Body MK5 Jetta Golf PDF

Volkswagen Golf V: Lock carrier Page 1 / 6
50 - 1
Lock carrier
Tools
Required special tools, workshop equipment, testing and

measuring equipment, and aids
Guide rod T 10093
Torque wrench 550 Nm V.A.G 1331
Lock carrier service position, assembly overview

Lock carrier Page 2 / 6
Lock carrier with attachments
Removing and installing

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

Service position
Screw
Qty 4
8 Nm
Screw
Qty. 8
60 Nm
Service position
Performing service position
- Remove front bumper 63-1, Front

bumper cover, removing and installing
- Disengage hood release cable in

coupling 55-1, Hood release cable,
disconnecting
- In vehicles with charge air cooler,

disconnect pressure hoses 50-1,
Releasing pressure hoses .
- Remove signal horn - 4 - with bracket

from longmember at right side
Repair Manual, Electrical Equipment,

Repair Group 96, Lights, lamps, interior
switch, signal horn, removing and
installing
- Unscrew bolts - 3 - at left and right

longmembers.
- Screw in guide rod T 10093 at left and

right longmembers.
- Remove bolts - 2 - at left and right on

top of lock carrier - 1 - .
- Lock carrier - 1 - can be pulled toward

front approx. 10 cm on guide rod T
10093 .
Resetting service position
Installation is performed in the reverse order of removal.
- Center lock carrier on side rails and between fenders
Repair Manual, Body Collision Repair, Repair Group 00,

Technical data; Body gap dimensions
Note:
Make sure that pressure hoses for charge air cooler

are re-engaged correctly.
Hoses and lines must not be pinched.
Releasing pressure hoses
- Disengage connector coupling - 1 - and disconnect

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

coupling.
- When re-connecting pressure hoses, make sure that

connector couplings engage audibly.
Lock carrier with attachments, removing and installing
Removing
- Perform service position of lock carrier

with attachments - 1 - 50-1,
Performing service position .
- Disconnect the electrical harness

connectors present.
- Drain coolant and disconnect coolant

lines
Repair Manual, 2.0 Liter 4-Cyl. 4V

Turbo Engine Mechanical, Fuel Injection
Ignition, Engine Code(s): BPY, Repair
Group 19, Cooling system parts; draining
and filling coolant
- Disconnect condenser lines
Repair Manual, Heating Air

Conditioning, Repair Group 87, A/C
system; removing and installing
condenser
- With a second technician, unscrew

guide rod T 10093 on longmember on
left and right sides and lift out lock
carrier.
Warning!
If lines for A/C system and/or for coolant are

disconnected, the powertrain aggregate must no
longer be started.
Note:
Do not hang condenser and hydraulic oil cooler on

hoses.
Lines for condenser and hydraulics must not be

kinked.
Installing
Make sure that all plug and hose connections are

corrected installed when re-assembling.
- Center lock carrier on side rails and between fenders

Volkswagen Golf V: Fender Page 1 / 6
50 - 2
Fender
Tools
Special tools, testers and auxiliary items required
Heat gun V.A.G 1416
Front fender, assembly overview
Note :
The illustration shows the left side. The right side is

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

50-2, Fender, removing and
installing
Screw
Qty. 1, A-pillar
Qty. 2, side member
Qty. 2, wheel housing
Qty. 2, fender brace
Qty. 3, fender connecting

piece
6 Nm
Fender Page 3 / 6
Foam piece
Loosely inserted between

fender and upper
longmember
Fender brace

50-2, Fender brace,
Molded foam part
Placed on upper
longmember.
Secures at fender.
Hex nut
Qty. 1, at fender connecting

piece
6 Nm
Fender, removing and installing
Note:
Removing and installing is described only for the left

fender. Removing and installing right fender is
derived accordingly from this.
Removing
Fender Page 4 / 6
- Remove front bumper 63-1, Front

bumper cover, removing and installing
- Remove wheelhousing liners 66-1,

Front wheel housing liner, removing and
installing
- Unscrew guide profile Item - 10 -
- Loosen hex nut - 6 - and remove bolts

- 2- .
- Pull out foam piece - 3 - between

fender and longmember.
- Lightly heat fender - 1 - from outside in

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

- 5 - loosens and fender - 1 - can be
removed.
Fender Page 5 / 6
Installing
- Make sure gaps are parallel and pay attention to gap

dimensions

Fender brace, removing and installing
Note:

fender brace. Removing and installing right fender
brace is derived accordingly from this.
Removing
Fender is removed.
- Remove screws - 2 - and remove fender brace - 1 - .
Installing
Fender Page 6 / 6
- Assemble the fender brace - 1 - .
- Tightening torques: Bolts - 2 - 6 Nm.
- Fender brace is installed together with fender to hood

and bumper:

Volkswagen Golf V: Noise insulation Page 1 / 3
50 - 3
Noise insulation
Tools
Noise insulation panel, assembly overview
Note :
Slight changes may have to be made to removal and

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

of travel.
Removing:
- Remove bolts - 2 - and -

3 - .
Screw
Qty. 8
2 Nm
Screw
Qty. 3
Noise insulation Page 3 / 3
6 Nm
Volkswagen Golf V: Underbody trim Page 1 / 3
50 - 4
Underbody trim
Tools
Underbody trim, assembly overview
Note :

Underbody trim Page 2 / 3
Underbody cover
- Arrow - points in direction

of travel.
Removing:
- Remove hex nuts - 2 - .
Hex nut
Qty. 8
1.5 Nm
Rear underbody cover
Only installed on the left

side.
Underbody trim Page 3 / 3
Removing:
- Remove hex head nuts -

4 - and screws - 5 - .
Hex nut
1x
1.5 Nm
Screw
Qty. 3
2 Nm
Cover
Removing:
- Remove bolts - 7 - .
Screw
Qty. 2
2 Nm
Volkswagen Golf V: Plenum chamber bulkhead Page 1 / 2
50 - 5
Plenum chamber bulkhead

Tools
Plenum chamber bulkhead, assembly overview

Plenum chamber bulkhead Page 2 / 2
Plenum chamber bulkhead
Hex nut
8 Nm
Seal for plenum chamber

bulkhead
Ensure seal is seated

correctly when installing
bulkhead.
Screw
8 Nm
Volkswagen Golf V: Front hood Page 1 / 18
55 - 1
Front hood
Tools
Pry lever - RMV outside mirror 80-200
Hood, assembly overview

Front hood Page 2 / 18
Hood

55-1, Hood, removing and
installing
Adjusting 55-1, Hood,

adjusting
Adjustment buffer
Qty. 2

adjusting
Stop buffer
Qty. 2
Insulation

55-1, Noise insulation,
Guide piece
Qty. 2
Hinge

55-1, Hood hinge, removing
and installing

adjusting
Gas strut
Removing 55-1,
Removing gas-filled strut
Venting gas 55-1, Gas-

filled strut, venting
Hood seal
Secured to interior hood with

17 clips.
Hood, removing and installing
Removing
- Remove left and right spray nozzles - 6

-

Repair Group 92, Windshield washer and
wiper system; Windshield washer
system; Windshield washer system spray
nozzles, removing and installing
- Unclip line - 2 - from hinge - 3 - and

hood - 5 - .
- Remove line - 2 - from opening of

hood - 5 - .
- Loosen hex nuts - 1 - at left and right

(do not unscrew completely).
A second technician is required for the

rest of the removal procedure.
- Remove gas-filled strut - 4 - at hood -

5- 55-1, Removing gas-filled strut
- Remove hex nuts - 1 - and lift hood - 5

- from hinges - 3 - .
Installing
- Tightening torques: Hood hex head nut, 22 Nm
- Adjust hood - 1 - 55-1, Hood, adjusting
- Route line - 2 - as shown - arrow - . If line is installed

twisted, the line is kinked.
- Open hood and support hood.
- Reach under spring clips - 2 - using a small

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

clips can be slid over ball socket in - direction of arrow -
.
- Remove gas-filled strut - 1 - from ball studs - 3 - and - 4

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

back spring clips - 2 - again.
Warning!
Proceed carefully when re-using gas-filled strut.

Spring clips must not be pried completely out of ball
socket, otherwise spring clips will be damaged. Gas-
filled strut springs out of mount and leads to damage
and injury to the operator.
- Tightening torques of ball studs - 3 - and - 4 - : 22 Nm.
- Gas-filled strut, venting 55-1, Gas-filled strut, venting
Gas-filled strut, venting
- Clamp gas-filled strut in vice area - x - . Dimension of -

x - = 50 mm (2 in.).
Warning!
Clamping the gas-filled strut must only be done in this

area - x - , otherwise there is a risk of an accident.
- Using saw, cut into cylindrical part of strut at point within

first third of cylinders length (measured from cover edge at
piston rod end of cylinder).
Note:
Always wear eye protection when performing this

procedure.
Cover the area of the separated portion with a clean

rag.
Dispose of fluid and cleaning rag in a proper

manner.
Hood hinge, removing and installing
Note:

hood hinge. Removing and installing right hood
hinge is derived accordingly from this.
Removing
- Hood, removing 55-1, Removing
- Remove screws - 2 - and remove hood hinge - 1 - .
Installing
- Assemble the hood hinge - 1 - .
- Tightening torque for bolts - 2 - : 22 Nm

- Hood, installing 55-1, Installing
Noise insulation, removing and installing
Removing
- Using pry lever 80-200 , pry out

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

longitudinal holes.
Installing
- Slide noise insulation - 2 - under gas-

filled strut and insert mounting tabs into
longitudinal holes.
- Engage all retaining clips - 1 - (qty. 10)

in noise insulation - 2 - .
When installing noise insulation - 2

- , make sure that retaining clips -
1 - are inserted with wide side
facing outside.
Locking and unlocking components of hood, assembly

overview
Catch
Removing:
- Unscrew bolts - 2 - and

remove catch.
Adjusting:
- Catch can be adjusted

toward the left or right in its
longitudinal holes.
Screw
Qty. 3
10 Nm
Spreader nut
Qty. 2
Mounting bracket
Hood release cable
Clipped into mounting

bracket.
Screw
Qty. 2
1.5 Nm
Release lever

55-1, Release lever,
Hood release cable
Clipped in on wheelhousing
and lock carrier.
Hood release cable coupling
Disconnecting 55-1, Hood

release cable,
disconnecting
Hood lock

55-1, Hood lock, removing
and installing
Adjusting 55-1, Hood lock,

adjusting
Hood lock, removing and installing
Removing
- Open hood.
- Remove radiator grille 66-3, Radiator grille, removing

and installing
- Disconnecting hood release cable 55-1, Hood release

cable, disconnecting
- Disconnect harness connector - 5 - for Front Hood

Switch F 266 .
Harness connector is secured over right headlight.
- Remove bolts - 4 - (three pieces) on lock carrier - 3 -

and remove hood lock - 1 - upward.
- To unclip hood release cable - 2 - , press together tabs

on hood release cable - arrows - .
- The locking mechanism is released and hood release

cable - 2 - can be removed from hood lock - 1 - .
Installing
- Clip hood release cable - 2 - into hood lock - 1 - .
- Install hood lock - 1 - in lock carrier - 3 -
- Tightening torque for bolts - 4 - : 12 Nm.
- Connect harness connector - 5 - for Front Hood Switch F

266 .
- Install hood release cable - 2 - 55-1, Hood release

cable, disconnecting .
- Adjust hood lock 55-1, Hood lock, adjusting
Before the hood is closed, a function test of the

release lever and hood release cable must be
performed.
Hood release cable, disconnecting
- Open hood.
- Unclip hood release cable coupling - 1 - over headlight

on drivers side of lock carrier - 2 - .
- Open hood release cable coupling - 1 - and remove

hood release cable - 3 - in - direction of arrow - from
hood release cable coupling.
Note:
When installing, make sure that hood release cable

sleeve is inserted correctly and coupling is locked.

operating lever and hood release cable must be
performed.
Hood, adjusting
- For Basic Setting of hood - 1 - , vehicle

must stand on the ground and catches
must be removed.
- Remove catches - 9 - Item - 1 - .
- Remove gas-filled strut - 2 - at hood -

1- 55-1, Removing gas-filled strut
- By loosening hex nuts - 5 - and bolt -

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

be adjusted to fenders with adjusting
screw - 6 - on left and right sides.
- Stop buffers - 7 - (qty. 2) do not serve

to adjust. Their function is to stabilize and
to cushion the hood - 1 - .
- Hood - 1 - can be adjusted in height

relative to fenders in the front area using
the stops - 8 - (qty. two).
- Ensure gap dimensions are even
Repair Manual, Body Collision Repair,

Repair Group 00, Technical data; Body
gap dimensions
- After installing or adjusting perform

corrosion protection measures on hinges
- 4 - , hex head nuts - 5 - screws - 3 -
.
- After hood - 1 - has been adjusted,

catches can be reinstalled and adjusted:
Item - 1 -
Hood lock, adjusting

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

they had been adjusted, adjustment can be corrected
slightly by the hood lock and catches.
- Remove radiator grille 66-3, Radiator grille, removing

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

can be corrected or adjusted

- Tightening torques: Bolts - 1 - 12 Nm
- Adjust catches Item - 1 - .
Release lever, removing and installing
Removing
- Engage the release lever - 1 - and release hood.
- Insert a small screwdriver into gap between release lever

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

release lever off.
Installing
- Slide clip - 2 - completely into release lever - 1 - .
- Then push release lever - 1 - onto mount in mounting

bracket and lock the release lever.

release lever and hood release cable must be

performed.
Volkswagen Golf V: Rear lid Page 1 / 19
55 - 2
Rear lid
Tools
Rear lid, assembly overview

Rear lid Page 2 / 19
Rear lid

55-2, Rear lid, removing and
installing
Adjusting 55-2, Rear lid,

adjusting
Rear lid lock

55-2, Rear lid lock, removing
and installing
Adjustment buffer
Left and right
Adjusting 55-2,
Adjustment buffer, adjusting
Gas strut
Removing 55-2,
Venting gas 55-2, Gas-

filled strut, venting
Hinge

55-2, Rear lid hinge,
Striker pin

55-2, Latch bracket,
Adjusting 55-2, Adjusting

latch bracket
Cap
Left and right
Adjustment buffer stop.
Rear lid, removing and installing
Removing
- Open rear lid - 1 - .
- Remove rear lid trim
Repair Manual, Body Interior, Repair

Group 70, Trim panels, insulation; rear lid
trim
- Disconnect connectors on electrical

components present and remove rear
window washer system hose.
- Guide lines and hose through opening.
- Loosen bolts - 3 - at left and right lid

hinges - 4 - (do not unscrew
completely).

- Remove left and right gas struts - 2 - at

rear lid - 1 - 55-2, Removing gas-filled
strut
- Remove screws - 3 - and remove rear

lid - 1 - .
Installing
- Rear lid screw torque specification: 10 Nm.
- Rear lid, adjusting 55-2, Rear lid, adjusting
Before the rear lid is closed, a function test of the

unlocking components must be performed.
- Open rear lid and support rear lid.
- Reach under spring clips - 2 - using a small

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

clips can be slid over ball socket in - direction of arrow -
.
- Remove gas-filled strut - 1 - from ball studs - 3 - and - 4

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

back spring clips - 2 - again.
Warning!
Proceed carefully when re-using gas-filled strut.

Spring clips must not be pried completely out of ball
socket, otherwise spring clips will be damaged. Gas-
filled strut springs out of mount and leads to damage
and injury to the operator.
- Tightening torques of ball studs - 3 - and - 4 - : 21 Nm.
- Gas-filled strut, venting 55-2, Gas-filled strut, venting
Gas-filled strut, venting
- Clamp gas-filled strut in vice area - x - . Dimension of -

x - = 50 mm (2 in.).
Warning!
Clamping the gas-filled strut must only be done in this

area - x - , otherwise there is a risk of an accident.
- Using saw, cut into cylindrical part of strut at point within

first third of cylinders length (measured from cover edge at
piston rod end of cylinder).
Note:
Always wear eye protection when performing this

procedure.
Cover the area of the sawn portion with a clean rag.
Dispose of fluid and cleaning rag in a proper

manner.
Rear lid hinge, removing and installing

Note:
Removal and installation is described for right rear

lid hinge. Removal and installation for the left-hand
rear lid hinge is performed in the same manner.
Removing
- Remove rear lid - 1 - 55-2,

Removing
- Lower rear molded headliner

Group 70, Trim, noise insulation; roof
trim; removing and installing molded
headliner
- Remove hex head nut - 3 - and rear lid

hinge - 2 - from roof side member.
Installing
Note :
After installing rear lid - 1 - , retighten hex head nut

- 3 - for rear lid hinge - 2 - to 24 Nm.
- Install rear lid hinge - 2 - and tighten

hex head nut - 3 - to 24 Nm.
- Install rear lid - 1 - 55-2, Installing
- At end of installation, retighten hex

head nut - 3 - to 24 Nm.
- Install molded headliner


headliner
Latch bracket, removing and installing
Removing
- Remove lock carrier cover
Repair Manual, Body Interior, Repair Group 70,

Luggage compartment trim; removing and installing lock
carrier cover
- Remove screws - 1 - and striker pin.
Installing
- Assemble the latch bracket - 2 - .
- Tightening torque for bolts - 1 - : 23 Nm.

- Adjust latch bracket 55-2, Adjusting latch bracket
Further installation is in reverse order of removal.
Rear lid, adjusting
Note:
Vehicle must be standing on its wheels for basic

setting of rear lid.
Rear lid lock is bolted directly to the lid. It does not

have longitudinal holes and therefore cannot be
adjusted.
Stops recognized in other vehicles do not serve to

adjust the lid. They serve to stabilize and to cushion
the lid.
Next, adjusting the rear lid is described in several steps.
To adjust or check the gap dimensions, use special tool

3371

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

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

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

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

adjusting
Note:
Rear lid is properly adjusted when there is an overall

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

- Remove lock carrier cover

Luggage compartment trim; removing and installing lock
carrier cover
- Disengage the latch bracket - 2 - .
- Bring striker pin - 2 - to rear position - arrow - and

tighten screws - 1 - .
- Close rear lid and test the adjustment.
- Latch bracket - 2 - can be slid in oversized holes by

loosening bolts - 1 - .
Adjustment buffer, adjusting
Note:
The following adjustment is only for the right

adjustment buffer. Adjustment for the left adjustment
buffer is derived accordingly from this.
- Loosen clamping screw - 2 - far enough until it is visible

in rubber buffer.
- Now pull notched slider - 1 - out of adjustment buffer.
- Set notched slider to dimension - a - = 12.5 mm.
- Close rear lid to initial locking position using light

pressure over the center.
- Open rear lid again.
- Screw in adjustment buffer locking screw - 1 - to a depth

of dimension - a - 25 mm.
- Check the adjustment.
Locking and unlocking components of rear lid, assembly

overview
Rear Lid Handle Unlock Switch -

E234-

55-2, Unlocking element,
Screw
Qty. 5
4 Nm
Emergency release
Emergency release is
accessed through an
opening in the rear lid trim.
Rear lid lock

55-2, Rear lid lock, removing
and installing
Lid lock connector
Angle bracket
Unlocking element connector
Unlocking element, removing and installing
Note:
If rear lid does not open, it can opened by hand via

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

Group 70;, Trim panels, insulation; rear
lid trim
- Rear window washer motor, removing

Repair Group 92, Window wiper and
washer system; Rear window washer
system
- Disconnect harness connector - 7 -

from unlocking element - 1 - .
- Disengage unlocking element opposite

- arrow - angle brackets - 6 - .
- Then you can remove the unlocking

element - 1 - .
Installing
- Tightening torques for unlocking element: 4 Nm

Rear lid lock, removing and installing
Note:
If rear lid does not open, it can opened by hand via

the emergency release - 1 - on lid lock - 2 - .
Emergency release is accessed through an opening
in the rear lid trim.
Removing
Repair Manual, Body Interior, Repair Group 70;, Trim

panels, insulation; rear lid trim
- Disconnect harness connector - 4 - from lid lock - 2 - .
- Remove screws - 3 - and guide lid lock - 2 - downward

out of lid.
Installing
- Guide lid lock - 2 - into lid and install screws - 3 - .
- Connect harness connector - 4 - to lid lock - 2 - .

