VOLKSWAGEN UNITED STATES, INC.

CAUTION:

Never disengage support piece in the removed condition - danger of injury.

When re-installing the old bumper cover, the old support piece remains installed.

• When replacing the bumper cover, a new support piece must be clipped into the bumper cover from below.
• After completely installing bumper cover, disengage support piece by pulling on disengaging cord - arrow -.

NOTE:

By pulling disengaging cord, tension is released from support piece and reinforces the bumper cover against the crossmember.

Guide piece, removing and installing

Up to Vehicle Identification Number (VIN) 400 000

• Bumper removed.

Fig. 213: Guide Piece Remove/Install Components (Up To Vehicle Identification Number (VIN) 400 000)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - 1 - and remove guide piece - 2 -.
• Tightening torque: 1.5 Nm
• Clip - 3 - pressed into side panel.

As of Vehicle Identification Number (VIN) 400 001

Fig. 214: Guide Piece Remove/Install Components (As Of Vehicle Identification Number (VIN) 400 001)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Bumper removed.
• Remove bolts - 1 - and remove guide piece - 2 -.
• Expanding clip - 3 - pressed into side panel.

Crossmember for bumper, removing and installing

NOTE:

Bumper cover removed.

Fig. 215: Crossmember For Bumper Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Shock absorber

2 - Bolt

• 10 Nm
• 4x

3 - Bolt

• 20 Nm
• 2x

4 - Nut

• 20 Nm
• 2x

5 - Cross member

USA version

NOTE:

Bumper cover removed.

Fig. 216: Crossmember For Bumper Remove/Install Components (USA Version)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Shock absorber

2 - Bolt

• 10 Nm
• 4x

3 - Bolt

• 20 Nm
• 2x

4 - Nut

• 20 Nm
• 2x

5 - Cross member

Crossmember for bumper (vehicles with trailer hitch), removing and installing

NOTE:

Bumper cover removed.

Fig. 217: Crossmember For Bumper (Vehicles With Trailer Hitch) Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Trailer hitch carrier

2 - Bolt

• 60 Nm
• 4x

3 - Nut

• 23 Nm
• 2x

4 - Mounting clamps

• 4x

5 - Spacer

• 2x

6 - Bolt

• 23 Nm
• 2x

7 - Cross member

Threaded plate for trailer hitch

Fig. 218: Threaded Plate For Trailer Hitch
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Note the various mounting points for the threaded plate. - Arrow A - as of Vehicle Identification Number (VIN) 400 001 - Arrow B - up to Vehicle Identification Number (VIN) 400 000

• Contact surface of threaded plate must be clean and even.
• Mount threaded plate - 1 - with pop rivets - 2 - starting from outside working toward inside.

64 Glass

Flush-bonded windows

Flush-bonded windows, removing and installing - general information

Fig. 219: Identifying Special Tools - Flush-Bonded Windows, Removing And Installing - General Information
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

• Suction lifter V.A.G 1344
• Electric cutter V.A.G 1561 A
• Universal cutting blade V.A.G 1561/11
• Cartridge gun V.A.G 1628

• Window removing kit V.A.G 1755
• Cutting tools for glass V.A.G 1351
• Cutting tool kit V.A.G 1474 B
• Cartridge heater V.A.G 1939 A

• Cutting cord 357 853 999

Fig. 220: Spooling Tool V.A.G 1654 A
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Spooling tool V.A.G 1654 A

Fig. 221: Double Cartridge Gun VAS 5237
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Double cartridge gun VAS 5237

Servicing windows using special tool

NOTE:

Windshields damaged by flying rocks can be repaired using the repair kit for windshields VAS 6092. These damaged areas must not exceed a certain dimension or lie within the drivers field of sight. For further details on use, refer to Users Manual enclosed with each kit.

Materials

2C- window adhesive		DA 004 600 A2 * See note, 2)
1C- window adhesive		DH 009 100 03 * See note, 4)
Glass primer/paint primer		D 009 200 02
Cleaning solution		D 009 401 04
Primer applicator		D 009 500 25
Adhesive remover		D 002 000 10
Cutting cord		357 853 999
Cutting wire		357 845 955

* Observe minimum curing time --> Minimum curing times!

* Double cartridge pistol VAS 5237 must be used to process this material

* Heat according to manufacturers instructions using cartridge heater V.A.G 1939 A

* Small cartridge (110 ml) for sealing and/or when a 400 ml double cartridge is not sufficient.

Minimum curing times!

CAUTION:

For safety reasons, use only electrically non-conductive 2C-adhesive when installing windshield and rear window using the materials listed below. Vehicle is only safe for operation after minimum curing time has elapsed and only then may it be used.

Window	Vehicle	Adhesive sealing material	Curing time in hours
Windshield	With airbag	DA 004 600 A2	3
Rear window		DA 004 600 A2	3
Side window		DH 009 100 03	3

Cleaning when soiled by adhesive sealing material

Adhesive removal solution D 002 000 10 is the recommended cleaning solution. Observe safety precautions when processing.

CAUTION:

When cleaning from vehicle interior out, the window just installed must not be pressed outward.

Paint surfaces:

• First, clean paint surfaces with a dry cloth. Remove further material using adhesive removal solution D 002 000 10.

Plastic trim:

• Allow adhesive sealing material to harden (about 1 hour) and then peel off.

Windshield, removing and installing

Assembly overview

Fig. 222: Windshield, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Windshield

• Removing --> Removing
• Installing --> Preparing for window installation
• Distance to roof dimension - a - = 6 mm ^{+ 0. 5 mm}
• Align distance - d - at sides.

NOTE:

Stickers on windshield (e.g. for airbag) must be replaced in same position on new windshield.

2 - Adhesive bead

• Observe curing times --> Minimum curing times!
• Note varying spacing dimensions to window edge.
• Distances of top and side window edge dimension - b - and dimension - d - = 4 mm
• Distance at lower window edge measured from inner side of clip dimension - c - = 10 mm.

• Bead cross section
• Bead width = 8 ± 2 mm
• Bead height = 13.5 +1.5 mm

3 - Spacers

• 5x
• Affix in regular intervals to retaining strip

4 - Protective piping

• Only installed as new part.
• Only remove after installing windshield and before installing plenum chamber cover

5 - Plenum chamber cover

• Pull protective piping - 4 - from retaining strip before installing plenum chamber cover.
• Press into fastening strip only after window adhesive curing time has elapsed.

Removing

Necessary tools and materials --> Flush-bonded windows, removing and installing - general information.

CAUTION:

Always wear protective glasses and leather gloves when removing a window.

• Remove wiper arms.
  • 92 WINDSHIELD WIPER WASHER SYSTEM
  • 92 WINDSHIELD WIPER & WASHER SYSTEM for ELECTRICAL EQUIPMENT, CABRIOLET
• Remove cowl panel trim.
• Pull left and right drip rails out from retaining strips (from bottom upward).
• Remove sun visors on left, center and right. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

• Remove interior rear-view mirror. -->
  • 68 - INTERIOR EQUIPMENT
  • 68 - INTERIOR EQUIPMENT for BODY INTERIOR - CABRIOLET
• Remove upper trim panels of A-pillars -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

Fig. 223: Piercing Hole In Adhesive Sealing Material From Inside Of Vehicle Using Awl V.A.G 1755 Or Awl V.A.G 1351 At Bottom-Left Of Windshield
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pierce hole in adhesive sealing material from inside of vehicle using awl V.A.G 1755 or awl V.A.G 1351 at bottom-left of windshield.
• Pull cutting cord through adhesive sealing material into inside of vehicle using awl.

Fig. 224: Laying Cutting Cord Underneath And All Around Inside Of Windshield
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Lay cutting cord underneath and all around inside of windshield.

Fig. 225: Securing End Of Cutting Cord At Bolt For Securing Window Wiper Frame
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Secure end of cutting cord at bolt - arrow - for securing window wiper frame.
• Insert protective foil V.A.G 1474/13 between windshield and instrument panel.