Rear lid seal
Rear lid seals are equipped at the factory with sealant,

applied to rear lid flange and then rolled on.
Note:
During removal of the seal, sealant is distributed on

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

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

seal" .
For partially removed seals, seal flanks must be

pressed together before installation.
Rear lid seal, removing and installing
Removing
- Pull off rear lid seal - 1 - from body flange.
Installing
- Align rear lid seal - 1 - with vulcanized point - arrow - to

center of left tail light.
Volkswagen Golf V: Tank lid unit Page 1 / 6
55 - 3
Tank lid unit

Tools
Socket wrench T 10010
Tank flap unit, assembly overview

Tank lid unit Page 2 / 6
Tank lid unit
removing 55-3, Fuel tank

flap unit, removing
Screw
1.5 Nm
Drain hose
Assembly component
Release rod
Mounting bolt for actuator
Qty. 2
1.5 Nm
Fuel Filler Cap Central Locking

Actuator (F219)
Removing 55-3, Actuator,

removing
Gasket
Fuel tank flap unit, removing
Note :
If tank flap does not open, it can be opened by hand

via the release rod - 5 - . Side trim must be
removed for this.
- Open fuel tank filler flap.
- Unscrew fuel tank cap.

- Remove bolt - 2 - .
- Remove rubber part from tank filler

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

3 - toward rear and swivel tank flap unit
out of side panel.
- Unclip assembly piece - 4 - from side

panel and pull off assembly piece from
release rod - 5 - .
Installing
Assembly piece - 4 - is slid on.
- Insert drain hose - 3 - through opening

in tank flap unit and pull drain hose
through until it stops.
- Guide drain hose into side panel.
- Slide tank flap unit - 1 - with hinge side

first into side panel.
- Then swivel tank flap unit completely

into side panel, make sure that upper and
lower catches engage correctly in side
panel.
- Pull rubber piece over tank filler neck

and tighten bolt - 2 - .
Tightening torque for bolt - 2 - : 1.5 Nm.
Actuator, removing
- Remove side luggage compartment

trim

Group 70, Trim/noise insulation; luggage
compartment trim
- Disconnect harness connector at

actuator - 7 - .
- Remove actuator - 7 - using special

tool socket wrench T 10010 .
- Remove actuator - 7 - together with

release rod - 5 - from seal - 8 - .
Installing

Volkswagen Golf V - Front door Page 1 / 44
57 - 1
Front door
Tools
Special tools, testers and auxiliary items

required
Assembly tool T 10118
Door adjusting wrench 3320
Joint for 3320 3320/1
Box wrench 3320/2

Front door Page 2 / 44
Box wrench 3320/3
Application roller for door insulation

foil 3356
Torque wrench 550 Nm V.A.G

1331
Adjusting gauge 3371

required
Cartridge gun V.A.G 1628

Cartridge heater V.A.G 1939 A
Trim removal wedge 3409
Assembly tool set T 10237
Materials
DH 009 100 01 1) 2)
1C- window adhesive
D 009 200 02 3)
Glass primer/paint primer
D 009 401 04 3)
Cleaning solution
D 009 500 25 3)
Primer applicator
3) Materials are stored in box D 004 700.

1) Observe minimum curing time 57-1, Minimum curing
time
2) Heat according to manufacturers instructions using
cartridge heater V.A.G 1939 .
Door construction, assembly overview
The door consists of inner door part - 6 -

and outer door plate - 1 - .
Parts are joined by the front - 7 - and the

rear - 5 - retaining tracks.
Retaining tracks are bolted to inner door

part and bonded to outer door plate.
Inner door part - 6 - undertakes among

other things the function of the previously
known subframe. Loudspeakers, window
regulators, window regulator motors,
wires, window guide, exterior mirror and
door lock are installed on inner door part.
Outer door plate - 1 - is also bolted to

inner door part on the lower edge.
Exterior window shaft seal, insulation and

outer door handle are installed on outer
door plate.
Caution!
Various bolts are used to secure the

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

58-1, Outer door plate,
Edge protection
Between outer door panel

and inner door part.
Screw
Characteristic: Bolt has point

and thinner washer.
6 pieces on lower edge
2 piece in rear rail area
10 Nm
Rear retaining track
Adhesive: DH 009 100 03
Screw
Characteristic: Bolt without

point but with thick washer.
Qty. 10 for both retaining

tracks on 4-door version
Qty. 11 for both retaining

tracks on 2-door version
14 Nm
Inner door part
Assembly overview 57-1,

Inner door part, assembly
overview
Front retaining track
Screw

and thick washer
Qty. 1 for front rail area
10 Nm
Insulation
Self-adhesive
To adhere, insulation must

be preheated and then
pressed on firmly
Clip
Qty. 6
Window shaft seal
Must be installed before

installing outer door shell.
Door hinges, assembly overview
Caution!
The nut for eccentric pin - 9 - must

not be loosened under any
circumstances. It cannot be secured
again using workshop equipment.
Note :
The description applies to the right side. The left side

is derived accordingly from this.
Bolts for door hinges must always be replaced after

loosening.
Hinges are no longer manufactured as separated

parts.
Door

57-1, Door, removing and
installing
Adjusting 57-1, Door,

adjusting
Guide bolt
10 Nm
Door hinge with door arrester
Socket head bolt
20 Nm + 1 / 4 turn further (90

)
Always replace bolts after

loosening
Socket head bolt
Installed from the vehicle

interior
Remove lower A-pillar trim

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

)

loosening
Socket head bolt

)

loosening
Socket head bolt

)

loosening
Guide screws
10 Nm
Nut
For the eccentric pin, must

not be loosened. Used for
making adjustments during
production.
Door hinge
Door hinge is no longer

manufactured as separated
parts.
Socket head bolt

)

loosening
Socket head bolt

)

loosening
Socket head bolt

)

loosening
Door, removing and installing
Note:
Removing and installing is described only for the

right door. Removing and installing the left door is
Removing
- Release boots - 6 - by pressing on

locking mechanism - arrow a - and
remove boots from A-pillar.
- Swivel locking lever - 7 - downward -

arrow b - and disconnect electrical
harness connector - 8 - from connector
station.
- Remove screws - 4, 5 and 11 - using

door adjustment wrench 3320 and bit
insert 3320/3 from hinge.
- Pull door in - direction of arrow - from

guide bolts - 2 and 9 - .
Installing
- Torque specification for screws - 4, 5 and 11 - : 20 Nm +

1 / 4 (90 ) additional turn.
Screws - 4, 5 and 11 - must always be replaced.
- Observe gap dimension of front door

Door, adjusting
Warning!

circumstances. The nut cannot be
secured again using workshop
equipment.
Note :
The door is properly adjusted when there is an

overall even gap dimension when closed, it is not too
far inward or outward and contours align.
Vehicle must stand on its wheels in order to be able

to perform the adjustment.
If outer door plate is removed, window frame of inner

door part must be adjusted in relation to roof frame
and B-pillar, and to rear door.
- Observe gap dimension of front door

gap dimensions
For correct gap dimension adjustment,

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

Group 70, Pillar and side trim
Other measures, such as aligning the

door upward, are not effective. Excess
pressure thereafter will again cause the
door to sag.
For correct alignment adjustment, screws

- 4, 6 and 14 - and guide screws - 2 and
8 - must be loosened.
Door adjusting wrench 3320 with bit

insert 3320/3 must be used for this.
Outer door plate, removing and installing
Removing
- Pry off clips - 3 - beginning at bottom

of door - 1 - and remove cover - 2 - .
- Removing lock cylinder 57-1, Housing, removing and

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

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

behind outer door plate.
- Remove all screws - 2, 3, 4 - .
- Carefully remove outer door plate.
Installing
Caution!
Various bolts are used to secure the outer door plate.

Outer door plate is damaged if not allocated correctly.
- Carefully set outer door plate in.
- Start all screws - 2, 3, 4 - .
Make sure that the various bolts

are used correctly.
Characteristic for bolt - 2 - : Bolt has point and

thinner washer.
Characteristic for bolt - 3 - : Bolt without point but

with thick washer.
Characteristic for bolt - 4 - : Bolt has point and thick

washer
- Check whether guide pins for retaining

tracks are located in the corresponding
guide holes of inner door part. Then
tighten all screws - 2, 3, 4 - .
Observe the correct tightening

torques for the various bolts.
Tightening torque for bolt - 2 - : 10 Nm.
Further installation is performed in the

reverse order of removal.
New outer door plate, installing
Caution!

Note:
Observe the chapter of installation notes, bonding

new outer door plate 57-1, Installation notes for
adhering a new outer door plate
Old (damaged) outer door plate

with retaining tracks removed
57-1, Outer door plate, removing
and installing
- Install front - 2 - and rear - 6 -

retaining tracks on inner door part. For
this, use the "bolt without point with thick
washer" .
Torque for bolt - 3 - and - 5 - : 10 Nm.
- Screw two guide screws into bottom

edge of inner door part.
The painted outer door plate is fitted first

without applying adhesive.
The assembly block from the assembly

tool set T 10237 is needed to fit the outer
door shell. One strip of "Tesa Power
Strips large" - 6 - is affixed onto the
lowered side. The pin has the minimum
dimension for the gap width. The surface
without adhesive is placed onto the
neighboring component until it makes
contact.
- Adhere assembly blocks - 3 - to outer

door plate.
- Guide the outer door plate - 1 - in

lower edge of inner door part via the
guide bolts.
- Using wedges - 4 - from assembly tool

set T 10237 , adjust gap dimension to sill
panel and outer door shell height.
- Lay outer door panel with assembly

blocks on adjoining components - 2 and
5- .
- Check gap dimension with adjustment

gauge 3371

gap dimensions
- If gap dimensions can no longer be

adjusted, inner door part must be
adjusted 57-1, Door, adjusting
- Remove outer door plate again.
- Apply adhesive beads - 2 - onto front -

1 - and rear - 3 - retaining tracks
cartridge gun V.A.G 1628 .
The securing block from assembly tool

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

guide bolts.
- Bring outer door plate with assembly

blocks - 3 - into contact with neighboring
components.

set, adjust gap dimension to sill panel
and outer door plate height.
- Check gap dimensions with adjustment

gauge 3371

gap dimensions
- Affix short securing blocks - 2 -

uniformly onto door to be replaced and
neighboring components.
Note:
A waiting time of 180 minutes must be observed

before performing further work on the affixed door.
- Rest of installation is performed in the reverse order of

removal 57-1, Installing
Retaining track on outer door plate, removing and

installing
Removing retaining track
Caution!
The following work must be performed very carefully.

Since the outer door plate is to be re-used, dents and
scratches must be prevented.
When cutting through adhesive bead, always hold

retaining track and outer door plate together as shown
in the illustration. Otherwise, outer door plate flaps off
the retaining track and must no longer be used again.
Note:
The following work is to be performed only with a

second technician.
Outer door plate with retaining tracks removed 57-1,

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

protect outer door plate against scratches.
- Secure spooling tool - 2 - .
- Secure cord - 5 - onto spooling tool and retainer - 4 - .
- Hold retaining track and outer door plate firmly together

when cutting through adhesive bead.
- Using cord, cut through adhesive bead from retaining

track - 3 - and outer door plate - 1 - until slightly out over
the center.
- After adhesive bead has been cut up to halfway in the

first step, move the spooling tool - 2 - and insert cord - 5 -
on the side not yet cut.
- Hold retaining track - 3 - and outer door plate - 1 - firmly

together when continuing to cut through adhesive bead.
- Cut through the second half of the adhesive bead.
Installing retaining track
- Carefully, cut remaining adhesive bead on outer door

plate up to the highest possible minimum without damaging
paintwork while doing so.
- Further work steps are described in chapter "installing

new outer door plate" 57-1, New outer door plate,
installing .
Note:
"Installation notes for adhering new outer door plate"

are also to be followed to install a new retaining
track.
- Install a new retaining track onto inner door part on

location of the removed retaining track.
- Apply adhesive onto the new retaining track.
- Firmly bolt door plate on lower edge and on the retaining

track.
- Secure outer door panel to new retaining track with

securing blocks.
Installation notes for adhering a new outer door plate
Note:
If both outer door plates must be replaced on a side,

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

damaged on the inside in the adhesion area, or was
damaged there, this area must be primed using
glass/paint primer D 009 200 02.
1K window adhesive DH 009 100 must be heated for

20 minutes in cartridge heater V.A.G 1939 A .
- Clean application surfaces on retaining tracks with

cleaning solution D 009 401 04.
- Apply adhesive material using cartridge gun V.A.G 1628

onto application surfaces at a right angle to the retaining
track.
Warning!
Outer door plate must be installed within 10 minutes,

otherwise bonding properties of adhesive will be
impaired.
Place outer door panel on retaining tracks with help

of both assembly blocks, center with wedges and
adjustment gauge 3371 and press assembly block
application surfaces onto surrounding components.
Secure outer door panel during curing time with

securing blocks.
After installing, align outer door plate to the other

components and gap dimensions must be uniform.
If the adhesive bead has been applied too thickly

and the adhesive expands out between retaining
track and outer door plate, then the excess adhesive
must be removed.
Minimum curing time
Warning!
Special requirements must be fulfilled for replacing

bonded outer door plates. One of these standards for
example is, that a freshly bonded outer door plate

must comply with the safety elements, even in an
accident, once the adhesive has exceeded the
prescribed curing time.
The minimum curing time for outer door panel with 1K

adhesive DH 009 100 is 180 minutes.
By minimum curing time, it is meant the time from bonding

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

minimum curing time has elapsed.
Cleaning when soiled by adhesive sealing material
- It is recommended to use adhesive remover D 002 000

10 as a cleaning solution. Observe safety precautions
when processing.
Caution!
When cleaning the vehicle, outer door plate bonded in

immediately beforehand must not be shifted.
- First clean paint surface coarsely using a dry rag.

Eliminate remaining soiling using adhesive removal
solution D 002 000 10.
- Clean plastic trim: Allow adhesive sealing material to

harden (about 1 hour) and then peel off.
Inner door part, assembly overview
Note :

Inner door part
Window shaft seal
Loudspeaker
Window regulator motor
removing 64-2, Window

regulator motor, removing
and installing
Insulation
4x
20 mm x 40 mm
commercially available cloth
reinforced adhesive tape
Door handle and door lock, assembly overview
Note :

Door lock

57-1, Door lock, removing
and installing
Cable
For disengaging lock of

exterior door handle.
Screw
For securing lock to inner

door part
18 Nm
Qty. 2
Mounting bracket

57-1, Bearing bracket,
Screw
For lock cylinder.
Bolt
Not available on all versions.
This screw is installed for

additional securing of
mounting bracket.
Backing
Lock cylinder housing
Only on drivers side.
Only one housing is installed

on front passengers side.

57-1, Housing, removing and
installing
Cover cap
For the lock cylinder

housing.
Is secured to lock cylinder

housing with three tabs.
Key
Changing battery 57-2,

Radio-frequency remote
control key (foldable) battery

- assembly overview
Adapting new/additional
keys to remote control and
immobilizer 57-2,
Adaptation of keys with
radio-frequency remote
control
Door handle with backing plate

57-1, Door handle, removing
and installing
Backing
Is a component of door
handle.
Torx screw
Expanding rivet
Not installed in Rabbit/GTI.
Angle bracket
Cable
To lock release mechanism

of door handle.
Cover
Does not belong to

packaged contents of door
lock
Is secured to door lock with

three tabs.
Housing, removing and installing
Note:

housing. Removing and installing lock cylinder is
Removing
- Pry out cover cap in front of bolt - 1 - .
- Pull door handle - 2 - in - direction of arrow - and turn

screw - 1 - with socket wrench T 10072 until housing - 3 -
can be removed.
Installing
- Insert housing - 3 - in right angle - arrow - into door

handle bearing bracket.
Door handle - 2 - must make contact only lightly at door

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

wrench T 10072 .
Door handle - 2 - engages again into housing - 3 - with a

very audible click.
Note:
During installation, housing must be pressed onto

door plate. The door handle rests only lightly against
the door panel.
Then a function test must be performed with door

open, since the door cannot be opened if hood
release cable is not correctly adjustment or clipped
in.
Door handle, removing and installing
Note:

right door handle. Removing and installing the left
door handle is derived accordingly from this.
Removing
- Remove housing 57-1, Housing, removing and

installing .
- Pry out clip - 2 - from door handle - 1 - .
- Swivel door handle - 1 - out of door - arrow - .
Installing
- Guide assembly tool T 10118 into door

through opening in inner door plate.
- Light the inner part of door using a

flashlight for better view.
- Hook assembly tool T 10118 into

spring - arrow A - .
- Engage spring into door lock by pulling

assembly tool T 10118 - arrow B - .
Release lever is now locked in position.
Note :
Lock is secured by engaging spring in the operating

lever. This prevents the cable from subsequently
being clipped in at door handle incorrectly.
- Swivel door handle - 1 - into door.
- Pull clip - 2 - into plate cutout and engage clip into door
handle - 1 - - arrow - .
Note:
During installation, door handle - 1 - must be

pressed onto door plate.
Clip - 2 - must engage into door handle - 1 - with a

very audibly click.
Install housing 57-1, Installing .

in.
Bearing bracket, removing and installing
Note:

right bearing bracket. Removing and installing the
left bearing bracket is derived accordingly from this.
Removing
- Remove lock cylinder housing 57-1,

- Remove door handle 57-1, Door

handle, removing and installing
- Remove outer door panel 58-1,

Outer door plate, removing and
installing
- Pull retaining rubber - 4 - upward from

guide pin.
- Pull bearing bracket - 1 - in - direction

of arrow - with guide pin - 2 - out of
mounts - 3 - .
Installing
- Slide bearing bracket - 1 - with guide

pin - 2 - into mounts - 3 - .
- Secure retaining rubber - 4 - on guide

pin and mounting pin on bearing bracket
mount.
Further installation is in reverse order of

removal.
Door lock, removing and installing
Note:

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

installing
- Remove mounting bracket 57-1,

Bearing bracket, removing and installing
- Disconnect connector - 5 - .
- Disengage cable - 1 - from actuator

lever - 8 - and remove door lock - 4 - .
Cover - 3 - is not supplied with delivery

casing of door lock.
Installing
Tightening torques for bolts: 18 Nm.


in.
Side impact protection, assembly overview
Caution!
The side impact member screws and nuts are painted

during production. That means that the threads could
shear off during removal with significant force.
Loosening of screws and nuts should be avoided
when possible
Side impact protection
Screw
4x
20 Nm
Insulation
Nut
Qty. 2
20 Nm
Inner door seal
Inner door seals are equipped at the factory with sealant,

applied to door flange and then rolled on.
Note:


seal" .

Inner door seal, removing and installing
Note:

inner door seal. Removing and installing the right
inner door seal is derived accordingly from this.
Removing
- Pull off inner door seal from body

flange.
Installing
- Align inner door seal with vulcanized

point - arrow b - at the height of the
lower hinge.
- Start installation of inner door seal in

upper radius - arrow a - of door
opening.
Outer door seal, removing and installing
Note:

right outer door seal. Removing and installing the left
outer door seal is derived accordingly from this.
Remove protective foil only immediately prior to

assembly. Processing temperature approx. 20 C.
Adhesive remover D 002 000 10 is to be used

exclusively.
The outer door seal must be applied immediately

after cleaning.
After 10 minutes, check the seal for a secure fit.
Removing
- Pull off outer door seal from door.
Installing
- Remove any adhesive residue still

present using radial disc for streak
remover Z 432 290 TE
- Thoroughly clean the adhesion surface

with adhesive remover D 002 000 10
immediately before adhering the outer
door seal.
Adhesion surfaces must be free of

dust and grease and there must be
no residual adhesive present.
- Align outer door seal with cut-out -

arrow b - with door lock securing
screw.
- Vulcanized point - arrow c - of outer

door seal is then located in center area of
door entry sill.
- Pull off foil cover and apply seal onto

door. Do not stretch outer door seal

excessively so that the seal is not too
long at the end.
- Press entire adhesive area of seal all

around onto door using application roller
3356 , starting in upper radius - arrow a
- of door.
Note :
Part numbers are for reference only. Always check

with your Parts Department for the latest part
number information
Checking seal for secure seating
Check seal for firm setting 10 minutes

after adhering the seal.
- Place seal - 1 - facing outward by

hand.
- If adhered area does not pull off in any

areas, press seal on further once more
using application roller 3356 .
Volkswagen Golf V - Central locking system Page 1 / 9
57 - 2
Central locking system

Component locations overview of components for
central locking system
Coupling station
Location: A-pillar, right
To disconnect harness
connector, release boots at
pillar 57-1, Removing
Comfort System Central Control

Module -J393-
Location: below passenger

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

Group 68, Interior equipment;
Compartments, covers and trim; Glove
compartment, removing and installing
Front Passengers Door Control

Module -J387-
Integrated in window
regulator motor.
Removing 64-2,
Removing
Door lock
Door lock is secured to inner

door part.
Electrical central locking

system is integrated in door
lock.
Removing 57-1,
Removing
Coupling station
Location: B-pillar, right.
Right Rear Door Control Module

-J389-
regulator motor.
Removing 64-3,
Removing
Door lock

door part.

lock.
Removing 58-1,
Removing
Right rear lid connector station
Location: behind C-pillar

trim.

Group 70, Trim/insulation; Pillars and
side trim; Upper C-pillar trim, removing
and installing
Fuel Tank Lid Unlock Motor -

V155-
Location: behind right

luggage compartment trim.
Removing 55-3, Actuator,

removing
Rear lid lock
Location: screwed to rear lid.
Removing 55-2,
Removing
Unlocking element with button
Location: screwed into rear

lid.
Removing 55-2,
Removing
Left rear lid connector station
Location: behind C-pillar

trim.

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

door part.

lock.
Removing 58-1,
Removing
Left Rear Door Control Module -

J388-
regulator motor.
Removing 64-3,
Removing
Coupling station
Location: Left B-pillar.
Door lock, LF

door part.

lock.
Removing 57-1,
Removing
Central switch for window

regulator
Location: installed in door

trim
Remove and installing

central window regulator
switch

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

J386-
regulator motor.
Removing 64-2,
Removing and 57-1,
Removing
Coupling station
Location: Left A-pillar.
Alarm signal horn
Location: below plenum

chamber cover.
Removing 64-1, Remove

plenum chamber cover
Front Hood Switch -F266-
Contact switch for anti-theft

warning system, cannot be
replaced individually.
Location: On hood lock.

Removing 55-1,
Removing
Adaptation of keys with radio-frequency remote control
Adaptation of keys with remote control is performed using

Vehicle Diagnostic, Testing and Information System VAS
5051 A .
- Select "Guided Fault-Finding" on Vehicle Diagnostic,

Testing and Information System VAS 5051 A .
- Via the "Go to" button, select "Function-/Component

selection" and the following menu points in sequence:
Body
Body Repairs
01 - On Board Diagnostic (OBD) capable systems
Comfort system
Functions - Comfort system
Adaptation of keys with radio-frequency remote

control
Radio-frequency remote control key (foldable) battery -

assembly overview
Key with variable code

transponder
Radio frequency unit - upper

part
LED
This LED must blink when

remote control is operated.
If LED does not blink when

remote control is operated,
the battery is completely
discharged and must be
replaced.
Battery
Removing battery 57-2,

Removing
Installing battery 57-2,

Installing
Radio frequency unit - lower

part
Battery for key with radio-frequency remote control

(foldable), removing and installing
Removing
- Insert screwdriver in the slot between radio-frequency

unit - 1 - and key - 2 - .
- Rotate screwdriver in - direction of arrow - and detach

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

- 2- .
- Use a screwdriver to unclip battery - 1 - out of holders -

2 - in - direction of arrow - .
Installing
Note polarity and installation position of battery when

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

positive terminal downward (positive terminal is marked in
housing).
- Press on battery with light pressure to engage it in radio-

frequency unit.
- Attach the cover and the radio frequency unit together

(do not damage seal).
- Then lock radio-frequency unit with key.

Volkswagen Golf 5 - Rear door Page 1 / 44
58 - 1
Rear door
Tools

required
Assembly tool T 10118
Door adjusting wrench 3320
Joint for 3320 3320/1
Box wrench 3320/2

Rear door Page 2 / 44
Box wrench 3320/3
Application roller for door insulation

foil 3356
Torque wrench 550 Nm V.A.G

1331
Adjusting gauge 3371

required

Cartridge heater V.A.G 1939 A
Assembly tool set T 10237
Materials
DH 009 100 01 1) 2)
1C- window adhesive
D 009 200 02 3)
D 009 401 04 3)
Cleaning solution
D 009 500 25 3)
Primer applicator

time
cartridge heater V.A.G 1939 .
Door construction, assembly overview
The door consists of inner door part - 6 -

and outer door plate - 1 - .
Parts are joined by the front - 7 - and the

rear - 4 - retaining tracks.
Retaining tracks are bolted to inner door

part and bonded to outer door plate.
Loudspeakers, window regulators,

window regulator motors, wires, window
guide and door lock are installed on inner
door part.
Outer door plate - 1 - is also bolted to

inner door part on the lower edge.
Exterior window shaft seal, insulation and
outer door handle are installed on outer
door plate.
Caution!
Various bolts are used to secure the

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

and installing 58-1, Outer
door plate, removing and
installing
Edge protection
Between outer door panel

and inner door part.
Screw

and thinner washer.
4 pieces on lower edge
2 piece in rear rail area
10 Nm
Rear retaining track
Screw
Characteristic: Bolt without

point but with thick washer.
11 pieces on both retaining

tracks
14 Nm
Inner door part
Assembly overview 58-1,

Inner door part, assembly
overview
Front retaining track
Screw

but thick washer.
Qty. 1 for front rail area
10 Nm
Insulation
Self-adhesive
To adhere, insulation must

be preheated and then
pressed on firmly
Clip
Qty. 5
Window shaft seal
Must be installed before

installing outer door panel.
Door hinges, assembly overview
Caution!

Note :

Bolts for door hinges must always be replaced after

loosening.
Hinges are no longer manufactured as separated

parts.
Door

58-1, Door, removing and
installing
Adjusting 58-1, Door,

adjusting
Guide bolt
10 Nm
Door hinge with door arrester
Socket head bolt

)

loosening
Socket head bolt
Installed from the vehicle

interior
Remove lower B-pillar trim

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

)

loosening
Socket head bolt

)

loosening
Socket head bolt

)

loosening
Guide bolt
10 Nm
Nut
For the eccentric pin, must

not be loosened. Used for
making adjustments during
production.
Door hinge
Hinge is no longer
manufactured as separated
parts.
Socket head bolt

)

loosening
Socket head bolt

)

loosening
Socket head bolt

)

loosening
Door, removing and installing
Note:

right door. Removing and installing the left door is
Removing
- Release boots - 6 - by pressing on

locking mechanism - arrow a - and
remove boots from B-pillar.
- Swivel locking lever - 7 - downward -

arrow b - and disconnect electrical
harness connector - 8 - from connector
station.
- Remove screws - 4, 5 and 11 - using

door adjustment wrench 3320 and bit
insert 3320/3 from hinge.
- Pull door in - direction of arrow - from

guide bolts - 3 and 9 - .
Installing
- Tightening torque: Screws - 4, 5 and 11 - : 20 Nm + 1 / 4

(90 ) additional turn
Screws - 4, 5 and 11 - must always be replaced.
- Observe gap dimension of rear door

Door, adjusting
Caution!

Note :
The door is properly adjusted when there is an

overall even gap dimension when closed, it is not too
far inward or outward and contours align.
Vehicle must stand on its wheels in order to be able

to perform the adjustment.
If outer door plate is removed, window frame of inner

door part must be adjusted in relation to roof frame
and C-pillar, and front door.
- Observe gap dimension of rear door

gap dimensions
To adjust the gap dimension correctly

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

Group 70, Pillar and side trim
Other measures, such as aligning the

door upward, are not effective. Excess
pressure thereafter will again cause the
door to sag.
For correct alignment adjustment, screws

- 4, 6 and 14 - and guide screws - 2 and
8 - must be loosened.
Door adjusting wrench 3320 with bit

insert 3320/3 must be used for this.
Outer door plate, removing and installing
Removing

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

of door - 1 - and remove rear cover - 4 -
.
- Removing lock cylinder housing: 57-1, Housing,

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

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

behind outer door plate.
- Remove all screws - 2, 3 and 4 - .
- Carefully remove outer door plate.
Installing
Caution!

- Carefully set outer door plate in.
- Start all screws - 2, 3, 4 - .
Make sure that the various bolts

are used correctly.
Characteristic for bolt - 2 - : Bolt has point and

thinner washer.
Characteristic for bolt - 3 - : Bolt without point but

with thick washer.
Characteristic for bolt - 4 - : Bolt has point and thick

washer
- Check whether guide pins for retaining

tracks are located in the corresponding
guide holes of inner door part. Then
tighten all screws - 2, 3, 4 - .
Observe the correct tightening

torques for the various bolts.
Further installation is performed in the

reverse order of removal.
New outer door plate, installing
Caution!

Note:
Observe the chapter of installation notes, bonding

new outer door plate 58-1, Installation notes for
adhering a new outer door plate
Old (damaged) outer door plate

with retaining tracks removed
58-1, Outer door plate, removing
and installing
- Install front - 2 - and rear - 6 -

retaining tracks on inner door part. For
this, use the "bolt without point with thick
washer" .
Torque for bolt - 3 - and - 5 - : 10 Nm.
- Screw two guide screws into bottem

edge of inner door part.
The painted outer door plate is fitted first

without applying adhesive.

tool set T 10237 is needed to fit the outer
door plate. One strip of "Tesa Power
Strips large" - 6 - is affixed onto the
lowered side. The pin has the minimum
dimension for the gap dimension. The
surface without adhesive is placed onto
the neighboring component until it makes
contact.
- Adhere assembly blocks - 3 - to outer

door plate.

guide bolts.

set T 10237 , adjust gap dimension to sill
panel and outer door plate height.
- Lay outer door panel with assembly

blocks on adjoining components - 2 and
5- .
- Check gap dimension with adjustment

gauge 3371

gap dimensions
- If gap dimensions can not be adjusted,

inner door part must be adjusted 58-1,
- Remove outer door plate again.
- Apply adhesive beads - 2 - onto front -

1 - and rear - 3 - retaining tracks
cartridge gun V.A.G 1628 .

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

guide bolts.
- Place outer door panel with assembly

blocks - 3 - on adjacent components.
- Using wedges - 4 - from set, adjust

gap dimension to sill panel and outer
door shell height.
- Check gap dimensions with adjustment

gauge 3371

gap dimensions
- Affix short securing blocks - 2 -

uniformly onto door to be replaced and
neighboring components.
Note:
A waiting time of 180 minutes must be observed

before performing further work on the affixed door.
- Rest of installation is performed in the reverse order of

removal 58-1, Installing
Retaining track on outer door plate, removing and

installing
Removing retaining track
Caution!
The following work must be performed very carefully.

Since the outer door plate is to be re-used, dents and
scratches must be prevented.
When cutting through adhesive bead, always hold

retaining track and outer door plate together as shown
in the illustration. Otherwise, outer door plate flaps off
the retaining track and must no longer be used again.
Note:
The following work is to be performed only with a

second technician.
Outer door plate with retaining tracks removed 58-1,

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

protect outer door plate against scratches.
- Secure spooling tool - 2 - .
- Secure cord - 5 - onto spooling tool and retainer - 4 - .
- Hold retaining track and outer door plate firmly together

when cutting through adhesive bead.
- Using cord, cut through adhesive bead from retaining

track - 3 - and outer door plate - 1 - until slightly out over
the center.
- After adhesive bead has been cut up to halfway in the

first step, move the spooling tool - 2 - and insert cord - 5 -
on the side not yet cut.
- Hold retaining track - 3 - and outer door plate - 1 - firmly

together when continuing to cut through adhesive bead.
- Cut through the second half of the adhesive bead.
Installing retaining track
- With utmost care, cut down remaining adhesive bead on

outer door plate up to the highest possible minimum
without damaging paintwork while doing so.
- Further work steps are described in chapter "installing

new outer door plate" 57-1, New outer door plate,
installing .
Note:
"Installation notes for adhering new outer door plate"

are also to be followed to install a new retaining
track.
- Install a new retaining track onto inner door part on

location of the removed retaining track.
- Apply adhesive onto the new retaining track.
- Firmly bolt door plate on lower edge and on the retaining

track not cut.
- Secure outer door panel to new retaining track with

securing blocks.
Installation notes for adhering a new outer door plate
Note:
If both outer door plates must be replaced on a side,

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

damaged on the inside in the adhesion area or if
there is paint there, this area must be primed using
glass/paint primer D 009 200 02.
1K window adhesive DH 009 100 must be heated for

20 minutes in cartridge heater V.A.G 1939 A .
- Apply adhesive material using cartridge gun V.A.G 1628

onto application surfaces at a right angle to the retaining
track.
Warning!
Outer door plate must be installed within 10 minutes,

impaired.
Place outer door panel on retaining tracks with help

of both assembly blocks, center with wedges and
adjustment gauge 3371 and press assembly block
application surfaces onto surrounding components.
Secure outer door panel during curing time with

securing blocks.
After installing, align outer door plate to the other

components and gap dimensions must be uniform.
If the adhesive bead has been applied too thickly

and the adhesive expands out between retaining
track and outer door plate, then the excess adhesive
must be removed.
Minimum curing time
Warning!

bonded outer door plates. One of these standards for
example is, that a freshly bonded outer door plate
must comply with the safety elements, even in an
accident, once the adhesive has exceeded the
prescribed curing time.
The minimum curing time for outer door panel with 1K

adhesive DH 009 100 is 180 minutes.
By minimum curing time, it is meant the time from bonding

in the outer door plate up to use in the vehicle, or until
further work can be performed. During this time, the vehicle
least 15 C).
Warning!

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

cleaning solution. Observe safety precautions when
processing.
Warning!
When cleaning the vehicle, outer door plate bonded in

immediately beforehand must not be shifted.


Note :

Window shaft seal
Insulation
Qty. 4
20 mm x 40 mm
commercially available cloth
reinforced adhesive tape
Door handle and door lock, assembly overview
Note :

Door lock
Door lock can only be

removed in conjunction with
the outer door plate.

58-1, Door lock, removing
and installing
Angle bracket
Expanding rivet
Cable

interior door handle.
Cover
Does not belong to

packaged contents of door
lock
Is secured to door lock with

three tabs.
Mounting bracket
Removing 58-1, Bearing

bracket, removing
Screw
Backing
Component of door handle
Door handle with backing plate

58-1, Door handle, removing
and installing
Cover cap
For lock cylinder housing

without opening for lock
cylinder.
Is secured to lock cylinder

housing with three tabs.
Housing

58-1, Housing, removing and
installing
Without lock cylinder.
Backing
Torx screw
By loosening this bolt,

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

exterior door handle.
Note:

right housing. Removing and installing the left
housing is derived accordingly from this.
Removing
- Pry out cover cap in front of bolt - 1 - .
- Pull door handle - 2 - in - direction of arrow - and turn

screw - 1 - with socket wrench T 10072 until housing - 3 -
can be removed.
- Remove housing - 3 - at right angle to door from door

handle bearing bracket.
Installing
- Insert housing - 2 - at right angle into door handle

mounting bracket.
Door handle - 1 - must make contact only lightly at door

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

socket wrench T 10072 .
Door handle engages again into lock cylinder housing with

a very audible click.
Note:
During installation, housing must be pressed onto

door plate. The door handle rests only lightly against
the door panel.
- Then, continue in reverse order of removal.

in.
Door handle, removing and installing
Note:

right door handle. Removing and installing the left
door handle is derived accordingly from this.
Removing
- Removing housing: 58-1, Housing, removing and

installing .
- Pry out clip - 2 - from door handle - 1 - .
- Swivel door handle - 1 - out of door - arrow - .
Installing
- Guide assembly tool T 10118 into door

through opening in inner door plate.
- Light the inner part of door using a

flashlight for better view.
- Hook assembly tool T 10118 into

spring - arrow A - .
- Engage spring into door lock by pulling

assembly tool T 10118 - arrow B - .
Release lever is now locked in position.
- Swivel door handle - 1 - into door.
- Pull clip - 2 - into plate cutout and engage clip into door
handle - 1 - - arrow - .
Note:
During installation, door handle - 2 - must be

pressed onto door plate.
Clip - 2 - must engage into door handle - 1 - with a

very audibly click.
Install housing 58-1, Installing

in.
Bearing bracket, removing
Note:

right bearing bracket. Removing and installing the

left bearing bracket is derived accordingly from this.
Removing
- Remove housing 58-1, Housing,

- Remove door handle: 58-1, Door

handle, removing and installing
- Remove outer door panel: 58-1,

installing
- Pull off retaining rubber - 4 - from

guide pin and retaining bolts on mount
upward.
- Pull bearing bracket - 1 - with guide pin

- 2 - out of mounts - 3 - .
Installing
- Slide bearing bracket - 1 - with guide

pin - 2 - into mounts - 3 - .
- Secure retaining rubber - 4 - on guide

pin and retaining bolts on mount.
Door lock, removing and installing
Note:

right door lock. Removing and installing the left door
lock is derived accordingly from this.
Removing
- Remove outer door panel 58-1, Removing
- Remove mounting bracket 58-1, Bearing bracket,

removing
- Disconnect harness connector - 4 - .
- Disengage cable - 3 - from actuator lever - 5 - and

remove door lock - 1 - .
Cover - 2 - is not supplied with delivery casing of door

lock.
Installing
Tightening torques for bolts: 18 Nm

in.
Side impact protection, assembly overview
Caution!
The side impact member screws and nuts are painted

during production. That means that the threads could
shear off during removal with significant force.
Loosening of screws and nuts should be avoided
when possible
Side impact protection
Bolts
Qty. 2
20 Nm
Nut
Qty. 2
20 Nm
Inner door part
Internal door seals
Inner door seals are equipped at the factory with sealant,

applied to door flange and then rolled on.
Note:


seal" .

Inner door seal, removing and installing
Note:

right inner door seal. Removing and installing the left
inner door seal is derived accordingly from this.
Removing
- Pull off inner door seal from body

flange.
Installing
- Align inner door seal with vulcanized

point - arrow b - at the height of the
lower hinge.
- Start installation of inner door seal in

upper radius - arrow a - of door
opening.
Outer door seal, removing and installing
Note:

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

It is exclusively adhesive remove D 002 000 10.