Fig. 226: Laying Cutting Cord Underneath And All Around Inside Of Windshield
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Secure beginning of cutting cord in winding device and cut out first area of adhesive (up to about center of windshield).

Fig. 227: Moving Spooling Tool And Continue Cutting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Move spooling tool as shown in diagram and continue cutting.

Fig. 228: Moving Spooling Tool And Attaching Relay Pulley
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Move spooling tool as shown in diagram and attach relay pulley.

• Route cutting cord as shown.

• Cut adhesive up to point where cord no longer runs in relay pulley.

Fig. 229: Removing Relay Pulley And Continue To Cut Adhesive
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove relay pulley and continue to cut adhesive.

Fig. 230: Moving Spooling Tool And Attaching Relay Pulley In Upper Corner Of Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Move spooling tool as shown in diagram and attach relay pulley in upper corner of window.

• Route cutting cord as shown.

• Insert protective foil V.A.G 1474/11 between windshield and molded headliner.
• Cut adhesive up to point where cord no longer runs in relay pulley.
• Remove relay pulley and continue to cut adhesive.
• Repeat these steps in top left and bottom left corners of windshield.

• Cut window completely free.
• Remove window using two double suction cups.

Preparing for window installation

NOTE:

If windshield flange was damaged during removal, paint structure should be repaired according to specifications in article, "Vehicle-Paint" and if necessary, corrosion repair measures should be taken according to guidelines in "Surface Technology/Chemical Materials Folder".

For undamaged removed windshield

• When reusing an undamaged window, cut back smoothly residual adhesive sealing material on window and flange using electric cutter V.A.G 1561A and scraper V.A.G 1561/10; do not remove completely!
• Residual material acts as a base for the new adhesive sealing material.

CAUTION:

Keep adhesive surface free of dirt and grease. Only cut back adhesive surface shortly before installation. Do not prime or use a cleaning solution on the adhesive surface.

New window, installing

• Clean windshield in adhering area using D 009 401 04 and prime using D 009 200 02 glass/paint primer.

Applying primer

Fig. 231: Applying Primer Evenly In One Pass Using Applicator
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Apply primer - 2 - along circumference evenly and in one motion using applicator - 1 -.
• Begin application with a fully saturated felt. Air drying time approx. 10 minutes.

• Primer dimensions: Dimension - a - = approx. 20 mm

• Apply primer in center of adhesive bead.

CAUTION:

Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material!

Fig. 232: Dimensions For Application Of Adhesive
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Dimensions for application of adhesive

1 - Adhesive bead

2 - Primer

3 - Washer

• Bead width - a - = 8 ± 2 mm
• Bead height - b - = 12 + 3 mm
• Dimension - c - = note varying spacing dimensions to window edge --> Windshield, removing and installing

Windshield, installing

• After preparatory work has been performed, apply the adhesive.

Fig. 233: Positioning Complete Surface Of Nozzle Onto Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Position complete surface of nozzle - 2 - onto window.
• - Arrow - indicates direction of application

NOTE:

Cross-section thickness of adhesive bead - 1 - is determined by dimension of opening in nozzle tip and rate of application.

Fig. 234: Applying Adhesive Sealing Material All Around
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Apply adhesive sealing material all around, as shown in illustration.
• Note varying spacing dimensions to window edge --> Windshield, removing and installing
• Using two suction lifters, install windshield in windshield opening.

CAUTION:

Window must be installed within 15 minutes, otherwise bonding properties of adhesive will be impaired.

• Align windshield at sides.
• Spacing between edge of window and roof frame must be 6 mm + 0.5 mm.

Fig. 235: Pressing Drip Rail Into Retaining Clips Until It Stops Only After Curing Time Has Elapsed
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Press drip rail - 1 - into retaining clips - 2 - until it stops only after curing time has elapsed.
• When pressing in drip rail, make sure sealing lip - arrow - lies flat against windshield and does not slip behind edge of windshield.

Fig. 236: Affixing Stickers On Windshield In Same Position On New Windshield
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Affix stickers on windshield (e.g. for airbag) in same position on new windshield. "Caution- Safety information" sticker

• Dimension - a - = 25 mm
• Dimension - b - = 10 mm

Side window (Sedan), removing and installing

Side window with molding - assembly overview

Fig. 237: Side Window With Molding - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Side window

• Removal --> Undamaged side window, removing.
• Note varying spacing dimensions of adhesive bead to window edge.
• When inserting window, make sure that retaining tabs on molding at D-pillar, or at joint of D-pillar to side panel, are slide behind roof trim molding.

2 - Roof trim molding

Side window with gloss package - assembly overview

Fig. 238: Side Window With Gloss Package - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Side window

• Removal --> Undamaged side window, removing.
• Note varying spacing dimensions of adhesive bead to window edge.
• When installing, set window first on side panel at bottom.
• Press in window up to lower stop - arrow - and into window cut-out.

• After curing time has elapsed, install roof trim molding and trim to D-pillar

2 - Roof trim molding D-pillar

• C-pillar trim removed.
• To remove, pry carefully out of retaining clips beginning first at bottom on C-pillar.
• Then pry out of retaining clips at D-pillar and pull downward out of roof trim molding.

3 - C- pillar trim

• To remove, pull trim panel out of clips - 4 - toward rear.
• When installing, insert trim panel first at top on roof trim molding and press completely into clips - 4 -.
• Dimension - a - = 0.5 ± 0.1 mm

4 - Retaining clips

• Riveted to C- pillar.

Undamaged side window, removing

Side window with molding

Fig. 239: Undamaged Side Window, Removing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Apply fabric reinforced adhesive tape - 6 - to area of window edges along circumference to protect paint from damage.
• Using awl from V.A.G 1755, pierce through adhesive bead on window glass - 1 - at top in direction of B-pillar from inside vehicle toward outside.
• Pull cutting cord - 4 - through toward inside and secure it in grab handle - 3 -.
• Secure the other end in pull handle - 5 -.

• Second technician pierces adhesive bead at bottom using grab handle as shown.
• Pull cutting cord on the outside through adhesive bead - 2 - downward.

NOTE:

At the corners, move cutting cord in sawing motions to cut through the adhesive more easily.

Fig. 240: Pulling Cutting Cord Toward Inside And Inserting Grab Handle Into Adhesive Bead At D-Pillar At Rear
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull cutting cord - 4 - toward inside and insert grab handle - 3 - into adhesive bead - 2 - at D-pillar at rear.
• Pull cutting cord - 4 - toward rear through adhesive bead using pull handle.

Fig. 241: Pulling Cutting Cord Toward Inside And Inserting Grab Handle Into Adhesive Bead At D-Pillar At Top
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull cutting cord - 4 - toward inside and insert grab handle - 3 - into adhesive bead - 2 - at D-pillar at top.
• Pull cutting cord - 4 - upward through adhesive bead using pull handle.
• Remove window from cut-out.

Side window with gloss package

• Remove C-/D-pillar trim -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
  .

Fig. 242: Removing/Installing Roof Trim Molding And Slide Trim
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Apply adhesive tape - 3 - to C-/D-pillar trim as well as side panel to protect paint from damage.
• Pull off trim molding - 1 - from retaining clips - 2 - toward front.

CAUTION:

Roof trim molding must not be bent.

Fig. 243: Removing/Installing Roof Trim Molding
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Carefully pull roof trim molding - 1 - from below, beginning at C-pillar, out of retaining clips using a plastic wedge.
• Pry out roof trim molding at D-pillar in the same manner out of retaining clips and pull off downward.
• Insert cutting cord around the side window as depicted in the illustration.

Fig. 244: Securing Ends X And Y In Two Pull Grips From Special Tool V.A.G 1351
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Secure ends X and Y in two pull grips from special tool V.A.G 1351.
• Pull cutting cord in - direction of arrow A - using light sawing motions and cut through lower adhesive sealing material at side panel and at roof frame.
• Then pull cutting cord through in - direction of arrow B - downward through adhesive sealing material.
• Remove window from window opening.