The outer door seal must be applied immediately

after cleaning.
After 10 minutes, check the seal for a secure fit.
Removing
- Pull off outer door seal - 1 - from door -

2- .
Installing
- Remove any adhesive residue that is

still present using the erasure disc for
stripe remover erase disc Z 432 290
TE .
- Always clean adhesion surface

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

dust and grease and there must be
no residual adhesive present.
- Vulcanized point - arrow b - of outer

door seal - 1 - is located in center area
of door entry sill.
- Pull off foil cover and apply seal onto

door in upper radius - arrow a - . Do not
stretch outer door seal excessively so
that the seal is not too long at the end.
- Press entire adhesive area of seal onto

door all around using application roller
3356 .
- After 10 minutes, perform test for

proper seal seating.
Note :

number information
Checking seal for secure seating
Check seal for firm setting 10 minutes

after adhering the seal.
- Try to put seal - 1 - outward by hand.
- If adhered area does not pull off in any

areas, press seal on further once more

using application roller 3356 .
Volkswagen Golf V: Sunroof with glass panel (Meritor) Page 1 / 29
60 - 1
Sunroof with glass panel (Meritor)

Tools

Pinch roller 3356
Special hook 3370

Sunroof with glass panel (Meritor) Page 2 / 29
Function
All moving functions of sunroof with glass panel can be

performed with ignition switched on.
After ignition is switched off, the movement functions can

be performed until either the driver or front passenger door
is opened.
The opening of glass panel for sliding and tilt position is

pre-selected using the rotary switch.
On the rotary switch, there are markings for preset sliding

and tilt positions of the glass panel.
Opening the sunroof in the so-called comfort position

prevents most driving noise which may occur when open
completely.
Switch for automatic preset
The sunroof with glass panel is equipped with a closing

force limit. Glass panel runs in the opposite direction if it
runs into an obstruction during the closing or opening
procedure from the tilt or sliding position.
In addition, there is an emergency close function. If there

are problems closing, sunroof with glass panel can be
forced closed by pressing the preselector, which must be
located in the "sunroof closed" position.
For the emergency close function, the closing force limit is

deactivated.
The drive motor for sunroof with glass panel is protected

against overheating via a running time limit. The protective
mechanism activates after an uninterrupted operation of
approx. two minutes. It can only be operated again after a
cool-off phase.
If current fails, sunroof with glass panel can be moved at

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

located in a holder on the back side of the molded
headliner near the cutout for the rear light unit.
Sunroof with glass panel, assembly overview
Glass panel for sunroof (one-

piece safety glass)
Remove glass panel for

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

for sliding/tilting sunroof,
installing
Adjusting glass panel for

for sunroof, adjusting (height
adjustment)
Panel seal
Adjusting panel seal 60-1,

Panel seal, adjusting
Seal joint at center in rear

area.
Panel seal, replacing 60-

1, Panel seal, replacing
Sun shield panel
Sun shield panel, removing

and installing 60-1, Sun
shield panel, removing and
installing
Screw
Screws are
microencapsulated and must
always be replaced after
removing.
4x
1.8 Nm
Spring glider
Bolted on to sun protection

panel.
4x
Can be replaced separately
Removing 60-1,
Removing
Boots
For covering slotted guide

rail.
Removing 60-1,
Removing
Installing 60-1, Installing

Water channel
Removing 60-1,
Removing
Guide locking hook
Removed together with

slotted rail
Removing 60-1,
Removing
End piece, upper part
Clipped to lower part of end

piece.
Removing 60-1,
Removing
End piece, lower part
Can be replaced separately
Use butyl adhesive sealing

cord AKL 450 005 05 for
sealing.
Assembly unit

installation unit 60-1,
Installation unit, removing
and installing
If necessary use special

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

number information
Screw
Screws are
microencapsulated and must
always be replaced after
removing.
Qty. 3
3.5 Nm
Hex key wrench for emergency

operation
Hex wrench is located in

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

lights, removing

Repair Group 96, Rear interior and
reading lights, removing
Electrical drive motor
Removing 60-1, Drive

motor for glass panel of
sunroof, removing and
installing
Adjusting drive motor (zero

position) 60-1, Drive
motor for glass panel of
sunroof, adjusting (zero
position)
Spring
Qty. 2
To open wind deflector.
Clipped in on wind deflector

and cannot be replaced
individually.
Removing 60-1, Wind

deflector, removing and
installing
Wind deflector
Removing 60-1, Wind

installing
Bearing for wind deflector
Qty. 2
Clipped in on wind deflector

and cannot be replaced
individually.
Removing 60-1, Wind

installing
Front guide
Can be slid individually out

of guide rail.
Removing 60-1,
Removing
Rear guide, lower part
Removed together with

slotted guide rail.
Removing 60-1,
Removing
Torx screw
Torx T25
3 per side
5 Nm
Slotted guide rail

60-1, Slotted guide rail,
Spacer

60-1, Slotted guide rail,
Boots, removing and installing
Removing
- Slide sun shield panel toward rear.
- Tilt open sunroof glass panel.
- Carefully unclip boots - 1 - from lower

section of slotted guide rail - 3 - using a
trim removal wedge 3409 .
- Pull boots - 1 - off mounting pins - 4 -

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

- Remove boots - 1 - .
Installing
- Slide sun shield panel toward rear.
- Tilt open sunroof glass panel.
- Engage boots - 1 - first at top - rear - 2

- .
- Clip boots - 1 - with mounting pins - 4

- into slotted guide rail.
- Engage boots - 1 - at bottom, rear - 3 -

and clip boots in starting at front in lower
section of slotted guide rail.
Glass panel for sliding/tilting sunroof, removing

- Remove boots 60-1, Removing .
- Remove mounting bolts - 1 - on left and right sides.
- Remove glass panel for sunroof - 2 - upward.
Warning!
Slotted guide rail must not be driven into "opened"

position with sunroof glass panel removed because
the rain channel is no longer pressed down by the
glass panel and may be wedged in roof.
Glass panel for sliding/tilting sunroof, installing
Panel must be installed in zero position (panel

closed).
Zero position:
Marking - arrow - on upper part of rear guide - 1 - must

be located on both sides between markings dimension - a
- at slotted guide rail - 2 - .
Link guide - 2 - must be engaged in guide rail (cannot be

moved by hand).
If this is not the case, adjust parallel movement 60-1,

Parallel movement, adjusting
- Insert glass panel for sunroof - 2 - from above and screw

in mounting bolts - 1 - .
- Tighten mounting bolts - 1 - lightly.
- Adjust glass panel for sunroof (height adjustment): 60-

1, Glass panel for sunroof, adjusting (height adjustment)
Note:
Tighten bolts after panel height adjustment (4.5

Nm).
Install boots after panel height adjustment.
Glass panel for sunroof, adjusting (height adjustment)
Note:
The glass panel height adjustment is to be

performed after the glass panel has been closed out
of sliding position.
Zero position of glass panel for sunroof OK.

- Remove boots: 60-1, Removing
- Loosen mounting bolts - 1 - for glass panel of sunroof -

2- .
- Drive sunroof glass panel into position "open" .
- Drive sunroof glass panel into position "closed" .
- Perform height adjustment for glass panel for sunroof at

front and rear on both sides as follows:
Panel adjustment at front:
- a - = 01 mm lower than roof
- arrow - = direction of travel
- Tighten front bolts to 5 Nm.
Panel adjustment at rear:
- b - = 01 mm higher than roof
- arrow - = direction of travel
- First tighten center, then rear bolts to 5 Nm.
Note:
To achieve the best possible exterior optical

characteristics, make sure that the adjustment on left

and right sides is performed as evenly
(symmetrically) as possible.
Glass panel must not be higher than roof at any

point at front or lower than roof at any point at rear.
- Install boots 60-1, Installing .
Panel seal, adjusting
- Using a strip of cardboard about 0.3 mm thick (e.g.

business card), check if pretension between panel seal - 2
- and body is even all around. Cardboard should slide
through gap with firm resistance.
- Removing glass panel for sunroof 60-1, Glass panel

for sliding/tilting sunroof, removing
- If pretension is insufficient, the panel seal - 2 - can be

pressed open using a trim removal wedge 3409 - 1 - .
- If the pretension is excessive, press the panel seal - 1 -

closed around circumference using application roller
3356 .
Panel seal, replacing

- Pull off seal - 1 - from glass panel for sunroof - 2 - .
- Pull new seal - 1 - at rear panel edge in center,

beginning from bottom to top, onto glass panel for sunroof -
2- .
Note:
Coat edge of panel with soapy water to facilitate

installation of seal.
If the seal is not correctly installed, the seal surface

is wavy.
Panel seal must be shortened corresponding to the

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

sliding/tilting sunroof, installing
- Adjusting panel seal 60-1, Panel seal, adjusting

Wind deflector, removing and installing
Removing
- Open sunroof glass panel completely.
- Press wind deflector with height stop out of front roof cut-
out and tilt wind deflector open vertically.
- Insert special tool hook for front end 3370 between roof
edge and wind deflector bearing - arrow - .
- Pull wind deflector bearing out of side locking mechanism

of left and right guide rails using special tool hook for front
end 3370 in - direction of arrow - .
- Remove wind deflector upward from guide rail.
Installing
- Insert wind deflector into guide rail and slide wind

deflector with height stop under front roof cut-out at left and
right sides.
- Using light pressure, press wind deflector bearing into

guide rails.
Note:
Wind deflector bearing must engage in guide rails

audibly.
Sun shield panel, removing and installing
Removing
- Removing glass panel for sunroof: 60-1, Glass panel

for sliding/tilting sunroof, removing .
- Slide sun shield panel slightly toward rear.
- Unthread front bolts - arrow - at left and right. Slide out

spring glider forward over the stop - 1 - .
- Slide sun shield panel forward and lift sun shield panel
slightly over the roof cutout and out.
- Unscrew rear bolts - arrow - at left and right. Slide

spring glider toward rear and remove sun shield panel - 1 -
upward.
Installing
Then perform a function test.
Drive motor for glass panel of sunroof, removing and

installing
Removing
- Remove lights and operating unit

Repair Manual, Electrical Equipment, Repair Group 96,

Interior lights, lamps, switches; lights and switches in roof
trim; removing and installing Front Interior Light -W1-,
vehicles with sunroof
Changing motor - detection of preselector switch:
Note:
In order to interrupt the release signal and thereby to

activate switch detection, the conditions described
below must be met.
If this is not the case, it may lead to the drive motor

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

panel when roof is closed (zero position).
Requirements for removing and installing the drive

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

door.
This state must be maintained up to installation of

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

sunroof.
- Disconnect harness connector for drive motor of sunroof.

Installing
The bolts for the sunroof drive motor are

microencapsulated and must always be replaced 3.5
Nm.
- After installation has been performed, key can be

reinserted into lock cylinder of ignition/starter switch.
Drive motor for glass panel of sunroof, adjusting (zero

position)
Adjustment of zero position may be necessary if the drive

motor was removed while not in zero position or the glass
panel of sunroof was closed or opened via emergency
operation.
Drive motor removed, but electrical wires connected.
- Move automatic rotary switch to "roof opened" position.
- Move automatic rotary switch to "roof closed" position.
- Move automatic rotary switch to "roof tilted" position.
- Move automatic rotary switch to "roof closed" position.
- Install drive motor in this position (zero position) with

sunroof glass panel closed.
Drive motor for glass panel of sunroof is in zero

position when a white dot can be seen in the
opening - arrow - of drive motor.
Automatic rotary switch for glass panel of sunroof,

- Remove automatic rotary switch for sunroof glass panel

Interior lights, lamps, switches; removing and installing
sunroof switch
Checking parallel movement

for sliding/tilting sunroof, removing .


moved by hand).
Parallel movement, adjusting
Note:
The parallel movement adjustment can only be

performed with removed drive motor and glass panel
(in zero position).
- Remove drive motor for sunroof glass panel 60-1,

installing .


moved by hand).
- Slide upper part of guide - 1 - at left and right centered

between the markings.
- Install drive motor (zero position) in this position.
Then check zero position.
Installation unit, assembly overview

Assembly unit

60-1, Installation unit,
Screw
Qty. 12
8 Nm
Connector
Connections for water drain

hoses
Drive motor for sunroof

60-1, Drive motor for glass
panel of sunroof, removing

and installing
Installation unit, removing and installing
Warning!
Only remove and install drive motor for sunroof glass

panel when roof is closed (zero position).
Requirements for removing and installing the drive

motor are: Engine and ignition off, remove key and
open door.
Removing
- Remove molded headliner


headliner
- Disconnect water drain hoses - 4 -

from installation unit - 1 - .
- Disconnect harness connector - 3 -

from drive motor of glass panel for
sunroof - 5 - .
- Remove bolts - 2 - and remove

installation unit - 1 - from vehicle with a
second technician.
Installing
- With a second technician, insert

installation unit - 1 - into roof cutout.
- During installation, align installation unit

- 1 - via two cylindrical pins (reversed

drill bit) 12 mm at right front - arrow -
and 10 mm left rear - arrow - in roof.
Installation unit must not make contact

with roof frame.
- Insert bolts - 2 - .
- Check wires and harness connectors

for electrical consumers at roof for
correct routing and reproduce if
necessary.
- Firmly bolt (8 Nm) installation unit - 1 -

of drive motor for sunroof - 5 - beginning
at left and right toward rear.
- Install water drain hoses - 4 - .
- Connect harness connector - 3 - for

drive motor of glass panel for sunroof - 5
- .
- Install molded headliner

headliner
Operation without electricity
Note:
If current fails, sunroof with glass panel can be

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

Lights, lamps, switches - interior; Lights and switches in
roof trim
- Guide hex wrench in bolt of drive motor.
- Push wrench upward - arrow - to release the drive

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

Glass panel of sunroof can be moved only in this position.
Slotted guide rail, removing and installing
Removing

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

guide rail - 1 - and retaining hooks - arrows - at rear of
guide.
- Pull spacer - 2 - in - direction of arrow - out of slotted

guide rail - 1 - and guide retaining hook.
- Fold up slotted guide rail - 1 - in - direction of arrow -

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

guide rail - 1 - in - direction of arrow - from front guide -
2- .
Installing
Link, removing and installing
Note:
Always replace guides with cable as a pair.
Removing

- Removing installation unit 60-1, Installation unit,

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

installing .
- Remove slotted guide rail 60-1, Removing
- Using a screwdriver, carefully disengage rain channel - 1

- in - direction of arrow - on both sides at bearing on
guide retaining tabs - 2 - and remove rain channel.
- Disengage clip mechanism - arrows - of upper end

piece - 1 - from lower end piece - 2 - using a screw driver
and pull upper end piece off.
- Slide lower part of rear guide - 1 - in - direction of

arrow - in guide rail - 3 - until the lock mechanism of
guide catch - 2 - is released.
- Pull lower part of rear guide - 1 - and guide catch - 2 -

together in - direction of arrow - out of guide rail - 3 - .
Installing
Water drain hoses, cleaning
Note:
For cleaning, an assisting tool is recommended,

such as a speedometer drive shaft inner cable,
approx. 2300 mm (90.5 in.) long.
Front water drain hoses:
Route water drain hoses at front on A-

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

The rear water drain hoses run through

the C-pillars and end in the rear wheel
housings. Start cleaning from the
wheelhousing outward, wheelhousing
liner must be removed to do so.
Volkswagen Golf 5 - Front bumper Page 1 / 10
63 - 1
Front bumper
Tools
Bumper cover, repairing
Note:
Before replacing bumper cover, explore possibility of

repairing damage to plastic.
Description under Plastic repair methods
Bumper cover, assembly overview

Front bumper Page 2 / 10
Cover
Material PP/EPDM

63-1, Front bumper cover,
Screw
1.5 Nm
Screw
Qty. 4 per side
2 Nm
Screw
Qty. 6
1.5 Nm
Screw
Qty. 2
5 Nm
Screw
Qty. 2
5 Nm
Front bumper cover, removing and installing
Note:
Due to model variations, small deviations must be

considered during removal and installation.
Removing
- Remove radiator grille 66-3, Radiator

grille, removing and installing
- Remove bolts - 5 - and - 6 - .
- Remove bolts - 4 - from below.
- Unscrew bolts - 3 - and - 2 - (pointing

upward) in area of left and right
wheelhousing liners.

- With a second technician, pull cover - 1

- parallel out of guide profiles.
- Disconnect harness connectors of

installed electrical components and
hoses.
Installing

dimensions

Front bumper attachments
Cover
Material PP/EPDM

63-1, Front bumper cover,
Left protective molding

Material PP/EPDM
Locked to cover.
Protective molding can be

carefully released from
locking mechanisms using a
plastic wedge from outside
and removed.
Left vent grille
Pull forward out of locking

mechanism in - direction of
arrow -
Formed piece
Locked to cover.
Only to be removed from

removed bumper.
Spoiler bracket

removed bumper.
Spoiler
Material PC/ABS
Locked to cover.

removed bumper.
Center ventilation grid
Pull forward out of locking

mechanism in - direction of
arrow -
Screw
1.5 Nm
Right vent grille

Remove screw - 8 - and pull

out forward in - direction of
arrow - .
Right protective molding
Material PP/EPDM
Locked to cover.

and removed.
Front bumper, substructure
Left air guide

Locked to lock carrier.
Left guide piece
Bolted to lock carrier.
Screw
Qty. 2 per bracket
2 Nm
Cross member
Screw
Qty. 6
8 Nm
Right air guide
Screw
Qty. 2 per bracket
2 Nm
Right guide piece
Spreader nut
Qty. 3
Guide trim
Left and right
Removing:
- Attach at sides to fender

with screws - 11 - .
Screw
Qty. 3
2 Nm
Bumper carrier, assembly overview
Bumper carrier
Screw
Qty. 4 per side
60 Nm
Screw
Qty. 6
8 Nm
Foam piece
Self-adhesive
Volkswagen Golf 5 - Front bumper (GTI) Page 1 / 11
63 - 2
Front bumper (GTI)

Tools
Note:

GTI front bumper cover, assembly overview

Front bumper (GTI) Page 2 / 11
Cover
Material PP/EPDM

63-2, GTI front bumper
cover, removing and
installing
Screw
1.5 Nm
Screw
Qty. 4 per side
2 Nm
Screw
Qty. 8
1.5 Nm
Screw
Qty. 2
5 Nm
GTI front bumper cover, removing and installing
Note:

Removing
- Remove radiator grille: 66-3, GTI

radiator grille, removing
- Remove bolts - 4 - from below.
- Unscrew bolts - 3 - and - 2 - (pointing

upward) in area of left and right
wheelhousing liners.


- Disconnect harness connectors of

installed electrical components and
hoses.
Installing

dimensions

GTI front bumper, components

Cover
Material PP/EPDM

63-2, GTI front bumper
cover, removing and
installing
Left protective molding
Material PP/EPDM
Locked to cover.

and removed.
Left vent grille
Removing:
- Remove screw - 4 -
- Starting at front - arrow a

- , loosen from locking
tabs, then remove from
cover toward center of
vehicle - arrow b - .
Screw
1.5 Nm
Upper part of spoiler
Material PC/ABS
Locked to cover.
Only to be removed with

bumper removed and lower
part of spoiler unscrewed.
Lower part of spoiler
Material PC/ABS
Screwed to the upper part of

spoiler and noise insulation.
Screw
7x
1.5 Nm
Center ventilation grid
Can only be removed with

radiator grille removed.
Center of vent grille can be

carefully loosened from
latches from outside with a
plastic wedge and removed.
Right vent grille
Removing:
- Remove screw - 4 -
- Starting at front - arrow a

- , loosen from locking
tabs, then remove from
cover toward center of
vehicle - arrow b - .
Right protective molding
Material PP/EPDM
Locked to cover.

and removed.
Front bumper, substructure

Left air guide
Left guide piece
Screw
Qty. 2 per bracket
2 Nm
Cross member
Screw
Qty. 6
8 Nm
Right air guide
Screw
Qty. 2 per bracket
2 Nm
Right guide piece
Spreader nut
Qty. 3
Guide trim
Left and right
Removing:
- Attach at sides to fender

with screws - 11 - .
Screw
Qty. 3
2 Nm

Bumper carrier
Screw
Qty. 4 per side
60 Nm
Screw
Qty. 6
8 Nm
Foam piece
Self-adhesive
License plate bracket, installing
Note:
Guide - 4 - shown in illustration does not apply for

this application
- Place license plate bracket - 2 - on grille.
Note:
The correct position of the license plate bracket - 2 -

is obtained by inserting the slot - 3 - on the license
plate bracket, into the center uppermost opening of
the grille.
- After aligning bracket and making sure bracket is level,

mark four points - 5 - to be drilled on grille.
- Drill four points - 5 - .
Hole diameter: 7.7 +0.2 mm.
- Install license plate bracket with four plastic expanding

rivets - 1 - .
Volkswagen Golf 5 - Rear bumper Page 1 / 11
63 - 3
Rear bumper
Tools
Note:

Bumper cover, assembly overview

Rear bumper Page 2 / 11
Cover
Material PP/EPDM

63-3, Bumper cover,
Screw
Qty. 2
5 Nm
Screw
4x
5 Nm
Expanding rivet
Qty. 2
Screw
3 per side
2 Nm
Screw
4x
5 Nm
Bumper cover, removing and installing
Note:

Removing
- Remove tail light assemblies

Repair Group 94, Lights, lamps, switches
- exterior; removing and installing tail
lamp assemblies
- Unscrew bolts - 5 - in area of left and

right wheelhousing liner.
- Pry out expanding rivet - 4 - in area of

left and right wheel housing liners using a
screwdriver.
- Remove bolts - 2 - and - 3 - from

below.
- Remove bolts - 6 - from above.