Preparing for window installation

NOTE:

If windshield flange was damaged during removal, paint structure should be repaired according to specifications in article, "Vehicle-Paint" and if necessary, corrosion repair measures should be taken according to guidelines in "Surface Technology/Chemical Materials Folder".

For undamaged removed windshield

• When reusing an undamaged window, cut remaining adhesive sealing material on window and flange using a carpet knife so that it is even, but do not remove completely!
• Residual material acts as a base for the new adhesive sealing material.

CAUTION:

Keep adhesive surface free of dirt and grease. Only cut back adhesive surface shortly before installation. Do not prime or use a cleaning solution on the adhesive surface.

• Apply adhesive onto residual adhesive bead

• Bead width = 8 ± 2 mm
• Bead height = 13.5 ± 1.5 mm

NOTE:

Adhesive sealing material DH 009 100 03 (small cartridge) is recommended when bonding a single window; D 004 300 05 (2K- adhesive) is recommended when bonding more than one window.

New window, installing

• Clean windshield in adhering area using D 009 401 04 and prime using D 009 200 02 glass/paint primer.
• Ensure an air drying time of 10 minutes for primer.
• Apply adhesive

Fig. 245: Dimensions For Application Of Adhesive
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Dimensions for application of adhesive

1 - Adhesive bead

2 - Primer

3 - Washer

• Bead width - a - = 8 ± 2 mm
• Bead height = 13.5 ± 1.5 mm
• Dimension - c - = note varying spacing dimensions to window edge

Side window, installing

Vehicles with molded side window

• Place window onto lower D-pillar and press into window opening.
• Side window molding must engage behind roof trim molding --> Side window (Sedan), removing and installing
• Secure window in opening using adhesive tape.
• Observe curing time.

Vehicles with gloss package

• Press roof trim molding into retaining clips at D-pillar.

Fig. 246: Removing/Installing Roof Trim Molding
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Press trim - 1 - into retaining clips - 2 - at D-pillar and lower side panel.
• Position window at lower side panel and press into opening.
• Secure window in opening using adhesive tape.

Fig. 247: Removing/Installing Roof Trim Molding And Slide Trim
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Position upper B-pillar trim at roof trim molding and slide trim - 1 - into side retaining clips.
• Observe curing time.

Side window (Avant), removing and installing

Side window (Avant), removing and installing - assembly overview

Fig. 248: Side Window (Avant), Removing And Installing - Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Side window

2 - Adhesive bead

• Note varying spacing dimensions to window edge.
• Dimension - a - = 8 mm behind window molding
• Dimension - b - = 25 mm
• Bead cross section

• Bead width = 8 mm ± 2 mm
• Bead height = 13.5 ± 1.5 mm

3 - Spacers

• Height 8 mm

4 - Double sided adhesive

• D 004 400

5 - Securing pin

• 2x

6 - Trim for side panel

• When installing, first insert into roof trim molding at bottom, then press at sides into retaining clips on side panel.

Undamaged side window, removing

CAUTION:

Always wear protective glasses and leather gloves when removing a window.

Remove the following trim pieces:

• Side luggage compartment trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• D-pillar trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• Trim above rear side window. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• C-pillar trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

Fig. 249: Removing C-Pillar Trim From Rear Side Window Toward Front
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove C-pillar trim from rear side window toward front - arrows -.

Side window with gloss package

Fig. 250: Identifying Lower Trim Molding & Retaining Springs
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Beginning at C-pillar, pull lower trim molding - 1 - from retaining springs - 2 -.
• Disengage lower trim molding from roof trim molding.

CAUTION:

To prevent damage to paint when removing and installing trim molding, cover area below side window and on side panel using adhesive tape. Also, a slightly bent roof trim molding is damaged and must be replaced.

All vehicles:

Fig. 251: Piercing Through Adhesive Sealing Material Using Guide Needle With Handle From V.A.G 1755 Window Removing Kit
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pierce through adhesive sealing material using a guide needle with handle from V.A.G 1755 window removing kit.
• Remove handle and thread cutting cord through eye of the guide needle.

Fig. 252: Pulling Cutting Cord End Inward (Use Pliers And Protective Gloves) To Opposite Window Side With Guide Needle From V.A.G 1755 Window Removing Kit
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull cutting cord end - A - inward (use pliers and protective gloves) to opposite window side with guide needle from V.A.G 1755 window removing kit.

Fig. 253: Pulling Cutting Cord With Small Tube From V.A.G 1755 Window Removing Kit Under Polyurethane Molding Of Side Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull cutting cord - B - with small tube from V.A.G 1755 window removing kit under polyurethane molding of side window.

Fig. 254: Inserting Cutting Cord Completely Around Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Insert cutting cord completely around window.
• Pierce through adhesive sealing material using a guide needle with handle from V.A.G 1755 window removing kit.
• Remove handle and thread end of cutting cord - B - through eye of the guide needle.
• Pull through cutting cord end - B - with guide needle inward (use pliers and protective gloves).

• Secure cutting cord end - B - to belt guide console.

Fig. 255: Attaching Spooling Tool V.A.G 1654 Together With Cutting Cord
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Attach spooling tool V.A.G 1654 as shown together with cutting cord.

Fig. 256: Cutting First Area At C-Pillar And Window Bottom
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Cut first area at C-pillar and window bottom.

NOTE:

Press cutting cord in direction of chassis during cutting procedure.

Fig. 257: Positioning V.A.G 1474/1 Roller
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Position V.A.G 1474/1 roller as depicted in the illustration.
• Move spooling tool V.A.G 1654 and continue cutting.

Fig. 258: Positioning V.A.G 1474/1 Roller, Moving Spooling Tool V.A.G 1654 & Continue Cutting (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Position V.A.G 1474/1 roller as depicted in the illustration.
• Move spooling tool V.A.G 1654 and continue cutting.

Fig. 259: Pressing Side Window Into Window Opening Using V.A.G 1344 Double Suction Cups
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove side window using V.A.G 1344 double suction cups.

Preparing for window installation

NOTE:

If windshield flange was damaged during removal, paint structure should be repaired according to specifications in article, "Vehicle-Paint" and if necessary, corrosion repair measures should be taken according to guidelines in "Surface Technology/Chemical Materials Folder".

For undamaged removed windshield

• When reusing an undamaged window, cut remaining adhesive sealing material on window and flange using a carpet knife so that it is even, but do not remove completely!
• Residual material acts as a base for the new adhesive sealing material.

CAUTION:

Keep adhesive surface free of dirt and grease. Only cut back adhesive surface shortly before installation. Do not prime or use a cleaning solution on the adhesive surface.

• Apply adhesive onto residual adhesive bead

• Bead width = 8 ± 2 mm
• Bead height = 13.5 ± 1.5 mm

NOTE:

Adhesive sealing material DH 009 100 03 (small cartridge) is recommended when bonding a single window; D 004 300 05 (2K- adhesive) is recommended when bonding more than one window.

New window, installing

• Clean windshield in adhering area using D 009 401 04 and prime using D 009 200 02 glass/paint primer.
• Ensure an air drying time of 10 minutes for primer.
• Apply adhesive

Fig. 260: Dimensions For Application Of Adhesive
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Dimensions for application of adhesive

1 - Adhesive bead

2 - Primer

3 - Washer

• Bead width - a - = 8 ± 2 mm
• Bead height = 13.5 ± 1.5 mm
• Dimension - c - = note varying spacing dimensions to window edge --> Side window (Avant), removing and installing - assembly overview

Side window, installing

• Adhere spacer onto side window.
• Apply double sided adhesive tape D 004 400 on window gasket, rear.

Vehicles with gloss package

Fig. 261: Identifying Lower Trim Molding & Retaining Springs
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install lower trim molding - 1 - into retaining clips - 2 -.

Fig. 262: Pressing Side Window Into Window Opening Using V.A.G 1344 Double Suction Cups
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Press side window into window opening using V.A.G 1344 double suction cups and align it according to window opening.
• Secure window in opening using adhesive tape.
• Observe curing time.

Fig. 263: Pressing It Into Retaining Clips At C-Pillar
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• On vehicles with trim attached, press it into retaining clips at C-pillar - arrows -.

Rear window (Sedan), removing and installing

Assembly overview

Fig. 264: Rear Window (Sedan) Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear window

• Removal --> Undamaged rear window, removing
• When installing, note direction of joint - arrow - in magnified area of illustration.
• After inserting window, pull up to dimension - a - = 6.5 mm at roof.
• Align window at sides.

2 - Adhesive end profile

• Adhere next to vertical rear window defrosting strips
• Adhesive must not touch distributing wire for rear window defroster.

3 - Adhesive bead

• Note varying spacing dimensions to window edge.
• The dimensions - b - and - c - are achieved when you allow the application nozzle to touch each inner edge of the molding.
• The distance to lower window edge dimension - d - is 15mm.
• Bead cross section

• Bead width = 8 ± 2 mm
• Bead height = 13.5 ± 1.5 mm

4 - Spacers

• Note different heights for standard glass and tinted glass.
• Place spacers at distance of 3mm to lower window edge onto markings applied in ceramic screen printed area.

Undamaged rear window, removing

NOTE:

Always wear protective glasses and leather gloves when removing a window.

• Unclip rear shelf. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• Disconnect connections for rear window defrost and window antenna.
• Press connections at window towards center of vehicle.

Fig. 265: Pressing Awl Through Adhesive Sealing Material In Lower Window Corner, Until Eye Of Awl Is Visible Outside Of Vehicle
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Press awl through adhesive sealing material in lower window corner, until eye of awl is visible outside of vehicle.
• Thread beginning of cutting cord through eye and pull into vehicle interior.

Fig. 266: Placing Cutting Cord Around Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Thread cutting cord through spooling tool and clamp securely.
• Place cutting cord around window as shown.
• Cutting cord must be pressed under gap covers on upper window edge and side window edges.

Fig. 267: Laying End Of Cutting Cord Around Buffer Stop
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Lay end of cutting cord around buffer stop - arrow - and tighten with bolt for rear lid hinge.

Fig. 268: Placing Cutting Cord Around Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Cut first section.

Fig. 269: Moving Winding Device And Attaching Relay Pulley In Lower Window Radius
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Move winding device as shown and attach relay pulley in lower window radius.

• Route cutting cord as shown.

• Cut adhesive up to point where cord no longer runs in relay pulley.

Fig. 270: Removing Relay Pulley And Continue To Cut Adhesive
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove relay pulley and continue to cut adhesive.

Fig. 271: Moving Winding Device And Attaching Relay Pulley In Lower Window Radius
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Move winding device as shown and attach relay pulley in lower window radius.

• Route cutting cord as shown.

• Cut adhesive up to point where cord no longer runs in relay pulley.
• Insert 1474/12 protective foil between molded headliner and rear window.

Fig. 272: Removing Relay Pulley And Continuing To Cut Adhesive
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove relay pulley and continue to cut adhesive.
• Repeat these steps in top right and bottom right corners of windshield.
• Cut glass completely free in this manner.
• Remove window using double suction cups.

Damaged rear window, removing

CAUTION:

Always wear protective glasses and leather gloves when removing a window. Protect body and interior from glass splinters.

• Remove glass pieces up to adhesive material.

Fig. 273: Disconnecting Connector For Antenna And Amplifier
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect connector - 1 - for antenna and amplifier.
• Remove harness connectors for glass defroster.
• Mask flange all around with fabric reinforced adhesive tape.

Fig. 274: Removing Adhesive Sealing Material (With Glass Residue) From Window Opening Using Electric Cutter And Knife V.A.G 1561/11 (With Stopper Roll)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove adhesive sealing material (with glass residue) - 1 - from window opening using electric cutter and knife V.A.G 1561/11 (with stopper roll).

Preparing for window installation

NOTE:

If windshield flange was damaged during removal, paint structure should be repaired according to specifications in article, "Vehicle-Paint" and if necessary, corrosion repair measures should be taken according to guidelines in "Surface Technology/Chemical Materials Folder".

• Observe different spacers for tinted glass and standard glass.
• Adhere lower spacer onto rear window according to the markings.

Fig. 275: Preparing For Window Installation
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Adhesive stopper profile - 2 - must be adhered onto left side, centered on antenna wire next to distributing wire for rear window heater.
• On the right side, adhere inner edge of profile onto outer edge of distributing wire for rear window heater.

NOTE:

If adhesive sealing material leaks out at lower window edge during installation, this must be removed immediately.

CAUTION:

Window adhesive must not come into contact with the antenna wire or the distributing wire for rear window heater under any circumstances.

For undamaged removed windshield

• When reusing an undamaged window, cut back smoothly residual adhesive sealing material on window and flange using electric cutter V.A.G 1561A and scraper V.A .G 1561/10; do not remove completely!
• Residual material acts as a base for the new adhesive sealing material.

CAUTION:

Keep adhesive surface free of dirt and grease. Only cut back adhesive surface shortly before installation. Do not prime or use a cleaning solution on the adhesive surface.

New window, installing

• Clean windshield in adhering area using D 009 401 04 and prime using D 009 200 02 glass/paint primer.

Applying primer

Fig. 276: Applying Primer Evenly In One Pass Using Applicator
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Apply primer - 2 - along circumference evenly and in one motion using applicator - 1 -.
• Begin application with a fully saturated felt. Air drying time approx. 10 minutes.

• Primer dimensions: Dimension - a - + approx. 20 mm

• Apply primer in center of adhesive bead.

CAUTION:

Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material!

NOTE:

Do not touch up primer strip until after primer has thoroughly dried.

Fig. 277: Dimensions For Application Of Adhesive
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Dimensions for application of adhesive

1 - Adhesive bead

2 - Primer

3 - Washer

• Bead width - a - = 8 ± 2 mm
• Bead height - b - = 12 + 3 mm
• Dimension - c - = note varying spacing dimensions to window edge --> Rear window (Sedan), removing and installing

Installing rear window

• After preparatory work has been performed, apply the adhesive.

Fig. 278: Positioning Complete Surface Of Nozzle Onto Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Position complete surface of nozzle - 2 - onto window.
• - Arrow - indicates direction of application

NOTE:

Cross-section thickness of adhesive bead - 1 - is determined by dimension of opening in nozzle tip and rate of application.

Fig. 279: Applying Adhesive Sealing Material All Around
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Apply adhesive sealing material all around, as shown in illustration.
• Note varying spacing dimensions to window edge --> Rear window (Sedan), removing and installing.
• Using two double suction cups, install rear window in window opening.

CAUTION:

Window must be installed within 15 minutes, otherwise bonding properties of adhesive will be impaired.

• Align windshield at sides.
• Spacing between edge of window and roof frame must be 6.5 mm.
• Observe curing time.

Rear window (Avant), removing and installing

Assembly overview

NOTE:

The printed gap covers on window edges have been discontinued in vehicles as of Vehicle Identification Number (VIN) 400 001. New windows without gap covers can be installed retroactively in older vehicles.

Fig. 280: Rear Window (Avant), Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear window

• Undamaged side window, removing --> Undamaged rear window, removing.
• Removing damaged rear window --> Damaged rear window, removing.
• Dimension - a - even out when installing.

2 - Adhesive bead

• Observe curing times --> Minimum curing times!
• Note varying spacing dimensions to window edge.
• Dimension - b - = 6 mm
• Dimension - c - = 38 mm

• Dimension - d - = 6 mm
• Bead cross section
• Bead width = 8 +2 mm
• Bead height = 13.5 +1.5 mm

3 - High-mount brake light

• Removed before removing rear window. Refer to
  • 94 LIGHTS, SWITCHES - EXTERIOR
  • 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET

4 - Sealing strips

• Pull off before removing rear window.