- Disconnect connectors of electrical

components present, license plate light

- exterior; License plate light
and, if equipped,

- exterior; parking assist system
Installing

dimensions

Rear bumper attachments

Cover
Material PP/EPDM
Removing and installing:

63-3, Bumper cover,
License plate lighting
Qty. 2
Removing

- exterior; license plate light
Towing eyelet cap

Locked into the cover.
Spoiler
Material PC/ABS
Locked into the cover

removed bumper.
Rear bumper, substructure
Securing strip
Hex nut
4x
2 Nm
Guide trim
Left and right
Hex nut
3 per side
2 Nm
Foil
Left and right
Self-adhesive

Cross member
Screw
Qty. 6
20 Nm
Tow hitch, assembly overview
Bolts - 3 - are sealing threaded connections and seal

the interior from exhaust gases and must be installed
in any case.
Note:
Tightening torques only refer to tow hitches

manufactured at the factory.
Tightening torques of other trailer hitches must be

obtained from the respective manufacturer.
Tow hitch
Trailer hitch with removable

ball head is depicted.
Ball head
The removable ball head is

located in the left luggage
compartment storage
compartment.
Screw
Sealing threaded
connections
4x
20 Nm
Screw
4x
50 Nm + 90 turn

loosening
Cover
Material PP/EPDM

63-3, Bumper cover,
Spring clamp
Qty. 2
Cover cap - trailer hitch
Rotary fastener
Qty. 2
Retaining washer
Qty. 2
Volkswagen Golf 5 - Flush bonded windows Page 1 / 25
64 - 1
Flush bonded windows

Tools
Cutting tool kit V.A.G 1474 A
Suction lifter V.A.G 1344
Cutting tools for glass V.A.G 1351
Window removing kit V.A.G 1755
Cartridge heater V.A.G 1939

Flush bonded windows Page 2 / 25
Electric cutter V.A.G 1561 A
Cutting blade V.A.G 1561/2
Scraper V.A.G 1561/8
Double cartridge gun VAS 5237

Materials
DA 004 600 A2 1) 2)
2C- window adhesive
DH 009 100 03 3) 4)
1C- window adhesive
D 181 801 A1 5)
Activator
D 009 200 02 5)
D 009 401 04 5)
Cleaning solution
D 009 500 25 5)
Primer applicator
D 002 000 10 5)
Adhesive remover
357 853 999

Cutting cord

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

Windshield
Removing 64-1,
Windshield, removing
Installing 64-1,
Windshield, installing
Window adjuster
443 845 631 A
Plenum chamber cover
Must only be pulled out of

binding profile by hand.
Removing 64-1, Remove


Binding profile
Is part of windshield.
Spacer
PUR adhesive sealant
Bead cross section: Width =

6.5 mm, height = 10 mm
(including residual material
on window glass and window
flange)
Minimum curing time 64-

1, Minimum curing time
Water deflector
Removing 66-4,
Removing

Sealing lip
If sealing lip is damaged

when cut out, a new
windshield must be installed.
Plenum chamber cover, assembly overview
Plenum chamber cover
Must only be pulled out of

binding profile by hand.
removing 64-1, Remove


Plenum chamber - bulkhead
Windshield
Seal - plenum chamber
Binding profile
Remove plenum chamber cover
- Remove wiper arms

Repair Group 92, Front windshield wiper
system; Front windshield wiper system,
removing and installing; Wiper arms,
Warning!
Plenum chamber cover must not be

pried off using any tool. Window will
be damaged and may crack later
- Pull off seal of plenum chamber - 4 -

on the entire length of facing wall - 2 - of
plenum chamber.
- Pull out plenum chamber cover - 1 -

starting at right carefully upward from
binding profile - 5 - .
Installing plenum chamber cover
Warning!
Striking the plenum chamber cover

can cause cracks in the windshield.
- Spray binding profile - 5 - with soap

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

binding profile - 5 - and engage it with
binding profile - 5 - starting from center
using light pressure.
- Install plenum chamber seal - 4 - and

windshield wiper.
Note :
In new windshields, an insert is installed in the

binding profile. This insert must be removed before
installing the plenum chamber cover.
Windshield, removing
- Remove A-pillar trim

Trim/insulation; Pillars and side trim
- Remove all sun visors
Repair Manual, Body Interior, Repair Group 68, Interior

equipment; storage compartments, covers and panels
- Remove interior mirror
Repair Manual, Body Interior, Repair Group 68, Interior

equipment; interior mirror
- Remove left and right drip rails 66-4, Drip rail,

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

in between the windshield and instrument panel.
- Thrust awl V.A.G 1474/2 - 2 - through adhesive bead.
- Push cutting cord end - 3 - using awl V.A.G 1474/2 - 2 -

through adhesive sealing material into the vehicle interior.
- Secure cutting cord end on the inside against pulling out

using pull handle V.A.G 1351/1 - 3 - .
- Loosen sealing lip from window flange in upper area of

windshield with a plastic wedge and spray with cleaning
solution D 009 401 04 (as a substitute for lubricant).
- Insert cutting cord - 2 - in upper area of windshield by

aid of small tube - 1 - .
- For very narrow gap dimensions, guide cutting cord from

outside and press under lip using plastic wedge.
- Lay cutting cord - 2 - around the window and also guide

inside the second cord end.
Make sure that cutting cord - 2 - is inserted under

the window at the corners.
- Secure second cutting cord end onto spooling tool V.A.G

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

cut window free.
- While cutting free, press cutting cord against window

using a wedge V.A.G 1474/5 to prevent damage to
instrument panel and to have clearance at window flange.
Windshield, installing
Preparing undamaged window for glazing 64-1,

Undamaged window, preparing for glazing
Preparing new window for glazing 64-1, Preparing new

window without pre-coating for glazing
Preparing window flange for glazing 64-1, Window

flange, preparing for glazing
Installation notes 64-1, Installation notes
Minimum curing time 64-1, Minimum curing time
Rear window, assembly overview

Rear window
rRemoving 64-1,
Undamaged rear window,
removing
Installing 64-1, Rear

window, installing
Gasket
for rear window wiper
Rear lid

flange).

Trim
Removing trim

Group 70, Trim/insulation; Rear lid trim
Window antenna contact
Right and left
Undamaged rear window, removing
- Removing side luggage compartment trim

Trim/noise insulation; luggage compartment trim
- Removing rear window wiper motor

Rear window wiper and washer system, servicing
- Disconnect left and right heated rear window and window

antenna connectors - 1 - .
- Pull cutting cord - 2 - inside through adhesive material

using awl V.A.G 1474/2 - 1 - .
- Secure end of cutting cord - 3 - with handle - 1 - before

pulling out.
- Lay cutting cord - 3 - around the window and also guide

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

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

and cut window free.
- While cutting free, press cutting cord - 3 - against

window using wedge V.A.G 1474/5 to have clearance to
window flange.
Damaged rear window, removing
- Protect body and interior from glass splinters.
- Remove glass pieces from adhesive material.
- Disconnect harness connectors for window defroster and

window antenna.
- Bond flange - 1 - all around with fabric reinforced

adhesive tape.
- Cut through adhesive material (with glass residue) in

window cutout with electric cutter V.A.G 1561 A - 3 - and
cutting blade V.A.G 1561/10 - 2 - .
Warning!
Always wear protective goggles and leather gloves.

Rear window, installing


window with pre-coating for glazing

Rear side window, assembly overview
Side window
Remove side window 64-

1, Undamaged rear side
window, removing
Installing side window 64-

1, Rear side window,
installing

flange).

Window flange
Seal with spacer
Component part of side

window.
Undamaged rear side window, removing
- Loosen interior trim in upper area

Trim/insulation; Luggage compartment trim
- Remove B- and C-pillar trim
Repair Manual, Body Interior, Repair Group 70, Trim

panels/insulation; Pillar and side trim
- Push cutting cord through adhesive sealing material into

vehicle interior - 3 - using awl V.A.G 1474/2 - 2 - .
- Secure end of cutting cord on inside against pulling out

using pull handle V.A.G 1351/1 - 1 - .
- Loosen sealing lip all around from window flange and

spray with cleaning solution D 009 401 01 (as a substitute
for lubricant).
- Place cutting cord - 2 - around side window.
- Using a small tube - 3 - , guide cutting cord - 2 -

between lip and window flange and also guide second cord
end inside.
- Secure second cord end to spooling tool V.A.G 1654 A

and cut window free by positioning spooling tool.
- While cutting free, press cutting cord against window

using wedge V.A.G 1474/5 to have clearance to window
flange.
Damaged rear side window, removing
Removing a damaged side window is performed the same

as for removing a damaged rear window.
Rear side window, installing


window without pre-coating for glazing

Note:
When re-using an undamaged window, cut back

remaining adhesive sealant to 12 mm shortly before
re-adhering, do not damage primer and ceramic
coating.
Remaining material serves as adhesion base for

newly applied adhesive sealing compound.
Warning!
Do not prime or use a cleaning solution on the

adhesive surface. Keep adhesive surface free of dirt
and grease.
Exception: If bonding is not performed immediately after

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

number information
Preparing new window without pre-coating for glazing
Ceramic coating is only still applied on all new windows

and sprayed on sealing lips with spacer.
Exception: Rear window has no sealing lip and no spacer.
1 - Sealing lip
2 - Spacer
3 - Window
Note:
The application area for adhesive bead 3 is not pre-

coated and not primed.
- Clean window circumference to width of 20 mm all

around using cleaning solution D 009 401 04.
- Then rub window circumference dry using a lint-free rag.
Warning!
Ceramic application on window is not primer! It must

be primed before the application of adhesive sealing
material! Only use primer D 009 200 02!
- Apply primer - 4 - evenly in one motion using applicator

D 009 500 25 - 3 - to the previously cleaned area - 1 - of
window.
Make sure that glass adhesive is applied to primed area at

a distance of approx. 2 mm from sealing lip - 2 - .
Air dry time approx. 10 minutes
Preparing new window with pre-coating for glazing
The replacement rear window is pre-coated. A PUR

application area for adhesive bead is sprayed onto this
window.
- Rub off pre-coating with a dry, lint-free cloth.
Warning!
Do not prime or use a cleaning solution on the pre-

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

applicator D 009 500 25 - 1 - .
Allow activator to air dry for at least 10 minutes.
Note:
Activator must not come into contact with the paint,

otherwise paint will be damaged.
Window flange, preparing for glazing
- Cut back remaining material on body flange using electric

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

newly applied adhesive sealing compound. Keep
adhesive surfaces free of dirt and grease.
Warning!
Activator must not come into contact with the paint -


using the activator D 181 801 A1.
Note:

number information
If body flange is being worked on or is partially

replaced, it must be cleaned and primed again after
painting the corresponding area.
Installation notes
- Using double cartridge pistol VAS 5237 , apply adhesive

material all around on primed area - 1 - and onto cut back
adhesive head at right angle to window.
Warning!
Window must be installed within 10 minutes, otherwise

bonding properties of window adhesive will be
impaired.
Insert window into window cut out using two double

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

to spacer.
Secure windshield using window adjuster (443 845

631 A) during curing time.
The plenum chamber cover must always be installed

as described on page 64-1, Installing plenum
chamber cover .
Replace stickers (e.g. for airbag).
Insert rubber seal for axle of rear windshield wiper

motor into rear window.
Activator must not be applied onto distributing wire

for window heater.
Markings are placed at left and right on rear window

for applying adhesive material.
After installing, sides of rear window must not project

out beyond the contour of the rear lid under any
circumstances!
Secure rear window using adhesive tape during

curing time.
If the adhesive bead has been applied too thick and

the adhesive expands onto the area of the window
heating, then the excess adhesive must be
removed.
Minimum curing time
Warning!

bonded windows. One of these standards for example
is, that a freshly bonded windshield must comply with
the safety elements, even in an accident, once the
adhesive has exceeded the prescribed curing time.
The minimum curing time for 2K adhesive DA 004 600 A2

is 3 hours for all windows.
Curing time means the time from when the window is

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

Paint damage, repairing
For paint damage in visible areas and for severely

damaged points in the non-visible area of removed
window, paint structure must be repaired according to
specifications of "Paint Repair Manual" .
The following repair method applies to minor paint damage

in an area of removed window which is not visible: Apply
two coats of glass/paint primer D 009 200 02 over each
other (wet on wet) in opposite directions.
- Apply once over damaged area.
- Air dry for 10 minutes.
- Apply a second coat but apply it in the opposite direction

as the first one.
- It is recommended to use adhesive remover D 002 000

10 as a cleaning solution. Observe safety precautions
when processing.
Warning!
When cleaning from vehicle interior, the window that

was just installed must not be pressed outward.


Volkswagen Golf 5 - Front door window Page 1 / 17
64 - 2
Front door window

Tools
Front door window, assembly overview
Note :

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

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

64-2, Door window,
Window guide

64-2, Window guide,
Mount
Screw
Accessible from outside

(right-hand threads), loosen
by turning left, remove outer
door plate 58-1, Outer
door plate, removing and
installing
Accessible from insdie,

loosen by turning right,
remove trim from door

Group 70, Trim/insulation; Door trim
Qty. 2
8 Nm
Window regulator

64-2, Window regulator,
Cover cap
Qty. 2

64-2, Window regulator
motor, removing and
installing
Door window, removing and installing
Note:

right door window. Removing and installing the left
door window is derived accordingly from this.
Bolt - 4 - is accessible from inside and outside. The

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

Group 70, Trim panels/insulation; Door
trim
- Pry out cover caps - 4 - .
- Lower door window - 1 - until locking

screws - 3 - for mount - 2 - are
accessible.
Warning!
Loosen screw - 3 - from inside by

turning toward right.
- Loosen bolts - 3 - (do not remove)

from inside by turning toward right and
press apart clamping brackets.
Note :
If the work step is not possible due to a malfunction

via the electrical window regulator, window regulator
motor can be unscrewed to be able to slide window
down.
- Raise rear door window - 1 - and swivel out of door

toward front in - direction of arrow - .
Installing
- Insert door window - 1 - into door in - direction of

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

window guide.
- Now bolt must be tightened by turning toward left.
Then perform function test.

Door window, adjusting

trim
- Lower door window - 1 - until locking

screws - 3 - for mount - 2 - are
accessible.
Warning!
Loosen screw - 3 - from inside by

turning toward right.
- Loosen bolts - 3 - (do not remove)

from inside by turning toward right and
press apart clamping brackets.
- Press door window - 1 - using light pressure into

clamping brackets - direction of arrow - and align door
window to rear window guide without exerting pressure.
- While doing this, make sure that door window - 1 -

stands parallel to window guide.
- Tighten clamping brackets with screws - 3 - from inside

by turning toward left.
Tightening torque for bolt: 8 Nm.
Then perform function test.
Window regulator motor, assembly overview
Note :


motor, removing and
installing
Screw
Qty. 3
3.5 Nm
Window regulator motor, removing and installing
Note:

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

accordingly from this.
Window regulator motor should also be removed

with mounting plate with outer door plate removed.
Removing

trim
- Fix window using adhesive tape so that

it does not slip down.
- Disconnect harness connectors -

arrows - using a screwdriver in -
direction of arrow - .
- Remove the three bolts - 2 - .
- Remove window regulator motor with

control module - 1 - from mounting
plate.
Installing
- Attach window regulator motor - 1 -

and connect harness connector - arrows
- .
- Pull door window lightly up and down

so that splines are located better
between motor and cable drum.
- Tighten bolts - 2 - for window regulator

motor to torque setting 3.5 Nm).
- Drive the window regulator up and

down to the limit stops, twice. By doing
this, window regulator motor is normed
and ready for operation and activates
pinch protection.
Then, continue in reverse order of

removal.
Window guide, assembly overview
Note :

For reasons of clarity, outer door plate is not

depicted in the illustration.
Window guide
Trim
Screw
Qty. 2
2 Nm
Window frame at inner door

part
Window guide, removing and installing
Note:

right window guide. Removing and installing the left
window guide is derived accordingly from this.
For reasons of clarity, outer door plate is not

depicted in the removal and installation.
Removing
- Remove rearview mirror 66-2,

Exterior rearview mirror, removing and
installing .
- Pull window guide - 1 - out of mount.
- Remove bolts - 3 - (two pieces) and

pull off panel - 2 - in direction of B-pillar -
direction of arrow - .
- Pull window guide - 1 - all around from

window frame - 4 - and upward out of
window shaft.
Installing
Note:
While installing window guide, make sure it is seated

evenly (wind noise).
Window regulator, assembly overview
Note :

Window regulator

Screw
4x
8 Nm
Screw
Qty. 5, 4 door
Qty. 4, 2 door
8 Nm
Drive motor
Mounting plate
Window regulator, removing and installing
Note:

right window regulator. Removing and installing the
left window regulator is derived accordingly from
this.
Depending on model variations with 2 and 4 doors,

small deviations must be considered when removing
and installing.
Removing

installing
- Remove side impact protection 57-1,

Side impact protection, assembly
overview
- Remove door window 64-2, Door

window, removing and installing
- Remove bolts - 2 - from mounting plate

- 5- .
- Remove bolts - 3 - for window

regulator.
- Remove window regulator - 1 - with

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

window regulator motor 64-2,

Removing
Installing
A function test must be performed before outer door

plate is installed.
Volkswagen Golf 5 - Rear door window Page 1 / 17
64 - 3
Rear door window

Tools
Release tool T 10236
Rear door windows, assembly overview
Note :

Rear door window Page 2 / 17
Door window

64-3, Door window,
Window guide
Component of fixed door

window.

64-3, Fixed door window
with window guide, removing
and installing
Fixed door window
Is component of window
guide.

and installing
Window regulator guide
Spreader pin
Always replace when

performing assembly work at
door window
Spreader plug
Always replace when

performing assembly work at
door window
Cover cap
Window regulator


motor, removing and
installing
Door window, removing and installing
Note:

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

spreader pin and spreader plug are also accessible
from outside when outer door plate has been
removed.
Removing
- Remove rear door trim
Repair Manual, Body Interior, Repair Group 70, Trim

panels/insulation; Door trim
- Lower door window until spreader pin - 3 - and spreader

plug - 4 - are accessible in window regulator cut-out.
Note:
If the work step is not possible due to a malfunction

via the electrical window regulator, window regulator
motor can be unscrewed to be able to slide window
down.
- Screw in a 5 mm bolt (approx. 70 mm long) into spreader

pin - 3 - and pull bolt out of spreader plug - 4 - .
- Screw a 8 mm bolt (approx. 80 mm long) into spreader

plug - 4 - .
Note:
When screwing the bolt into spreader plug, do not

use excessive force on the plug otherwise it may fall
inside into the door.
- Pull spreader plug - 4 - our of clamping bracket - 1 -

and thereby out of door window.
- Pull window guide - 3 - out of mount.
- Remove bolts - 2 - and pull off panel - 1 - in direction of

B-pillar - direction of arrow - .
- Pull door window upward - arrow - out of window shaft.
Installing
Note:
Spreader plug and spreader pin must always be

replaced when performing assembly work on door
window.
Before inserting spreader plug and spreader pin,

check window for damage.
- With door window - 1 - removed, insert spreader plug -

3 - centered.
- Press spreader pin - 2 - flush into spreader plug - 3 - .
- Guide door window - 1 - into door and insert door

window onto mount of window regulator guide - 4 - .
- Using a light pressure from above - arrow - , engage

window - 1 - into window regulator guide - 4 - .
- Then, continue in reverse order of removal.
A function test must be performed before door trim is

installed.
Fixed door window with window guide, assembly

overview
Window guide
Component of fixed door

window

and installing
Fixed door window
Component of window guide

and installing
Window frame at inner door

part
Fixed door window with window guide, removing and

installing
Note:

right fixed window with window guide. Removing and
installing the left fixed window with window guide is
When removing and installing door window,

spreader pin and spreader plug are also accessible
from outside when outer door plate has been
removed.
Removing
- Remove outer door panel 58-1, Outer door plate,

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

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

window guide inward.
- Remove screws - 2 - and slide center bard - 3 -

downward - arrow a - .
- Remove center bar - 3 - from seal of fixed door window -

arrow b - .
- Disengage window guide - 1 - with fixed door window -

2 - on inside and outside all around from window frame - 4
- .
- Using release tool T 10236 , disengage retaining tab on

guide pin - 3 - in window frame - 4 - .
- Remove complete window guide - 1 -

with fixed door window - 2 - from window
frame - 3 - in - direction of arrow - .
Installing
Torque specification for screws on middle bar: 5.5 Nm
Note:
While installing fixed door window with window

guide, make sure it is seated evenly (wind noise).
Window regulator motor, assembly overview
Note :

Connector
Screw
Qty. 3
3.5 Nm

motor, removing and
installing
Window regulator motor, removing and installing

Note:

right window regulator motor. Removing and
installing the left window regulator motor is derived
Window regulator motor should also be removed

with mounting plate with outer door plate removed.
Removing
- Remove door trim

Group 70, Trim/noise insulation; door trim
- Fix window using adhesive tape so that

it does not slip down.
- Remove the three bolts - 2 - .
- Remove window regulator motor with

control module - 3 - from mounting
plate.
Installing
- Attach window regulator motor - 3 -

and connect harness connector - 1 - .
- Pull door window lightly up and down

so that splines are located better
between motor and cable drum.
- Tighten bolts - 2 - for window regulator

motor.
- Screw torque specification - 2 - 3.5

Nm
- Drive the window regulator up and

down to the limit stops, twice. By doing
this, window regulator motor is normed
and ready for operation and activates
pinch protection.
Then, continue in reverse order of

removal.
Window regulator, assembly overview
Note :

Window regulator

Screw
4x
8 Nm
Mounting plate
Drive motor
Screw
Qty. 2
8 Nm
Window regulator, removing and installing
Note:

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

installing
- Remove side impact member 58-1,

Side impact protection, assembly
overview
- Remove door window 64-3, Door

window, removing and installing
- Remove bolts - 2 - from mounting plate

- 3- .
- Remove bolts - 5 - for window

regulator.
- Remove window regulator - 1 - with

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

window regulator motor 64-3,

Removing
Installing
A function test must be performed before outer door

plate is installed.
Volkswagen Golf V - Wheel housing liner Page 1 / 7
66 - 1
Wheel housing liner

Tools
Front wheel housing liner, assembly overview
Note :


Front wheelhousing liner consists of front and rear

parts.
Wheel housing liner Page 2 / 7
Rear part of wheel housing liner
Material - PP/EPDM
Screw
Qty. 7
2 Nm
Front part of wheel housing liner
Material - PP/EPDM
Screw
Qty. 11
2 Nm
Spreader nut
Qty. 6
Front wheel housing liner, removing and installing
Note:

wheelhousing liner. Removing and installing right
wheelhousing liner is derived accordingly from this.
Removing
Rear part of wheel housing liner
- Unbolt wheel
Repair Manual, Suspension, Wheels,

Steering, Repair Group 44, Tightening
torques for wheel bolts
- Remove bolts - 2 - (Qty. 7).
- Remove rear part of wheelhousing liner

- 1- .
Front part of wheel housing liner
- Remove front part of wheelhousing liner

- 3- .
Installing
Rear wheel housing liner, assembly overview
Note :

Wheel housing liner
Material - PP/EPDM
Screw
Qty. 9
2 Nm
Spreader nut
Qty. 4
Rear wheel housing liner, removing and installing
Note:

wheelhousing liner. Removing and installing right
wheelhousing liner is derived accordingly from this.
Removing
- Unbolt wheel
Repair Manual, Suspension, Wheels,

Steering, Repair Group 44, Tightening
torques for wheel bolts
- Pull off wheelhousing liner - 1 - .
Installing

Volkswagen Golf V - Exterior rearview mirror Page 1 / 8
66 - 2
Exterior rearview mirror

Tools
Pry lever - RMV outside mirror 80-200
Rearview mirror, assembly overview
Note :

Exterior rearview mirror Page 2 / 8
Mirror base plate

66-2, Exterior rearview
mirror, removing and
installing
Screw
Qty. 3
8 Nm
Assembly component

66-2, Side turn signals,
Screw
Qty. 2
1 Nm
Screw
Qty. 2
1 Nm
Side turn signal

66-2, Side turn signals,
Trim

66-2, Trim panel, removing
and installing
Mirror glass

66-2, Mirror glass, removing
and installing
Mirror housing
Material - ABS

66-2, Mirror housing,
Mirror glass, removing and installing
Note:
Removing and installing is performed only for the left

mirror glass. Removing and installing right mirror
glass is derived accordingly from this.
Warning!
Wear protective eyewear and gloves when working!

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

using fabric-reinforced adhesive tape.
- Press mirror glass - 2 - at bottom into mirror housing - 1

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

bracket - 5 - and housing - 1 - - arrow 6 - .
- Swivel mirror glass - 2 - to the side - arrow 4 - and

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

glass.
- Press mirror glass at center onto holder in housing.
- Mirror glass will engage audibly.
Mirror housing, removing and installing
Note:
Removing and installing is performed only for the left

mirror housing. Removing and installing right mirror
housing is derived accordingly from this.
Removing
- Remove mirror glass 66-2, Removing
- To facilitate installation, fold rearview mirror forward.
- Press mirror housing using a screwdriver beneath

catches - 2 - out of locking mechanisms.
- Pull mirror housing in front area slightly off mirror carrier.
- Then, remove mirror housing - 1 - upward from mirror

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

mirror housing downward until catches - 2 - engage
audibly.
- Re-install mirror glass 66-2, Installing .
Trim panel, removing and installing
Note:

trim. Removing and installing right trim is derived

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

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

screwdriver.
- Remove trim - 1 - in - direction of arrow - .
Installing
Side turn signals, removing and installing
Note:

side turn signals. Removing and installing right side
turn signals is derived accordingly from this.
There are no conventional bulbs, but rather durable

light emitting diodes (LEDs) installed in the side turn
signals.
Therefore it is not necessary to change light bulbs.

In case of damage, the entire turn signal assembly
must be replaced.
Removing
- Remove mirror glass 66-2, Mirror glass, removing and

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

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

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

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

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

assembly piece - 1 - .
Installing
Exterior rearview mirror, removing and installing
Note:

rearview mirror. Removing and installing right rear
view mirror is derived accordingly from this.
Removing
- Remove front drivers side trim

Trim/insulation; Door trim; Front door, drivers side,
- Remove cable bracket - 2 - and disconnect harness

connector - 1 - for rearview mirror.
- Pry cover cap - 3 - out of door and remove bolts - 2 - .
- Remove rearview mirror - 1 - and guide wire through

opening in door.
Installing
- Tightening torques: Rearview mirror screws 8 Nm
Before installing door trim, check function of door

window.
Volkswagen Golf V - Radiator grille Page 1 / 8
66 - 3
Radiator grille
Tools
Radiator grille, assembly overview

Radiator grille Page 2 / 8
Radiator grille
Material - ASA
Catches
Qty. 6
Emblem
Clipped into radiator grille.
Can be removed only when

radiator grille is removed
Removing: Release catches

on rear side of emblem with
Installing: Guide
manufacturers emblem with
catch into recesses in

radiator grille - arrow b - ,
then twist slightly in direction
- arrow c - until
manufacturers emblem
engages in radiator grille.
Screw
Qty. 2
2 Nm
Radiator grille, removing and installing
Removing
- Using a small screwdriver, disengage

clips - arrows - from lock carrier.
- Tilt radiator grille - 1 - back slightly and

remove catches - 2 - upward out of
bumper cover.
Installing
- Insert radiator grille - 1 - tipped forward

slightly with catches. - 2 - in bumper
cover.
- Tip radiator grille - 1 - toward lock

carrier and engage clips - arrows - in
lock carrier.
- Screw in bolts - 4 - .
GTI radiator grille, assembly overview

Radiator grille
Material - ASA
Screw
Qty. 2
2 Nm
Decorative frame
Locked with radiator grille.
Can be carefully removed

from radiator grille.
Expanding rivet
4x
License plate bracket
Secured to radiator grille

with expanding clips.
Emblem
Clipped into radiator grille.

Removing: Release catches

on rear side of emblem with
Installing: Guide
manufacturers emblem with
catch into recesses in
radiator grille - arrow b - ,
then twist slightly in direction
- arrow c - until
manufacturers emblem
engages in radiator grille.
Front GTI name plate
Locked with radiator grille.

Loosen catches from

behind.
Screw
Qty. 2
2 Nm
Catches
Qty. 2
Guide hooks
4x
GTI radiator grille, removing
- Remove bolts - 3 - and - 6 - .
- Loosen catches - 2 - and - 4 - .
- Lift radiator grille - 1 - upward - arrow

a - out of guide hooks - 5 - .
- Tip upper edge of radiator grille forward

- arrow b - .
- Remove radiator grille from bumper

cover - arrow c - .
GTI radiator grille, installing

- Place radiator grille horizontally - arrow

a - with lower edge in bumper cover.
- Lift radiator grille upward - arrow b - .
- Guide radiator grille upward - arrow c -

into guide hooks - 5 - .
Catches - 2 - and - 4 - engage audibly.
- Secure screws - 3 - and - 6 - , torqe

specification: 2 Nm.
Volkswagen Golf V - Strips and trim Page 1 / 20
66 - 4
Strips and trim

Tools
Heat gun V.A.G 1416
Water deflector, assembly overview
Note :

Strips and trim Page 2 / 20
Water deflector
Retaining strip
Pop rivet
Qty. 5
Clip
Bracket
Drip rail, removing and installing
Removing
- Pry drip rail - 1 - from retaining strip -

2 - starting from top.
- Remove clip - 4 - from bracket - 5 - in

lower fender area.
Installing
- Engage clip - 4 - in bracket - 5 - .
- Press drip rail - 1 - from bottom to top

into retaining strip - 2 - .
Side protective moldings, assembly overview
Note :

Side protective molding, front

door
Material PP/EPDM
Self-adhesive
Left and right protective

moldings have a different
hole pattern.
Side protective molding, side

panel
Material PP/EPDM
Self-adhesive
Left and right protective

moldings have a different
hole pattern.
Replacing side protective moldings
Note :
The description applies to the left side. The right side

is similar and can be determined from this.

Stand time after installing side protective moldings

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

exclusively.
Side protective moldings must be applied

immediately after cleaning.
- Before removing, heat side protective

moldings - 1 - and - 2 - using a hot air
gun V.A.G 1416 and remove side
protective moldings.
- Remove any adhesive residue present

using erasure disc for stripe removal Z
432 290 TE .

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

number information
- Pull off protective foil on side protective

moldings - 1 - and - 2 - only before
installation.

dust and grease.
- Place the side protective moldings - 1 -

and - 2 - on vehicle and press side
protective moldings on forcefully.
Stone chip protective moldings, removing and installing
Removing
- Guide a small screwdriver from below

through the opening in the side trim and
release the catch - 2 - by pressing the
screwdriver upward - arrow a - .
- Slide stone chip protective molding - 1

- forward - arrow b - until screwdriver
comes in contact with screw - 3 - . Then
remove screwdriver. Slide stone chip

protective molding farther until it can be
removed from all retaining screws.
Installing
Note:
Stone chip protective molding screws are corrosion-

resistant. It does not need any further treatment.
If a screw was over-torqued, this must be replaced

with a "black" oversize screw.
There are no holes for the screws.
- Secure template - 1 - to side members

with commercially-available adhesive
tape - 4 - .
The template must be flush with upper

edge - 3 - and front edge of side
members - 2 - .
Template must not sag.
- Punch holes - 5 - for screws, template

can not be removed.
- Drill holes with a 1.5 mm bit.
All screw holes are present.
- Install self-tapping screws - 2 - with battery thread tap

VAS 5036 at highest speed until threads catch. Battery
thread tap must now be removed.
- Tighten screw with lowest torque so that screw is not

over-torqued.
- Position stone chip protective molding - 1 - evenly -

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

technician so that all screws remain in the openings when
molding is slid on.
- Slide stone chip protective molding forcefully opposite

direction of travel - arrow b - to stop.
Sill panel extension, assembly overview
Sill panel extension
Removing 66-4, Sill panel

extension, removing and
installing

Screw
Secures sill panel extension

to bracket
4x
2 Nm
Screw
Secures retaining stip to sill

panel
9x
1.2 Nm
Retaining strip
Removing 66-4, Sill panel

extension retaining strip
Sill panels
Bracket
Secured to underbody with

expanding clip.
Adhesive tape
Sill panel extension, removing and installing
Removing
- Warm sill panel extension - 1 - in

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

a plastic wedge - 5 - carefully between
sill panels - 3 - and sill panel extension -
1- .
- As soon as adhesive connection

loosens, life sill panel extension - 1 -
upward out of retaining strip - arrow - .
Installing
Note:
The description applies to the left side. The right side

is similar and can be determined from this.

Stand time after installing side protective moldings

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

exclusively.
Side protective moldings must be applied

immediately after cleaning.
Retaining strip is installed 66-4,

Sill panel extension retaining strip

with adhesive remover D 002000 10
immediately before adhering sill panel

extension.
Note :

number information
- Remove protective foil on sill panel

extension - 5 - just before installing.

dust and grease.
- Position sill panel extension - 3 - from

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

adhesive area.
- Secure secures - 4 - , beginning wtih

front screw on fender. With the rear
screw, tab - 5 - should be inserted first.
Sill panel extension retaining strip
Removing
Sill panel extension is removed

66-4, Sill panel extension,
- Slide retaining strip - 1 - in direction of

travel - arrows - from screws - 3 - and
remove from sill panels - 2 - .
Installing
Note:
Stone chip protective molding screws are corrosion-

resistant. It does not need any further treatment.
If a screw was over-torqued, this must be replaced

with a "black" oversize screw.
There are no holes for the screws.
- Secure template - 1 - to side members

with commercially-available adhesive
tape - 4 - .
The template must be flush with upper

edge - 3 - and front edge of side
members - 2 - .
Template must not sag.
- Punch holes - 5 - for screws, template

can not be removed.
- Drill holes with a 1.5 mm bit.

All screw holes are present 66-

4, Installing
- Install self-tapping screws - 3 - with

battery thread tap VAS 5036 at highest
speed until threads catch. Battery thread
tap must now be removed.
- Tighten screw with lowest torque so

that screw is not over-torqued.
- Position retaining strip - 1 - evenly -

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

technician so that all screws remain in
the openings when molding is slid on.
- Slide retaining strip forcefully opposite

direction of travel - arrow b - to stop.
Dimensions of rear name plates
Note:


exclusively.
Name plates must be applied immediately after

cleaning.
Dimension - a - = 50 mm
From outer edge of rear lid

up to name plate.
Dimension - b - = 90 mm
From lower edge of rear lid

to lower edge of name plate.
Volkswagen Golf V - Roof edge spoiler Page 1 / 11
66 - 5
Roof edge spoiler

Tools

required
Cutting tools for glass V.A.G

1351
Cutting tool kit V.A.G 1474 A
Window removing kit V.A.G 1755
Double cartridge gun VAS 5237

Roof edge spoiler Page 2 / 11
Materials
DA 004 600 A2 1) , 2)
2C- window adhesive
D 002 001
Mixer with cone shaped nozzle
D 181 801 A1 3)
Activator
D 181 711 A1
Primer
D 009 401 04 3)
Cleaning solution
D 009 500 25 3)
Primer applicator
D 002 000 10 3)
Adhesive remover
357 853 999 A

Cutting cord

time .
2) Double cartridge pistol VAS 5237 must be used to
process this material.
Roof edge spoiler, assembly overview

Rearlid
Primer surface
For adhesive bead on

retaining strip.
Position of primer surface

should be transferred from
adhesive bead depression to
retaining strip.
Primer surface
For adhesive bead on roof

edge spoiler.
Position of primer surface is

to be transferred from roof
edge spoiler.
Retaining strip
With adhesive bead

depression.
Removing 66-5, Retaining

strip, removing
Installing 66-5, Retaining

strip, installing
Installation notes 66-5,

Installation notes
Foam band
Self-adhesive
Foam band should be

checked for damage and
replaced if necessary before
installing roof edge spoiler.
Adhesive tape
Two strips for securing sides

of roof edge spoiler.
Adhesive surface
Is marked in interior side of

roof edge spoiler.
Roof edge spoiler
Material PC/PET
Removing 66-5,
Removing
Installation notes 66-5,

Installation notes
Roof edge spoiler, removing and installing
Removing
Warning!
When disassembling roof edge spoiler, a cutting cable

must not be used because of the danger of damaging
painted surfaces.
- Thread cutting cord - 6 - between rear

lid - 1 - and roof edge spoiler - 4 - .
- With "sawing motion" of both pull

handles - 5 - , cut through adhesive tape
- 2 - and adhesive bead - 3 - on one
side.
- Repeat cutting of adhesive tape and

adhesive bead on other side.
Vehicles as of 02.05
- Insert trim removal wedge 3409

between rear lid and roof edge spoiler
until middle catch - 3 - engages.
All vehicles
- To release remaining four catches - 2 -

, forcefully press roof edge spoiler onto
rear lid.
- Grasp between roof edge spoiler and

rear lide and carefully loosen roof edge
spoiler upward - arrow - from the four
catches - 4 - on the retaining strip,
beginning at sides and working toward
center of vehicle.
- After all catches have been released,

remove roof edge spoiler from retaining
strip.
Installing
Retaining strip - 6 - is installed

66-5, Retaining strip, installing
Brake light is installed in roof edge

spoiler

Repair Group 94,
Surfaces of roof edge spoiler - 3 -

and rear lid - 2 - are primed.
- Apply adhesive bead to primed surface

- 3 - or roof edge spoiler.
- Place roof edge spoiler - 5 - on

retaining strip - 6 - .
- Align roof edge spoiler - 5 - to rear lid -

1 - and press roof edge spoiler into catch
on retaining strip.
- With new rear edge spoilers, remove

adhesive tape protective foil - 4 - and
press roof edge spoiler firmly into
retaining strip.
- With reused roof edge spoiler, secure

corners to rear lid with commercially-
available adhesive tape.
Retaining strip
Retaining strip, removing
Roof edge spoiler is removed

66-5, Removing
- Cut through adhesive bead - 2 - with

help of cutting cord and pull handles.
Retaining strip, installing
Adhesive surfaces - 2 - on
retaining strip and rear lid are

primed.
- Apply adhesive bead in retaining strip

depression.
- Center retaining strip - 4 - on original

brake light cutout - 3 - .
- Secure retaining strip with commercially

available adhesive tape.
Preparing bodywork for adhesive
Note:

newly applied adhesive sealing compound. Keep
adhesive surfaces free of dirt and grease.

using the Activator D 181 801 A1 .
Warning!
Activator must not come into contact with the paint -

Note:

number information
If bodywork is being worked on or is partially

replaced, it must be cleaned and primed again after
painting the corresponding area.
Installation notes
The surfaces of the components to be primed must be free

of dirt.
- Remove adhesive residue using adhesive removal

solution D 002 000 10 .
- Saturate a cloth with silicone remover LSE 020 100 A3 .
- Always wipe application area for adhesive bead twice

using saturated cloth and allow to air dry.
- Now apply primer uniformly in one stroke using applicator

D 009 500 25 .
Air dry time approx. 10 minutes
- Adhesive material must be applied to the primed surfaces

of the component.
Warning!
Components must be installed within 10 minutes,

impaired.
Keep gap dimensions as narrow as possible,

approx. 1 mm.
Secure components using adhesive tape during

curing time.
Note:

number information
Minimum curing time
Minimum curing time for newly bonded components is 3

hours.
Minimum curing time is the time from applying the

components up to vehicle use. During this time, the vehicle
least 15 C).
Warning!

Paint damage, repairing
The paint structure must be re-established according to

specifications of "Paint Repair Manual" .
The following repair method is used for paint damage in

areas that are not visible:
- Paint twice (wet on wet) using glass/paint primer D 009

200 02 - minimum air drying time 10 minutes.
- Adhesive removal solution D 002 000 10 is the

recommended cleaning solution. Observe safety
precautions when processing.
- Roughly clean paint surfaces with a dry cloth. Remove

further material using adhesive removal solution D 002 000
10 .
Note:

number information
Volkswagen Golf 5 2004-> VW Rabbit GTI 2006->
(A5)
Interior rearview mirror

Tools

Automatic dimming interior rearview mirror
The automatically dimming interior rearview mirror dims

progressively when the driver is blinded from the rear.
It consists of a mirror element and an electrical element

with two photo sensors.
The electronic element registers light incidence from the

front and rear through the photo sensors.
If the incident light from the rear is greater than that from
the front, a current flows through the electronic element to
a conductive coating.
The applied current changes the color of the electrolytes.

The electrolyte becomes darker, the greater the current is.
The incident light will be reflected to a lesser degree.
The dimming function cuts out when reverse gear is

engaged. So one can back out of a dark garage, for
example, using the rearview mirror.
Interior rearview mirror with rain sensor, removing and

installing
Removing
- In vehicles with rain sensor, switch ignition off.