5 - Seal for rear window wiper

CAUTION:

When installing window, the axle of windshield wiper motor must be centered on grommet, otherwise there will be leaks.

Undamaged rear window, removing

CAUTION:

Always wear protective glasses and leather gloves when removing a window.

• Remove rear lid trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• Remove rear window wiper motor. -->
  • 92 WINDSHIELD WIPER WASHER SYSTEM
  • 92 WINDSHIELD WIPER & WASHER SYSTEM for ELECTRICAL EQUIPMENT, CABRIOLET
• Disconnect electrical harness connectors for heated rear window and antennas.
• Pull off side sealing strip at rear window.

Fig. 281: Piercing Through Adhesive Sealing Material Using A Guide Needle With Handle From V.A.G 1755 Window Removing Kit
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Open rear lid.
• Pierce through adhesive sealing material using a guide needle with handle - 1 - from V.A.G 1755 window removing kit.
• Remove handle and thread end of cutting cord through eye of the guide needle.

Fig. 282: Pulling Cutting Cord End Inward To Opposite Window Side With Guide Needle From V.A.G 1755 Window Removing Kit
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull cutting cord end - A - inward (use pliers and protective gloves) to opposite window side with guide needle from V.A.G 1755 window removing kit.

Fig. 283: Inserting Cutting Cord End Around Rear Window Using Small Tube From V.A.G 1755 Window Removing Kit
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Using plastic wedge, loose sealing lip from glass flange and spray with D009 401 04 cleaning solution (lubricant replacement).
• Insert cutting cord end - B - around rear window using small tube from V.A.G 1755 window removing kit.

Fig. 284: Using Needle And Handle To Pull Second Cutting Cord End
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Using needle and handle, pull second cutting cord end - B - inward as shown.

NOTE:

Cutting cord ends - A - and - B - may not be pulled diagonally.

• Thread in cutting cord end - A - into spooling tool V.A.G 1654 and secure.

Fig. 285: Removing Cover For Rear Lid Hinge And Cable Guide From Rear Lid Hinge
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove cover - 1 - for rear lid hinge and cable guide - 2 - from rear lid hinge - arrows -.

Fig. 286: Fastening Cutting Cord End To Lid Hinge
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Fasten cutting cord end - B - to lid hinge.

Fig. 287: Cutting Glass Free At Bottom
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Fasten V.A.G 1654 spooling tool as shown to rear window.
• When cutting side area, press cutting cord in - direction of arrow -.
• Cut glass free at bottom.

Fig. 288: Cutting Glass Free At Side
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Move winding device as shown, and continue to cut window free.
• When cutting lower area, press cutting cord in - direction of arrow -.
• Cut glass free at side.
• Move winding device as shown, and continue to cut window free.

Fig. 289: Cutting Glass Free At Top
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• When cutting side area, press cutting cord in - direction of arrow -.
• Cut glass free at top.
• Move winding device as shown, and continue to cut window free.

Fig. 290: Cutting Window Away Completely And Lift Out From Rear Lid
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• When cutting upper area, press cutting cord in - direction of arrow -.
• Cut window away completely and lift out from rear lid.

Damaged rear window, removing

CAUTION:

Always wear protective glasses and leather gloves when removing a window. Protect body and interior from glass splinters.

• Remove glass pieces up to adhesive material.
• Disconnect connections for heated rear window and antennas.
• Bond flange all around with fabric reinforced adhesive tape.
• Remove adhesive sealing material (with glass residue) from window opening using electric cutter and knife V.A.G 1561/10 (with stopper roll).

Preparing for window installation

NOTE:

If windshield flange was damaged during removal, paint structure should be repaired according to specifications in article, "Vehicle-Paint" and if necessary, corrosion repair measures should be taken according to guidelines in "Surface Technology/Chemical Materials Folder".

For undamaged removed windshield

• When reusing an undamaged window, cut back smoothly residual adhesive sealing material on window and flange using electric cutter V.A.G 1561A and scraper V.A.G 1561/8; do not remove completely!
• Residual material acts as a base for the new adhesive sealing material.

CAUTION:

Keep adhesive surface free of dirt and grease. Only cut back adhesive surface shortly before installation. Do not prime or use a cleaning solution on the adhesive surface.

New window, installing

• Clean windshield in adhering area using D 009 401 04 and prime using D 009 200 02 glass/paint primer.

CAUTION:

For this purpose, apply adhesive stopper profile next to distributing wire on new replacement windows.

Applying primer

Fig. 291: Applying Primer Evenly In One Pass Using Applicator
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Apply primer - 2 - D 009 200 02 uniformly all around on window, centering by markings, using applicator - 1 - , Part No. D 009 500 25 (felt ball with wire).
• This determines the distance to window edge - dimension b -.
• Primer width - dimension a - is determined by the markings on window.
• Begin application with a fully saturated felt. Air drying time approx. 10 minutes.

CAUTION:

Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material!

NOTE:

Do not touch up primer strip until after primer has thoroughly dried.

Fig. 292: Dimensions For Application Of Adhesive
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Adhesive bead cross section

1 - Adhesive bead

2 - Primer

3 - Washer

• Dimension - a - = 8 ± 2 mm.
• Dimension - b - =13.5 ± 1.5 mm.
• Dimension c is determined by markings on window

Installing rear window

• After preparatory work has been performed, apply the adhesive.

Fig. 293: Positioning Complete Surface Of Nozzle Onto Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Position complete surface of nozzle - 2 - onto window.
• - Arrow - indicates direction of application

NOTE:

Cross-section thickness of adhesive bead - 1 - is determined by dimension of opening in nozzle tip and rate of application.

Fig. 294: Applying Adhesive Sealing Material All Around
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Apply adhesive sealing material all around, as shown in illustration.
• Note varying spacing dimensions to window edge --> Rear window (Avant), removing and installing.
• Using two double suction cups, install rear window in window opening.

CAUTION:

Window must be installed within 15 minutes, otherwise bonding properties of adhesive will be impaired.

• Align windshield at sides.
• Secure window glass in windshield opening using adhesive tape during curing process.
• Observe curing time.

66 Exterior equipment

Roof moldings

Roof joint strip (Sedan), removing and installing

Fig. 295: Roof Joint Strip (Sedan) Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Roof joint strip

• Removing:
• Carefully pry out of roof joint starting from rear.
• Installing:
• Install seal profile - 2 - onto roof joint strip - 1 -.

• Coat seal profile with lubricant (e.g. soap).
• Slide in roof joint strip under gap cover starting at windshield - 3 - and press into roof joint in sections up to half way.
• Also slide in roof joint strip under gap cover at rear window and press completely into roof joint.

2 - Seal profile

• Coat with lubricant before installing.

3 - Windshield

Roof joint strip, removing and installing (Avant)

Fig. 296: Roof Joint Strip (Avant) Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Windshield

2 - Seal profile

• Coat with lubricant before installing.

3 - Roof joint strip

• Removing:
• Removing roof rail --> Roof rail, removing and installing.
• Carefully pry out of roof joint starting from rear.
• Installing:

• Install seal profile - 2 - onto roof joint strip.
• Coat seal profile with lubricant (e.g. soap).
• Slide on roof joint strip starting at windshield - 3 - below gap cover and press completely into roof joint by sections from front toward rear.

Roof trim molding (Sedan), removing and installing

NOTE:

To remove roof trim molding, it is not necessary to remove the side window.

Fig. 297: Roof Trim Molding (Sedan) Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Roof trim molding

• B-pillar trim removed --> B-pillar trim panel, removing and installing.
• Door seals in area of roof trim molding pulled off.
• Pry out cover strip - 2 - from roof trim molding.
• Drill off rivet heads of pop rivets - 3 - , strike rivet shafts through and remove roof trim molding.