Interior rearview mirror Page 2 / 6
- Using trim removal wedge 3409 ,

operate locking mechanism - 1 - of right
cover cap - 2 - .
- Remove right - 2 - and left cover caps -

3 - from mirror base.
- Slide interior mirror downward out of

mount along front windshield.
Installing
- Installation is performed in the reverse order of removal.
Holding plate for interior rearview mirror with rain

sensor, bonding
Removal of windshield is no longer necessary, as with

previous repair procedure.
At the same time, it is possible to re-use the old, detached

mirror base.
Preparing windshield
- All adhesive and primer residue must be removed up to

ceramic coating.
- Clean adhesion surface using cleaning solution D 009

401 04 .
- Dry off period must be at least 10 minutes.
- Apply glass-/paint primer D 009 200 02.
- Dry off period until bonding: at least 10 minutes to a

maximum of 1 hour.
Preparing detached and new mirror base
- Use a tool to remove adhesive residue (only for detached

mirror base).
- Prepare adhesive surface by wet-sanding with fine emery

paper (800-1200 grit) until water remains (does not bead
and run off) on adhesive surface.
- Then clean using D 009 401 04 cleaning solution.
Bonding mirror base
- Apply two part polyurethane adhesive D 180 KD2 A1

direct to prepared and cleaned mirror base adhesive
surface.
- Adhesive bead diameter: approx. 2.5 to 3 mm.
- Immediately after applying adhesive on mirror base,

press onto prepared windshield.
- Align mirror base on its designated position on ceramic

coating and secure using adhesive tape.
Cleaning and removing excess adhesive
- Carefully remove adhesive tape 0.5 to 1 hour after

attaching mirror base.
- Remove excess soft adhesive all around using spatula.
- Then remove any remaining excess adhesive using a

primer applicator or rag, saturated with cleaning solution.
Installation of rain sensor and mirror

- Mirror can be installed 2.5 hours after mirror base has

been attached!
Interior rearview mirror, removing and installing
Removing
- Rotate interior mirror - 1 - 90

counterclockwise - arrow - and remove
it from adhesive plate - 2 - .
Installing
Holding plate for interior rearview mirror without rain

sensor, bonding
Materials:
Glass-metal adhesive set D 000 703 A1
Tools:
1 - Window scraper (commercially available)

2 - Blade (commerically available)
- Remove retaining plate from mirror base.
- Remove PUR adhesive material from retaining plate with

wire brush.
- Grind the three spacer knobs off of adhesive surface. To

do this, lay sandpaper (360/400 grit) on flat surface.
- Keep sanded surface free of dirt and grease.
- Scrape off PUR adhesive and primer from windshield

down to ceramic layer using glass scraper.
- Clean adhesive surface with adhesive remover D 002

000 10 or cleaning solution D 009 401 04 .
Caution!
Do not damage ceramic layer. Scratches always

remain visible.
- Cut nylon mesh to exact dimensions of mirror base.
Note:
Protective gloves (rubber gloves) should be worn.
- Spread thick layer of adhesive evenly on mirror base.
- Lay nylon mesh on mirror base.
- While continuing to apply adhesive with tube dab nylon

mesh.
30 seconds are available from laying the nylon mesh on

the adhesive to pressing on the windshield.
- Press mirror base (without force) onto windshield and

hold for 15 seconds.
- Use a rag to remove excess adhesive.
Note:
Mirror can be installed after 15 minutes.

Storage compartments, covers and trim Page 1 / 40
68 - 2
Storage compartments, covers and trim

Tools

Release lever T10039
Front center console without adjustable/folding armrest

with storage compartment, removing and installing
Removing
- Switch off ignition.
Vehicles with automatic transmission
- Loosen boot from cover

Repair Manual, 6 Spd. Direct Shift Automatic

Transmission 02E Front Wheel Drive, Repair Group 34,
Vehicles with manual transmission and Direct Shift

Gearbox (DSG)
Repair Manual, Manual Transmission, Repair Group 34,
All vehicles
- Remove parking brake lever trim
Repair Manual, Brake System, Repair Group 46,
- Remove the two carpet mats - 1 - from

extension - 3 - .
- Remove the three bolts - 2 - (1.5 Nm).
- Loosen extension from mounts.

- Pull parking brake lever extension

forward through opening.
- Remove gear selector insulation - 1 -

from center console.
- Remove the two bolts - 2 - (1.5 Nm).
- Remove storage compartment - 3 -

from center console and (depending on
vehicle equipment) disconnect wiring
harnesses.
Note :
An ashtray may be installed instead of the storage

compartment - 3 - , removal is the same.
- Unclip cover - 1 - from trim using a

small screw driver.
- Remove bolt - 2 - (1.5 Nm).
- Pull left footwell trim - 3 - out of

mounts.
Note :
Removal of right footwell trim is identical.

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

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unclip trim panels - 4 - on both sides in
area of locking mechanisms.
- Remove two bolts - 1 - and - 2 - (1.5

Nm) respectively.
- Remove two bolts - 3 - and - 4 - (1.5

Nm) respectively.
Note :
When installing, bolts must be installed in the

sequence - 1 - , - 2 - , - 3 - , - 4 - and - 5 - .
- Remove center console from vehicle.
Installing
Front center armrest adjustable/folding with storage

Removing


Gearbox (DSG)
All vehicles
- Remove parking brake lever trim
Repair Manual, Brakes, Repair Group 46,
Vehicles with CD changer.
- Remove CD changer - 1 -

Repair Group 91,
- Remove carpet mat - 2 - from storage

compartment.
Vehicles with cooled storage

compartment

compartment.
- Remove cover - 2 - out of mounts in

storage compartment.
All vehicles
- Open beverage holder - 1 - and

remove two bolts - 2 - (1.5 Nm).
- Pull cup holder out of center console.
Note :
When installing, beverage holder must be inserted

(first at bottom) into center console while in a closed
state. Then it must be opened and then install the
two bolts - 2 - .
- Remove trim panel - 1 - from mounts

in lower area - arrow - .
- Remove trim panel from mounts in

center console in upper area.
- Remove bolts - 1 - and - 2 - (1.5

Nm).
- Release extension - 3 - from mounts in

lower area.
- Remove gear selector insulation - 1 -

from center console.

from center console and (depending on
vehicle equipment) disconnect wiring
harnesses.
Note :

compartment - 3 - , removal is the same.

small screw driver.

mounts.
Note :


unclip trim panels - 4 - on both sides in
area of locking mechanisms.

compartment.
- Remove the two sets of bolts - 2 - and

- 3 - (1.5 Nm).

- 5 - (1.5 Nm).
Note :

sequence - 2 - , - 3 - , - 4 - , - 5 - and - 6 - .
- Remove center console from vehicle.
- Remove bolts - 1 - , - 2 - , - 3 - and -

4 - (1.5 Nm).
- Remove center console trim carrier - 5

- from vehicle.
Installing
Center console mounting bracket, removing and

installing
Removing
- Remove center console:
Front center console without adjustable/folding

armrest with storage compartment 68-2, Front
center console without adjustable/folding armrest
Front center console with adjustable/folding armrest

with storage compartment 68-2, Front center
armrest adjustable/folding with storage
- Remove two nuts - 1 - (8 Nm) and

remove mounting bracket - 2 - .
Installing
Storage compartment/ashtray unit, removing and

installing
Removing



Gearbox (DSG)
- Remove storage compartment - 2 - from center console

and (depending on vehicle equipment) disconnect wiring
harnesses.
Note:

compartment, removal is the same.
Installing
Instrument panel center vent (vehicles without

Climatronic), removing and installing
Note:
To provide a better overview, components are

shown removed in the following illustration.
Removing

compartment.

from air outlet - 4 - .
Vehicles with Climatronic
Items - 5 - , - 6 - , - 7 - , - 8 - and - 9 -
only apply to vehicles with Climatronic.
Instrument panel center vent (vehicles

with Climatronic), removing 68-2,
Instrument panel center vent, removing
and installing (vehicles with Climatronic)
Note :

The two screws - 1 - in this location are already

removed on vehicles without Climatronic.
- Place two trim removal wedges 3409 in

lower vent seam - arrows - and press
vent upward out of instrument panel
mounts.
- Press the corresponding catches and

disconnect wiring harnesses from
passenger airbag warning light switch
and indicator light.
Installing
Instrument panel center vent, removing and installing

(vehicles with Climatronic)
Removing
- Pry sensor - 1 - out of indirect ventilation - 2 - using trim

removal wedge 3409 .
- Disconnect wiring harness from sunlight photo sensor.
Note :
To provide a better overview, components are

shown removed in the following illustration.
- Insert two trim removal wedges 3409

as shown in seam between indirection
ventilation - 1 - and vent - 2 - .
- Press metal clips - 3 - and - 4 - back

with trim removal wedge 3409 and
remove indirect ventilation upward out of
mounts in vent - arrow - .
- Remove vent - 2 - in front area from

mounts.
- Place two trim removal wedges 3409 in

lower vent seam - arrows - and press
vent upward out of instrument panel
mounts.
- Press the corresponding catches and

passenger airbag warning light switch
and indicator light.
Installing
Center instrument panel trim, removing and installing
Removing
- Remove instrument panel center vent:
Vehicles without Climatronic 68-2, Instrument

panel center vent (vehicles without Climatronic),
Vehicles with Climatronic 68-2, Instrument panel

center vent, removing and installing (vehicles with

Climatronic)
- Using trim removal wedge 3409 , pry

trim in area of locking mechanisms out of
mounts in instrument panel.
Installing
Instrument panel side covers, removing and installing
Removing

right side instrument panel cover - 1 -
out of locking mechanisms.

left side instrument panel cover - 2 - out
of locking mechanisms.
Installing
Steering column trim, removing and installing
Removing
- Disconnect vehicle battery
- Remove driver-side airbag unit 69-4, Driver airbag

module, removing and installing
- Remove steering wheel 69-4, Steering wheel,

- Disengage steering wheel adjustment

locking lever.
- Pull out steering wheel and push it

downward.
- Remove gap cover - 1 - and upper

steering column trim - 2 - from mounts.
- Remove lower steering column trim - 5

- from mounts.
Installing

Drivers side left trim, removing and installing
Removing
Note:
For clarity, the steering wheel is not depicted in the

illustration, it is not necessary to remove it.
- Remove side instrument panel cover on front passenger-

side 68-2, Instrument panel side covers, removing and
installing
- Press rotary light switch toward front, rotate it toward

right until it stands vertically, now pull it out and disconnect
wiring harness.
- Remove steering column trim gap cover from instrument

panel 68-2, Steering column trim, removing and
installing . It is not necessary to remove the complete
steering column trim.

from mounts.

- Disengage trim panel from instrument

panel and disconnect wiring harness
from headlight range control.
Installing
Note :

sequence - 2 - , - 3 - and - 4 - (1.5 Nm).
Drivers side right trim, removing and installing
Removing
- Remove side instrument panel cover on front passenger-

installing
- Remove right trim panel on drivers side 68-2, Drivers

side left trim, removing and installing
- Remove center cover 68-2, Center cover, removing

and installing
- Remove bolts - 1 - , - 2 - , - 3 - and -

4 - (1.5 Nm).

disengage trim panel from mounts.
Installing
Note :

sequence - 1 - , - 2 - , - 3 - , and - 4 - (1.5 Nm).
Sun visor, removing and installing
Note:
Removal and installation is described for the left-

hand side of the vehicle. Removal and installation for
the right-hand side is performed in the same
manner.
Removing
Note :
If only the sun visor is to be removed, screw - 3 -

and sun visor mount - 6 - do not have to be
removed.
- Using a small screwdriver, open cover

caps - 1 - and - 2 - .
- Remove bolts - 3 - and - 4 - (2 Nm).
- Carefully pull sun visor mount - 1 - out

of mount.
Caution!
Hold sun visor securely. Allowing sun

visor to hang by wiring harness is not
permitted!
- Grasp sun visor wiring harness - 1 -

with thumb and forefinger as shown in
area by molded headliner opening.
Caution!
When removing connector from

retaining clips as follows, it is
possible that the wiring harness may
be damaged. This is the case if the
connector is removed from the
retaining clip with a jerking motion.
For this reason, remove it extremely
carefully with one hand on wiring
harness while supporting the hand
with the ball of the hand on the
vehicle. This allows the pulling force
on the wiring harness to be measured
out better, thus avoiding rough
removal of the connector.
- Hold onto roof grab handle firmly, then

pull lightly on wiring harness in direction
of windshield until connector comes out
of retaining clip in molded headliner.
- Carefully pull connector - 1 - out

through opening in molded headliner,
pulling out just far enough until connector
is located closely beneath molded
headliner.
Caution!
Do not pull harness connector further, since the

excess length of flat wire - 2 - is limited and
there is a hazard it will shear off.
Flat wire must only be pulled a maximum of 1 cm

out of opening in molded headliner.
- Carefully disconnect connector without

pulling on flat wire.
Installing
Note:
Slide a small foam pipe (part number 535.971.790)

over harness connector when installing sun visor.
Center cover, removing and installing
Removing
- Lift cover - 1 - out of mounts using trim

removal wedge 3409 .
Installing
Glove compartment, removing and installing
Removing
- Remove side instrument panel cover on front passengers

installing
- Disengage sill panel trim from body in area of juncture to

lower A-pillar trim.
2door 68-3, Sill panel trim (2-door), removing and

installing
4door 68-3, Sill panel trim (4-door), removing and

installing
- Remove passengers side A-pillar trim 70-3, Passenger

side lower A-pillar trim, removing and installing

and installing
- Remove 7 screws - 1 - , - 2 - , and - 3

- (1.5 Nm)
- Slide glove compartment outward until

stops - arrow A - .
- Disengage glove compartment from

instrument panel - arrow B - .
- Disconnect wiring harness from lights

and contact switch.
- In vehicles with glove compartment

cooling, disconnect A/C channel from
glove compartment.
- In vehicles with footwell lights,

disconnect wiring harness from lights.
Installing
Glove compartment lock cylinder, removing and

installing
Removing
- Open glove compartment.
Note :
It is not possible to remove separately from lock

cylinder - 1 - , release button - 2 - must be
replaced.
- Remove screw - 3 - and remove

release button - 2 - from glove
compartment lid.
Installing
Drivers side footwell cover, removing and installing
Removing
- Remove cover from mounts and

disconnect wiring harness from footwell
lights.

- Press the two locking mechanisms -

arrows - and disconnect diagnostic
connector from cover.
Installing
Instrument panel decor trim, removing and installing
Note:
Trim is only installed with "Front center console with

adjustable/folding armrest with storage
compartment" version.
Removing
- Pry trim panels - 1 - and - 2 - out of

instrument panel on drivers side using
- Pry trim panel - 3 - out of mounts on

front passengers side using trim removal
wedge 3409 .
Installing

Sill panel trim Page 1 / 6
68 - 3
Sill panel trim

Sill panel trim (2-door), removing and installing
Note:
Removal and installation is described for the right-

the left-hand side is performed in the same manner.
Removing
- Remove seat bench 72-2, Rear seat bench, removing

and installing .
- Remove sill panel trim - 1 - out of

mounts in sill, side trim and door seal
molding.
Note :
Before installing, check the seven securing clips for

damage and replace if necessary.
Installing
Sill panel trim (4-door), removing and installing
Note:

manner.
Removing
- Remove rear seat bench 72-2, Rear seat bench,

- Remove 4-door side upholstery:

with rear side airbags 72-2, Side upholstery with

side airbag (4-door), removing and installing
without rear side airbags 72-2, Side upholstery (4-

door,), removing and installing
- Wheel housing trim, 4-door, removing 68-3, Wheel

housing trim (4-door), removing and installing
- Pull sill panel trim out of front sill panel

and door seal tubing.
- Remove guide - 1 - from lower B-pillar

trim.
- Pull sill panel trim out of rear sill panel

- Remove guide - 2 - from lower B-pillar

trim.
- Open strap - 3 - and feed seatbelt

through it.
Note :
Before installing, check the five securing clips for

Installing
Wheel housing trim (4-door), removing and installing
Note:

manner.
Removing
- Remove rear seat bench 72-2, Rear seat bench,




- Remove clip - 2 - from body flange.
- Pull trim - 3 - from door seal tubing - 4

- .
- Pull trim out of mounts in sill panel trim

- 5- .
- Pull out trim in direction of travel under

C-pillar trim panel.
Removing

Grab handles Page 1 / 2
68 - 4
Grab handles
Grab handles (roof), removing and installing
Note:
Illustration shows the right front grab handle,

removing and installing the remaining grab handles
is identical.
Removing
- Swing down grab handle and open the

two cover caps - 1 - and - 2 - using a
small screwdriver.
- Remove two screws - 3 - (2 Nm) and

remove grab handle.
Grab handles Page 2 / 2
Installing

(A5)
Seat belts
Safety regulations for belt tensioners
Testing, removing, installing and repair work may

only be performed by qualified personnel.
Belt tensioner components may not be opened nor

repaired; always use new parts (risk of injury).
Belt tensioners that were subject to hard blows or

have been dropped on the floor, must not be
installed in a vehicle.
Belt tensioners that are mechanically damaged

(dents, cracks) must always be replaced.
Storage and transport is subject to laws governing

explosive materials.
Belt tensioners should be installed immediately after

removing them from the shipping package.
An impact wrench may not be used to remove the

belt tensioner.
Belt tensioner is to be returned to shipping package

when work is interrupted.
It is not acceptable to leave belt tensioner

unattended.
The belt tensioner may not be treated with grease,

cleaning agents, or similar materials, and may not be
exposed, even briefly, to temperatures above 212
F (100 C)
The pyrotechnic propellant has no expiration date,

i.e. it has unlimited service life and is maintenance-
free.
Seat belts Page 2 / 22
Disposing of belt tensioner units
Make sure that your dealership complies with

federal, state and local regulations for explosive
substances.
Deployed airbags and pyrotechnic seatbelts can be

disposed of as normal scrap.
Undeployed airbags and pyrotechnic seatbelts are

considered to be hazardous materials. When
disposing of an undeployed airbag or pyrotechnic
seatbelt that is either defective or expired, use the
appropriate repair information and Airbag
Deployment Device J-44210. DO NOT deploy
airbags and pyrotechnic seatbelts in the vehicle
All airbags and pyrotechnic seatbelts of a vehicle

scheduled to be scrapped must be deployed using
the Airbag Deployment Device J-44210.
When using Airbag Deployment Device J-44210,

wear appropriate eye and ear protection.
If the airbag or pyrotechnic seatbelt cannot be safely

deployed or removed from the vehicle, contact the
Volkswagen Dealer Technicians Helpline.
Shipment of active airbag gas generators and

pyrotechnic seatbelt retractors must be in
accordance with the regulations published in the
latest edition of the Code of Federal Regulations #49
(49 CFR). Shipment must be initiated and received
by certified individuals. The penalties for
noncompliance are severe. Civil penalties range the
$250 to $27,500 per violation, per day. Criminal
penalties, for willfully violating the regulations, range
up to $250,000 for individuals and $500,000 for
corporations.
Front seat belts (2-door), removing and installing
Assembly overview
Screw
20 Nm
Screw
40 Nm
Window
Anchor rail
Screw
40 Nm
B-pillar belt retractor
Wiring harness
Bolts
Qty. 2
4.5 Nm
Belt guide
Screw
40 Nm
Belt guide ring
Belt latch
Removing 69-1, Belt latch

(2-door), removing and
installing
Removing
Note:

manner.
Warning!
Observe safety precautions for belt tensioners 69-1,

Safety regulations for belt tensioners .
- Remove upper B-pillar trim 70-3, Upper B-pillar trim,


and installing .
- Remove backrest 72-2, Backrest, removing and

installing
- Remove 2-door sill panel trim 68-3, Sill panel trim (2-
door), removing and installing
- Remove side trim 70-3, Side trim (2-door), removing

and installing
- Remove screw Item - 1 - (20 Nm).
- Remove screw Item - 2 - (40 Nm)

and remove window Item - 3 - .
- Remove anchor rail Item - 4 -

through loop in belt webbing.

and remove belt retractor Item - 6 -
from B-pillar.
Warning!
Electrostatic charges may result in

involuntary deployment of the belt
tensioner. Therefore the technician
must discharge static electricity from
the body before separating the
ignition and ground wiring. This is
done e.g. by briefly touching the body
or the door striker or pin.
- Disconnect wiring harness Item - 7 -

.
- Remove screws Item - 8 - (4.5 Nm)

and remove belt guide Item - 9 - .

and remove belt relay Item - 11 - from
belt height adjuster.
Installing
- Connect vehicle battery
Front seat belts (4-door), removing and installing
Assembly overview
Screw
40 Nm
Micro-encapsulated
Belt anchor
Screw
40 Nm
B-pillar belt retractor
Wiring harness
Bolts
Qty. 2
4.5 Nm
Belt guide
Screw
40 Nm
Belt guide ring
Belt latch
Removing 69-1, Belt latch

(4-door) removing and
installing
Removing
Note:

manner.
Warning!
Observe safety precautions for belt tensioners 69-1,

Safety regulations for belt tensioners .