2 - Cover strip

• To ease installation, coat edges with lubricant.
• Press into roof trim molding from front toward rear.

3 - Pop rivet

4 - Retaining clip

• 5x

5 - C- pillar trim

• Pull off in direction of travel.

6 - Roof trim molding, side window

• Pry off carefully using plastic wedge starting from bottom and pull off in - direction of arrow -.

CAUTION:

Roof trim molding, side window may not be warped or bent, otherwise there is visual damage.

Roof trim molding, removing and installing (Avant)

NOTE:

To remove roof trim molding, it is not necessary to remove the side window.

Fig. 298: Roof Trim Molding Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Roof trim molding

• B-pillar trim removed --> B-pillar trim panel, removing and installing.
• Remove door seals in area of roof trim molding
• Pry out cover strip - 3 - from roof trim molding.
• Drill off rivet heads of pop rivets - 3 - , strike rivet shafts through and remove roof trim molding.

• Carefully pry out roof trim molding from retaining clips - 2 - (7x) starting at A-pillar.
• On vehicles with gloss package, disengage roof trim molding from lower trim molding Disengaging roof trim molding from trim molding under side window

CAUTION:

Roof trim molding may not be warped or bent, otherwise there is visual damage.

2 - Retaining clip

• 7x

3 - Cover strip

• To ease installation, coat edges with lubricant.
• Press into roof trim molding from front toward rear.

4 - Pop rivet

Disengaging roof trim molding from trim molding under side window

Fig. 299: Disengaging Roof Trim Molding From Trim Molding Under Side Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Carefully disengage loose roof trim molding from lower trim molding.

Roof rail

Roof rail, removing and installing

Fig. 300: Roof Rail Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Special nut

• 18 Nm

2 - Gaskets with glued seal

• Check for proper seating

3 - Roof rail

• Removing:
• Remove upper A-pillar trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• Remove D-pillar trim. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• Remove trim above rear door. -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

• Unthread nuts - 1 - and remove roof rail.
• Installing:
• Check for correct seating of seals on threaded points of roof rail.
• Tighten nuts - 1 - to 18 Nm.

Protective moldings

Replacing side protective moldings

NOTE:

Protective moldings cannot be removed without destroying them.

Fig. 301: Removing Protective Moldings, Heating Using A Hot Air Blower And Pulling Off From Door
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To remove protective moldings - 1 - and - 2 - , heat using a hot air blower and pull off from door.
• Adhesion surface must be free of dust and grease.
• Clean outer panel with mineral spirits, treat with silicone remover and rub dry.

• Protective moldings must be affixed only at room temperature.
• For this purpose, bring vehicle and protective moldings to room temperature at least 2 hours before processing.
• Protective moldings must be adhered within 90 minutes after protective foil has been removed.

• Pull protective foil - 3 - from double-sided adhesive tape - 4 - shortly before installation.
• Apply protective molding to be adhered at front and adhere working toward rear.
• Heat protective molding to approx. 40°C using heat gun and forcefully press on or roll on.

• After adhering strip, leave vehicle 4 hours in room temperature.

Trim cover for sill panel, removing and installing

Fig. 302: Trim Cover For Sill Panel Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Front trim cover

• To remove, remove bolt - 3 - , slide trim cover with clip - 4 - toward rear and out of locking mechanism.
• Remove trim cover sideways.
• To install, insert trim cover in door, slide into locking mechanism toward front and secure with bolt - 3 -.

2 - Rear trim cover

• Removal as for front trim cover.

3 - Bolt

• 1 Nm

4 - Clip

Trim cover for sill panel, removing and installing S4

Front door

Fig. 303: Trim Cover For Sill Panel (S4) Remove/Install Components (Front Door)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To remove, remove bolts - 2 -.
• Pull trim cover - 3 - toward rear out of retainers.
• Remove trim cover sideways from door - 1 -.
• When installing trim cover, tighten bolts - 2 - to 1Nm.

Rear doors

Fig. 304: Trim Cover For Sill Panel (S4) Remove/Install Components (Rear Doors)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To remove, remove bolts - 2 -.
• Pull trim cover - 3 - toward rear out of retainers.
• Remove trim cover sideways from door - 1 -.
• When installing trim cover, tighten bolts - 2 - to 1Nm.

Face plates

B-pillar trim panel, removing and installing

Fig. 305: B-Pillar Trim Panel Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - B pillar trim panel

Removing:

• Unclip cover - 7 -.
• Remove bolts - 6 - pull trim panel off outward.

Installation:

• With rear door opened, guide trim panel into retaining bracket.
• With rear door closed, position at top and bottom according to magnified area in illustration.
• Screw in front bolt - 6 -.
• Outer lip of rear door window seal must make contact cleanly over entire range of trim panel.

NOTE:

Excessive pressure on seal at trim panel must be prevented, otherwise the projecting lip may cause wind noise. With door opened, screw in rear bolt - 6 -. Press grommet - 5 - into trim panel. Slide cover - 7 - on from below.

2 - Bolt

• 1.5 Nm

3 - Retaining bracket

4 - Clip

5 - Grommet

6 - Combination bolt

• 5 Nm

7 - Cover

Window weatherstrips

Window weatherstrips for front door (standard vehicle), removing and installing

• Remove door trim -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• Remove window frame and window regulator --> Window frame and window regulator, removing and installing.

Fig. 306: Removing Clips & Window Shaft Strip
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove clips - 2 -.
• Remove window shaft strip - 1 -.
• Installation is performed in the reverse order of removal.

Front window weatherstrips (vehicles with gloss package), removing and installing

NOTE:

Illustrations show window weatherstrips for rear door

Fig. 307: Covering Area Below Window Weatherstrips With Adhesive Tape
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Cover area below window weatherstrips - 1 - with adhesive tape - 2 -.

Fig. 308: Carefully Bending Up Window Weatherstrip Slightly At Rear
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Carefully bend up window weatherstrip - 1 - slightly at rear - arrow -.

Fig. 309: Using Plastic Wedge To Pry Off Window Weatherstrip From Carrier Part At Sides
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Using a plastic wedge, pry off window weatherstrip - 1 - from carrier part at sides.

Fig. 310: Widening Slightly The Lower Edge On Inside Of New Window Weatherstrip Using Plastic Wedge
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Carefully widen slightly the lower edge on inside of new window weatherstrip - 1 - using a plastic wedge - 2 -.
• Coat this edge and carrier part with e.g. soap solution to assist installation.

Fig. 311: Inserting Window Weatherstrip From Above And Pressing Window Weatherstrip Completely Onto Carrier Part By Hand
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Insert window weatherstrip - 1 - from above and carefully press window weatherstrip completely onto carrier part by hand.

Window weatherstrips for rear door (standard vehicle), removing and installing

• Remove door trim -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
• Remove window frame and window regulator --> Window frame and window regulator, removing and installing.

Fig. 312: Removing Clips & Window Weatherstrips
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove clips - 2 -.
• Remove window weatherstrips - 1 -.
• Installation is performed in the reverse order of removal.

Rear window weatherstrips (vehicles with gloss package), removing and installing

Fig. 313: Covering Area Below Window Weatherstrips With Adhesive Tape
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Cover area below weatherstrips - 1 - with adhesive tape - 2 -.

Fig. 314: Carefully Bending Up Window Weatherstrip Slightly At Rear
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Carefully bend up weatherstrips - 1 - slightly at rear - arrow -.

Fig. 315: Using Plastic Wedge To Pry Off Window Weatherstrip From Carrier Part At Sides
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Using a plastic wedge, pry off weatherstrips - 1 - from carrier part at sides.

Fig. 316: Widening Slightly The Lower Edge On Inside Of New Window Weatherstrip Using Plastic Wedge
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Carefully widen slightly the lower edge on inside of new weatherstrips - 1 - using a plastic wedge - 2 -.
• Coat this edge and carrier part with e.g. soap solution to assist installation.

Fig. 317: Inserting Window Weatherstrip From Above And Pressing Window Weatherstrip Completely Onto Carrier Part By Hand
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Insert weatherstrips - 1 - from above and carefully press weatherstrips completely onto carrier part by hand.

Outside rear view mirror

Outside rear view mirror, removing and installing

Special tools, testers and auxiliary items required

Fig. 318: Identifying Pry Lever 80-200
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Lever 80-200

Assembly overview

Fig. 319: Outside Rear View Mirror Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Mirror housing

• May be removed from door without removing entire rearview mirror --> Outside rear view mirror housing, removing and installing.

2 - Adjusting motor

• Removal --> Outside rear view mirror adjusting motor, removing and installing

3 - Mirror adjusting unit

• Before replacing, window frame must be removed --> Window frame and window regulator, removing and installing.
• Before removing, remove rearview mirror from door
• To remove, pry off mirror lens, disconnect electrical harness connectors for mirror heater, remove phillips-head screws - 6 - and remove mirror adjusting unit from mirror housing - 1 -.

4 - Mirror lens

• Use special tool Lever 80-200 to unclip.
• Protect mirror housing against damage using textile tape above and below.
• Press mirror lens first downward, then upward.
• To install mirror lens into guide pins and friction finger, insert into friction spring and press on.

• Apply pressure only on center of glass, wear protective gloves while doing so.

5 - Front door

6 - Electrical harness connector

7 - Combination bolt

• 12 Nm

8 - Seal

• Ensure correct seating when installing.

9 - Mirror base

Outside rear view mirror lens, installing

Fig. 320: Outside Rear View Mirror Lens, Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install mirror lens - 3 - with locking tabs onto mirror lens base - 2 - in - direction of arrow -.
• Friction finger must be inserted into friction spring - arrow - of housing - 1 - while doing so.
• Apply pressure only on center of glass, wear protective gloves while doing so.

Outside rear view mirror adjusting motor, removing and installing

• Mirror lens removed.

Fig. 321: Outside Rear View Mirror Adjusting Motor, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - arrows - from mirror adjusting unit.
• Remove motor - 2 - from mirror adjusting unit and disconnect electrical harness connector.
• When installing, tighten bolts to 1 Nm.

Outside rear view mirror housing, removing and installing

Fig. 322: Outside Rear View Mirror Housing Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Mirror housing

• Removing:
• Remove bolts - 4 - from cover trim - 3 - and remove them downward.
• Release housing from locking tabs on mirror adjusting unit and remove it upward.
• Installing

• Position mirror housing onto mirror adjusting unit - 2 - from above.
• While doing so, locking tabs - arrows - in mirror adjusting unit must engage above and below Lower mirror locking tab.

2 - Mirror adjusting unit

3 - Lower trim strip.

4 - Combination bolts

• 1Nm

Lower mirror locking tab

Fig. 323: Lower Mirror Locking Tab
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• When installing, locking tab (- arrow A -) of mirror adjusting unit - 2 - must be inserted into mirror housing catches - 1 - in - direction of arrow -.

Outer sill panel trim

Outer sill panel trim, replacing

NOTE:

Outer sill panel trim cannot be removed without destroying it.

Fig. 324: Removing/Installing Door Sill Panel Trim
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Heat door sill panel trim using a hot air gun and carefully pull upward and off.
• Clean adhesion surface with mineral spirits, treat with silicone remover and rub dry.

• Door sill moldings must be affixed only at room temperature.
• For this purpose, bring vehicle and door sill moldings to room temperature at least 2 hours before processing.
• Protective moldings must be adhered within 90 minutes after protective foil has been removed.

• Heat adhesion surface to approx. 40°C using a hot air gun.

Fig. 325: Removing/Installing Door Sill Panel Trim
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull protective foil from double-sided adhesive tape shortly before installation.
• Clip in door sill molding and press on.

• After adhering strip, leave vehicle 4 hours in room temperature.

Sill panel cover, removing and installing

Sill panel cover, removing and installing

Fig. 326: Sill Panel Cover Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Bracket for sill panel cover

• Removing and installing Removing bracket for sill panel cover

2 - Bolt

• 1 Nm

3 - Bolt

• 2 Nm

4 - Sill panel cover

• Removing:
• Then pull out of rear cover in - direction of arrow - and remove.
• Installing:
• Insert sill panel cover into rear cover.

• Then secure to bracket - 1 - Removing bracket for sill panel cover.
• Screw in bolts - 3 -.
• Screw in bolts - 2 -.

5 - Cover strip

6 - Rear sill panel cover

• Removing and installing Rear sill panel cover

7 - Bolt

• 2 Nm

8 - Bolt

• 1 Nm

9 - Wheelhousing liner

Removing bracket for sill panel cover

Fig. 327: Removing Bracket For Sill Panel Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Sill panel cover removed.
• Remove bolts at wheelhousing liner.
• Remove bolts - 2 - and remove bracket - 1 -.
• Expanding nut - 3 -.

• When installing, engage sill panel cover - 4 - completely into bracket - 1 -.

Rear sill panel cover

Fig. 328: Rear Sill Panel Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Sill panel cover - 1 - removed.
• Remove bolts - 1 - and remove rear sill panel cover - 2 -.
• Wheelhousing liner - 5 -.
• Rear wheel spoiler - 4 -.

Underbody covers

Underbody covers

Front underbody cover

Fig. 329: Underbody Covers (Front Underbody Cover)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Cd cover, right, front

2 - Cap for Cd cover

3 - Hex nut

• 2.3 Nm

4 - Expanding rivet

5 - Cd cover, left, front

6 - Right underbody cover

7 - Hex nut

• 2.3 Nm

8 - Left underbody cover

Rear underbody cover for Front Wheel Drive (FWD)

Fig. 330: Underbody Covers (Rear Underbody Cover For Front Wheel Drive (FWD))
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Blind rivet bolt

2 - Underbody cover for fuel tank

3 - Hex nut

• 1.7 Nm

4 - Hex nut

• 2.3 Nm

5 - Sheet-metal screw

• 1.7 Nm

6 - Sheet-metal screw

• 1.7 Nm

7 - Underbody cover, left, rear

Rear underbody cover for All Wheel Drive (AWD)

Fig. 331: Underbody Covers (Rear Underbody Cover For All Wheel Drive (AWD))
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Underbody cover for fuel tank

2 - Hex nut

• 2.3 Nm

3 - Expanding rivet

4 - Sheet-metal screw

5 - Spring nut

• 2.3 Nm

6 - Underbody cover, left, rear

Underbody cover for rough terrain package

Fig. 332: Underbody Covers (Underbody Cover For Rough Terrain Package)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Underbody cover for fuel tank

2 - Hex nut

• 2.3 Nm

3 - Expanding rivet

4 - Washer

5 - Hex bolt

• 5 Nm

6 - Stone impact protection plate

7 - Underbody cover, right, rear

Removing and installing tunnel brace

Fig. 333: Removing And Installing Tunnel Brace
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Underbody cover removed.
• Front tunnel brace - 2 -
• When installing, tighten hex bolts - 1 - to 55 Nm.
• Rear tunnel brace - 3 -

• When installing, tighten hex bolts - 4 - to 60Nm.

Wheelhousing liner, removing and installing

Front wheelhousing liner

Fig. 334: Front Wheelhousing Liner Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Fender

2 - Bolt

• 2.3 Nm

3 - Front wheelhousing liner

• Remove front wheel before disassembly.
• To disassemble, release quick-release screws - 6 -.
• Unscrew bolts - 2 -.
• Disengage wheelhousing liner from fender and pull downward and out.

4 - Expanding nut

5 - Sill panel cover

6 - Quick release screw

Rear wheelhousing liner

Fig. 335: Rear Wheelhousing Liner Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear wheelhousing liner

• Remove rear wheel before disassembly.
• Unscrew bolts - 2 -.
• Remove wheelhousing liner downward.

2 - Bolt

• 1.5 Nm

3 - Combination bolt

• Inserted only on the right side of vehicle.

4 - Expanding nut

Wheel spoiler

Front wheel spoiler, removing and installing

Fig. 336: Front Wheel Spoiler Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Brace for fender

2 - Clamping pin

• To loosen, rotate 180°.

3 - Front wheel spoiler

• To remove, remove bolts - 8 - , rotate clamping pins 180°, pull out and pull out wheel spoiler under wheelhousing liner - 7 -.

4 - Speed nut

• Slid onto noise insulation

5 - Noise insulation

6 - Guide piece for bumper

• Secured to fender

7 - Front wheelhousing liner

8 - Sheet-metal screw

• 1.5 Nm

Rear wheel spoiler, removing and installing

Fig. 337: Rear Wheel Spoiler Remove/Install Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear wheel spoiler

• Remove bolts - 2 - completely and pull out wheel spoiler downward under wheelhousing liner/underbody cover.

2 - Combination bolt

• 2Nm

3 - Front underbody cover

Ornamental parts

Lettering on rear lid (Sedan)

NOTE:

Outer edges of rear lid and lines extending from lower rear lights are used as reference edges.

Installation:

• Warm vehicle and type designation to room temperature.
• Bonding surfaces must be dry and free from dust and grease.
• Clean outer panel with mineral spirits, treat with silicone remover and rub dry.
• Pull off backing paper and press on characters - 1 - , maintaining pressure for approx. 3 seconds.

Dimensional data for Front-Wheel Drive (FWD) vehicles

Fig. 338: Dimensional Data For Front-Wheel Drive (FWD) Vehicles
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• a = 23 mm.
• b = 28 mm
• c = 2 mm
• d = 28 mm

• e = 11 mm

Dimensional data for All Wheel Drive (AWD) vehicles

Fig. 339: Dimensional Data For All Wheel Drive (AWD) Vehicles
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• a = 23 mm.
• b = 28 mm
• c = 4 mm
• d = 12.5 mm

• e = 28 mm
• f = 0.11 mm

Lettering on rear lid (Avant)

NOTE:

Outer edges of rear lid and lines extending from lower rear lights are used as reference edges.

Installation:

• Warm vehicle and type designation to room temperature.
• Bonding surfaces must be dry and free from dust and grease.
• Clean outer panel with mineral spirits, treat with silicone remover and rub dry.
• Pull off backing paper and press on characters - 1 - , maintaining pressure for approx. 3 seconds.

Dimensional data for Front-Wheel Drive (FWD) vehicles

Fig. 340: Dimensional Data For Front-Wheel Drive (FWD) Vehicles
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• a = 95 mm
• b = 33 mm
• c = 38 mm
• d = 28 mm

• e = 95 mm

Dimensional data for All Wheel Drive (AWD) vehicles

Fig. 341: Dimensional Data For All Wheel Drive (AWD) Vehicles
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• a = 33 mm
• b = 28 mm
• c = 4 mm
• d = 12.5 mm

• e = 38 mm
• f = 95 mm

Ornamental parts, as of Vehicle Identification Number (VIN) 400 001

Lettering on rear lid (Sedan)

NOTE:

Lower edge of rear lid is used as a reference edge, outer edge at crossover point for the corresponding height dimension.

Installation:

• Warm vehicle and type designation to room temperature.
• Bonding surfaces must be dry and free from dust and grease.
• Clean outer panel with mineral spirits, treat with silicone remover and rub dry.
• Pull off backing paper and press on characters - 1 - , maintaining pressure for approx. 3 seconds.

Dimensional data for Front-Wheel Drive (FWD) vehicles

Fig. 342: Dimensional Data For Front-Wheel Drive (FWD) Vehicles
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• a = 25 mm
• b = 30 mm
• c = 63 mm
• d = 25 mm

Dimensional data for All Wheel Drive (AWD) vehicles

Fig. 343: Dimensional Data For All Wheel Drive (AWD) Vehicles
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• a = 25 mm
• b = 30 mm
• c = 63 mm
• d = 25 mm

• e = 4 mm

Lettering on rear lid (Avant)

Dimensional data for Front-Wheel Drive (FWD) vehicles

Fig. 344: Dimensional Data For Front-Wheel Drive (FWD) Vehicles
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• a = 50 mm
• b = 30 mm
• c = 65 mm
• d = 50 mm

Dimensional data for All Wheel Drive (AWD) vehicles

Fig. 345: Dimensional Data For All Wheel Drive (AWD) Vehicles
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• a = 50 mm
• b = 30 mm
• c = 65 mm
• d = 50 mm

• e = 4 mm

Rear lid spoiler, removing and installing

Rear lid spoiler, removing and installing

Special tools, testers and auxiliary items required

Fig. 346: Identifying Heat Gun V.A.G 1416
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Heat gun V.A.G 1416

S4 sedan

Fig. 347: Rear Lid Spoiler - Assembly Overview S4 Sedan
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear lid spoiler

Removing

• Before removing spoiler, remove rear lid trim.
• Remove nuts - 2 -.
• Heat rear lid from inside using a hot air gun.
• Carefully pull off spoiler from rear lid, beginning at sides.

• Remove remaining adhesive tape from rear lid.

Installation:

• Rear lid must be free of dust and grease in adhesion area
• Clean adhesion area of rear lid with cleaning solution D 009 401 04.
• Before installing a new spoiler, pull backing paper - arrow - from adhesive tape.
• Place spoiler onto rear lid, centered and in flush position.

• Press spoiler firmly over entire length onto rear lid.
• Tighten nuts - 2 - to 2 Nm.

• Before reinstalling spoiler, remove remaining adhesive tape completely.
• Before installing, adhesive tape - 3 - must be applied all around and sealing washers around threaded pins in spoiler as shown in Apply adhesive tape on spoiler.

2 - Cap nut

• 2Nm

3 - Adhesive tape

• If a removed spoiler is to be reinstalled, first apply adhesive tape and sealing pieces for threaded pins in spoiler Apply adhesive tape on spoiler.
• Adhesive tape residue must be removed from spoiler before reinstalling.

Removing spoiler

Fig. 348: Heating Rear Lid In Adhesion Area For Spoiler Using Hot Air Gun V.A.G 1416
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Heat rear lid in adhesion area for spoiler using hot air gun V.A.G 1416.
• Carefully pull off spoiler upward from rear lid, beginning at sides.
• If spoiler is re-used, adhesive tape residue must be removed completely.

Apply adhesive tape on spoiler

Fig. 349: Apply Adhesive Tape On Spoiler
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull off backing paper from sealing pieces - 5 - and press seal over thread onto spoiler - 1 -.
• Pull off backing paper on one side from adhesive tape - 2 - or - 4 -.
• Press adhesive tape along circumference on spoiler as shown.
• In rear area, adhesive tape - 4 - must be pressed on in radius.

• Tighten nuts to 2 Nm when installing.

S-Line Avant

Fig. 350: Removing/Installing Rear Lid Spoiler - S-Line Avant
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Spoiler

• Remove rear lid trim before removing

• Remove bolts - 4 -.
• Heat adhesion area on lid using hot air gun V.A.G 1416.

• Pull spoiler from lid upward and off.
• Before assembling a spoiler, clean adhesion area on lid with cleaning solution D 009 401 04.
• Pull off backing paper from double-sided adhesive tape.
• Place spoiler over holes onto closed lid.

• Press on spoiler forcefully, starting at center and working outward over entire width.
• Open lid and tighten bolts to 4 Nm.

2 - Rear lid

• Lid must be free of dust and grease in adhesion area.
• Before assembling a spoiler, clean adhesion area on lid with cleaning solution D 009 401 04.

3 - Adhesive tape

• Remove protective paper before applying.

4 - Combination bolt

• 4 Nm

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