- Remove lower B-pillar trim 70-3, Lower B-pillar trim,


and remove belt anchor Item - 2 - from
body.
Caution!
Screw Item - 1 - is micro-

encapsulated. For this reason, it must
always be warmed with hot air gun
before loosening. While doing this,
protect the neighboring seatbelt
against excessive heat with a moist

towel.
Note :
The bolt is micro-encapsulated and must be

replaced every time it is loosened.
Before installing the new screw, threads on nut must

be cleaned, re-cut if necessary.

and remove belt retractor Item - 4 -
from B-pillar.
Warning!
Electrostatic charges may result in

involuntary deployment of the belt
tensioner. Therefore the technician
must discharge static electricity from
the body before separating the
ignition and ground wiring. This is
done e.g. by briefly touching the body
or the door striker or pin.
- Disconnect wiring harness Item - 5 -

.
- Remove screws Item - 6 - (2 Nm)

and remove belt guide Item - 7 - .

and remove belt relay Item - 9 - from
belt height adjuster.
Installing
Front seatbelt height adjuster, removing and installing
Note:


manner.
Removing

Note:
Belt anchor or anchor rail does not need to be

removed on seat belt.
- Remove bolt - 1 - (40 Nm) and remove

belt relay - 2 - from belt height adjuster.
- Remove bolt - 3 - (20 Nm) and

separate belt height adjuster - 4 - from
mounting in carrier plate.
Installing
Belt latch (2-door), removing and installing
Note:
Removal and installation is described for belt latch of

left seat. The same instructions apply for removal
and installation for belt latch of right seat.
Removing
- Remove front seat 72-1, Front seat, removing and

installing
- Position seat as far forward as possible.
- If present, disconnect wiring harness -

1 - from seat frame.
- Remove bolt - 2 - (20 Nm).
Note :
The screw is micro-encapsulated and must be

Before new bolts are installed, the thread of the

corresponding nut must be cleaned.
- Turn belt latch 90 clockwise - arrow

A - .
- Swivel belt latch toward outside - arrow

B - .
- Remove belt latch from mount in seat

rail - arrow C - .
Installing
Belt latch (4-door) removing and installing
Note:
Removal and installation is described for belt latch of

left seat. The same instructions apply for removal
and installation for belt latch of right seat.
Removing

installing
- Position seat as far forward as possible.
- If present, disconnect wiring harness

from seat frame.
Note :
The screw is micro-encapsulated and must be

Before new bolts are installed, the thread of the

corresponding nut must be cleaned.
- Remove belt latch - 2 - from mount in

seat rail - arrow - .
Installing
Rear outer seatbelts, removing and installing
Assembly overview
Screw
40 Nm
Belt anchor
Wiring harness
Screw
40 Nm
Automatic belt retractor with belt

tensioner
Screw
40 Nm
Automatic belt retractor without

belt tensioner
Removing
Note:

manner.
2-door vehicles


and installing .

installing

and installing
- Remove luggage compartment cover side compartment

70-5, Luggage compartment cover side storage
- Remove roof end strip 70-6, Roof end strip, removing

and installing
- Remove C-pillar trim 70-3, C-pillar trim, removing and

installing
4-door vehicles

and installing .




and installing

installing
- Unscrew bolt - 1 - (40 Nm) and remove

seatbelt guide - 2 - from body.
Vehicles with belt tensioner

Repair Group 27,
Warning!
Electrostatic discharges can lead to

an unintended deployment of the
airbag. Therefore the technician must
discharge static electricity from the
body before separating the ignition
and ground wiring. This is done e.g.
by briefly touching the body or the
door striker or pin.
- Disconnect wiring harness - 3 - .
- Remove screw - 4 - (40 Nm) and

remove automatic belt retractors - 5 -
from body - arrow A - .
Vehicles without belt tensioner


from body - arrow B - .
Installing
Rear center 3-point seatbelt, removing and installing
Assembly overview
Screw
Belt latch
Hex nut
40 Nm
Automatic belt retractor
Console
Removing

and installing .

installing
- Remove cover and upholstery from backrest 74-2,

Cover and cushion for backrest, removing and installing

remove belt latch - 2 - from body.
- Remove hex nut - 3 - (40 Nm) and

from console - 5 - .
- Guide belt latch - 2 - through console -

5- .
Installing
Center rear lap belt, removing and installing
Removing

and installing .

installing

remove lap belt - 2 - from body.
Installing
Rear double belt latch, removing and installing
Removing

and installing .

installing

remove double belt latch - 2 - from
body.
Installing

Seat belts, inspecting Page 1 / 5
69 - 2
Seat belts, inspecting

Warning!
After every accident the seat belt system must be

inspected systematically! If damage is determined
when inspecting the check points, customer must be
informed regarding necessity of changing belts.
Check points:
Check belt webbing
Check retractor (locking function)
Visually check belt latch
Check belt latch function
Check belt guide rings and locking tongue
Check securing components and anchorage points
Check points
Check belt webbing
- Pull belt completely out of retractor or lap belt adjustment

tongue.
- Inspect belt webbing for contamination and, if necessary,

wash with mild soap solution also refer to Operating
Manual.
If any of the following illustrated damage examples

(1 and 2) are discovered on an accident vehicle -
replace complete seat belt with belt latch and belt
height adjuster.
If one kind of damage under points 1, 2, 3 and 4 is

detected on a vehicle which has not been in an
accident, only the damaged seatbelt needs to be
replaced.
Belt webbing cut, torn or chafed.
Webbing loops on belt edge torn.
Burn marks from cigarettes or similar.

One side of belt edge deformed or area of belt edge

is wavy.
Check retractor (locking function)
The belt retractor has two locking functions.
The first locking function is initiated by belt being

jerked out of the retractor (belt extraction
acceleration).
Checking
- Pull belt webbing out of retractor with a firm jerk.
No locking function - replace compete seat belt with

belt latch.
If difficulties are experienced when pulling out or

retracting belt, first check whether position of
retractor has been altered.
The second locking function is initiated by change in

vehicle velocity (vehicle-dependent locking function).
For this, the vehicle must be moved on a level
surface.
Checking
- Fasten seat belt.
- Accelerate vehicle to 12 mph (20 km/h) and then perform

a full braking maneuver with foot brake.
If the locking mechanism does not lock the seat belt

during the braking maneuver, the complete seat belt
with belt latch must be replaced.
Warning!
For safety reasons, road test should be carried out on

traffic-free stretch to ensure that other
motorists/pedestrians etc. are not endangered.
Visually check belt latch
- Inspect belt latch for cracks and chipping.
If damage is discovered, replace complete seat belt

with belt latch.
Check belt latch function
Check belt latch:
- Insert locking tongue into belt latch until it audibly

engages. Check whether locking mechanism is properly
engaged by giving belt webbing a firm jerk.
If locking tongue fails to engage properly in belt latch

even once during at least 5 tests, replace complete
seat belt with belt latch.
Check release mechanism:
- Release seat belt by pressing button on belt latch with

finger pressure.
- When belt is slack, locking tongue must spring out of belt

latch on its own.
Perform test at least 5 times. If locking tongue fails

even once to spring out, replace complete seat belt
with belt latch.
Warning!
Under no circumstances may grease be used to

eliminate noise or stiffness at belt buckle buttons.
Check belt guide rings and locking tongue
The plastic-covered guides show fine parallel scoring after

straining belt system (belt was fastened during accident).
(Wear which has been brought about by frequent belt use
can be identified by smooth signs of wear which are free of
scoring.)
- Inspect for deformation, chipping and cracks in plastic.
If scoring and/or damage is discovered, replace

complete seat belt with belt latch.
Check securing components and anchorage points
Latch bracket deformed (stretched)
Height adjuster not functional
Anchorage points (seat, pillar, vehicle floor) distorted

or thread damaged
If damage is discovered on these components,

replace complete seat belt with belt latch.
Replace anchorage points.
Note:
In damage is discovered that is not accident-related,

e.g. wear, replace the particular part which is
damaged.
Inspecting child seat anchors (LATCH system "Lower Anchors and Tethers for CHildr... Page 1 / 1
69 - 3
Inspecting child seat anchors (LATCH system

"Lower Anchors and Tethers for CHildren"), after
accident
Check points
After an accident, child seat anchors must be

inspected for damage and deformation.
Child seat anchors that are welded into the body

cannot be repaired or corrected.
Child seat anchors that are bolted to the body must

be replaced if damaged or deformed.
Airbag Page 1 / 29
69 - 4
Airbag
Airbag components, Location overview,
Driver airbag unit
Removing 69-4, Driver

airbag module, removing
and installing
Airbag malfunction indicator

lamp (MIL) K75
Front passenger airbag module
Removing 69-4,
Passengers side airbag
module, removing and
installing
Airbag Page 2 / 29
Side airbag, driver side
Removing 69-4, Side

airbags for driver and front
passenger, removing and
installing
Side airbag, front passenger

side
Removing 69-4, Side

airbags for driver and front
passenger, removing and
installing
Rear driver-side side airbag
4-door only
Removing 69-4, Rear side

airbag (4-door), removing
and installing
Rear side-airbag, front

passengers side
4-door only
Removing 69-4, Rear side

airbag (4-door), removing
and installing
Airbag Control Module J234
Removing 69-4, Airbag

control module J234 ,
Adapting components
(coding) 69-4,
Components, adapting
Diagnostic connector
Airbag Page 3 / 29
10 - Front passenger-side side curtain

airbag
removing 69-4, Driver and

passenger side curtain airbags,
11 - Driver-side side curtain airbag
removing 69-4, Driver and

passenger side curtain airbags,
Safety precautions for work on airbags
Testing, removing, installing and repair work may

only be performed by qualified personnel.
When working on the airbag system, the battery

Ground (GND) strap must be disconnected. No
waiting time is necessary after disconnecting battery.
Airbag Page 4 / 29
When connecting the airbag system to a voltage

source, there must be no person present inside the
vehicle.
Before picking up (touching) the airbag unit, the

technician must electrostatically discharge
him/herself. This is achieved by touching a suitable
metal part, for example, a water pipe, heater pipe or
metal frame.
Airbag units should be installed immediately upon

removal from shipping package.
Airbag unit is to be returned to shipping package

when there is an interruption in work.
It is not acceptable to leave airbag unit unattended.
Airbag units which have been removed should be

stored so that padded side is facing up.
Airbag units that have fallen onto a hard surface or

show signs of damage must not be installed in
vehicle.
Additional safety precautions for side curtain airbag
Always replace damaged pillar trim panels, never

repair.
Head curtain airbags must not be kinked or twisted.
After body repairs, inspect the body for weld splatter,

deformations and chafing areas near the head
curtain airbag (compare with opposite side if
necessary).
If a deployed side curtain airbag is replaced, the

headliner, door seals with weather stripping, curtain
airbag guides, grab handle brackets, and the A, B, C
and (if equipped) D-pillar trim must be replaced. If
damaged, the rear interior lights, the roof grab
handles and the roof close-out molding must be
replaced.
Airbag Page 5 / 29
Disposing airbag units
Make sure that your dealership complies with

federal, state and local regulations for explosive
substances.
Deployed airbags and pyrotechnic seatbelts can be

disposed of as normal scrap.
Undeployed airbags and pyrotechnic seatbelts are

considered to be hazardous materials. When
disposing of an undeployed airbag or pyrotechnic
seatbelt that is either defective or expired, use the
appropriate repair information and Airbag
Deployment Device J-44210. DO NOT deploy
airbags and pyrotechnic seatbelts in the vehicle
All airbags and pyrotechnic seatbelts of a vehicle

scheduled to be scrapped must be deployed using
the Airbag Deployment Device J-44210.
When using Airbag Deployment Device J-44210,

wear appropriate eye and ear protection.
If the airbag or pyrotechnic seatbelt cannot be safely

deployed or removed from the vehicle, contact the
Volkswagen Dealer Technicians Helpline.
Shipment of active airbag gas generators and

pyrotechnic seatbelt retractors must be in
accordance with the regulations published in the
latest edition of the Code of Federal Regulations #49
(49 CFR). Shipment must be initiated and received
by certified individuals. The penalties for
noncompliance are severe. Civil penalties range the
$250 to $27,500 per violation, per day. Criminal
penalties, for willfully violating the regulations, range
up to $250,000 for individuals and $500,000 for
corporations.
Airbag units, replacing after an accident
Accident with airbag deployment
Note:
The airbag control module does not need to be

replaced after deployment unless "Control module
Airbag Page 6 / 29
faulty" DTC is set in the control module, or the

control module is physically damaged.
Always replace the following components after an

accident when airbag has deployed:
All deployed airbag units.
Supports and bracket from passenger module with a

deployed passenger airbag.
Return ring with slip ring, if drivers side airbag

deployed.
All seat belts with deployed seat belt tensioners.
If necessary (visual check) also replace the

following: All damaged components.
Accident without airbag deployment
The airbag control module does not need to be

replaced after deployment unless "Control module
faulty" DTC is set in the control module, or the
control module is physically damaged.
If the airbag malfunction indicator lamp (MIL) K 75

does not indicate a malfunction, it is not necessary
to replace any of the airbag components. Seat belts
must be inspected separately.
Airbag control module J234 , removing and installing
Warning!
Observe safety precautions for working on airbags

69-4, Safety precautions for work on airbags .
Removing
- Remove right and left footwell trim from center console

Airbag Page 7 / 29
(other center console components do not need to be

removed):


Note :
For the sake of illustration, center console is not

- Open locking mechanism of connector -

1 - and disconnect wiring harness from
control module - 2 - .
- Remove three nuts - 3 - (9 Nm).

Airbag Page 8 / 29
- Remove the control module from the

vehicle.
Installing
- Switch on ignition.
Warning!
Make sure that no persons are in the vehicle.
- If the control module was replaced, it must be coded.

Airbag Page 9 / 29
Adapting components (coding) 69-4, Components,

adapting
Driver airbag module, removing and installing
Note:
Removal and installation of airbag unit is described

for multi-function steering wheel.
The screwdriver mentioned in the following should

be about 175 mm long and have a blade width of 7
mm.
Removing
Warning!

- Adjust steering wheel height so that it is located in the

highest position.
- Adjust steering wheel depth (reach) so it is in the fully

extended position.
- Turn steering wheel into the position

depicted.
- Insert a screwdriver into hole on rear

side of steering wheel until it stops
(approx. 8 mm).
- Turn the screwdriver in the direction of

passengers side door - arrow - ; this
unlocks the airbag unit locking frame on
the right side of the steering wheel.
- Turn steering wheel 180 and

disengage airbag unit locking mechanism
on left side of steering wheel as
described.
- Turn steering wheel back 90 into

center position.
Airbag Page 10 / 29
- Remove airbag unit from steering

wheel.
Warning!

- Press connector lock and disconnect

connector - 1 - .
Note :
This connector is only installed with multifunction

steering wheel.
Airbag Page 11 / 29
- Release connector lock in - direction

of arrow - and disconnect airbag
connector - 2 - .
Installing
- Check whether wiring harness - 3 - is

routed as shown in the illustration.
- Insert airbag connector - 2 - into

connector coupling. Airbag connector
must engage audibly.
- Insert connector - 1 - into connector

coupling.
- Push airbag unit into steering wheel.

Airbag Page 12 / 29
- Check whether airbag unit is engaged

on the left and right-hand side of the
steering wheel.
Warning!
Make sure that no one is in the vehicle.
Steering wheel, removing and installing
Removing
Airbag Page 13 / 29

- Turn steering wheel into center position

(wheels in straight ahead position).
- Remove bolt - 1 - and pull steering

wheel off of steering column.
Installing
- Place steering wheel onto steering

column.
- Center markings for steering wheel and

steering column - arrows - must align.
Airbag Page 14 / 29
- The coil spring connector socket and

pin must be positioned in the openings
provided at the base of the steering
wheel.
- Fasten steering wheel with bolt - 1 - ;

torque is 50 Nm.
Airbag Spiral Spring/Return Spring With Slip Ring F138 ,

Airbag spiral spring/return spring with slip ring is a

component of steering column switch, depending on
construction type.
Repair Manual, Electrical equipment, Repair Group 94,

Steering column switch
Airbag Page 15 / 29
Passengers side airbag module, removing and installing
Removing
Warning!

- Remove side instrument panel cover 68-2, Instrument

panel side covers, removing and installing

and installing
- Remove glove compartment 68-2, Glove

Warning!

- Disconnect wiring harness from front

passengers side airbag.
- Remove the two bolts - 1 - (9 Nm).

- 3 - (9 Nm).
Airbag Page 16 / 29
- Remove front passengers airbag and

brackets - 4 - and - 5 - from mounts.
Installing
Warning!
Make sure that no one is in the vehicle.
.
Airbag Page 17 / 29
Side airbags for driver and front passenger, removing

and installing
Note:

manner.
Removing
Warning!


installing
- Remove front right seat trim 72-1, Right seat trim,

Vehicles with manual seat adjustment
- Remove front left seat trim 72-1, Left seat trim,

Vehicles with electric seat adjustment
- Remove left power seat trim 72-1, Left power seat

trim, removing and installing
All vehicles
- Remove front seat backrest 72-1, Front seat backrest,

- Remove cover and upholstery from front seat backrest

74-1, Front seat backrest cover and padding, removing and
installing
- Separate wiring harness - 1 - from

backrest frame.

Airbag Page 18 / 29
- Remove side airbag - 3 - from

mounting in backrest frame.
Installing
Warning!
.
Airbag Page 19 / 29
Rear side airbag (4-door), removing and installing
Note:

Removing
Warning!


and installing .
- Remove side upholstery with side

airbag (4-door), - 1 - 72-2, Side
upholstery with side airbag (4-door),
Note :
The bolts are microencapsulated and must therefore

be replaced after every removal.
Before installing the new bolts, the threads of the

corresponding nuts must be cleaned.
- Remove rear side airbag connector

coupling - 3 - from mount in side
upholstery - 1 - .
Airbag Page 20 / 29
- Remove rear side airbag - 3 - from

side upholstery.
Installing
Warning!
.
Airbag Page 21 / 29
Driver and passenger side curtain airbags, removing and

installing
Note:

Removal and installation for 4-door vehicle is

described. Removal and installation for 2-door
vehicle is identical.
Removing
Warning!

- If present, open sunroof.
- Remove sun visors 68-2, Sun visor, removing and

installing
- Remove roof grab handle 68-4, Grab handles (roof),

- Remove lights and switch in molded headliner
Repair Manual, Electrical Equipment, Repair Group 96.,

and installing
- Remove upper A-pillar trim 70-3, Upper A-pillar trim,

- Remove upper B-pillar trim. Belt anchors or front belt

anchor rails do not have to be removed 70-3, Upper B-
pillar trim, removing and installing
2-door only

and installing .
Airbag Page 22 / 29

installing

and installing
4-door only

and installing .


All vehicles

- Remove trim on C-pillars 70-3, C-pillar trim, removing

and installing
- Remove molded headliner 70-6, Headliner, removing

and installing
Warning!

- Disconnect wiring harness from side

curtain airbag
- Remove the four bolts - 1 - (4.5 Nm).
Note :
The four screws - 1 - must be replaced.
- Remove the two cap nuts - 2 - (9

Nm).
Airbag Page 23 / 29
- Remove all clips for curtain airbag from

body.
- Remove igniter - 3 - from threaded

pins - 4 - in body.
- Remove side curtain airbag from

vehicle via rear lid.
Installing
- After working on side curtain airbag,

ensure wiring harness - 1 - is routed as
shown.
Airbag Page 24 / 29
- Wiring harness - 1 - must be secured

with cable guide - 2 - in C-pillar area.
Warning!
Front Passenger s Seat Occupied Sensor G128 ,

Warning!
Airbag Page 25 / 29
If Front Passenger s Seat Occupied Sensor G128 is

replaced, also the upholstery, front seat cushion must
always be replaced!
Removing
- Mount the fixture for seat repair VAS 6136 on the engine
and transmission holder VAS 6095 .

installing
- Attach the seat to the fixture for seat repair VAS 6136 .


- Remove bracket and front seat operating lever 72-1,

Front seat bracket and operating lever, removing and
installing

- Remove retainer and power seat bracket 72-1,

Retainer and power seat bracket, removing and installing
All vehicles
- Remove front seat drawer mount 72-1, Seat drawer

mount, removing and installing
Note:
On vehicles with a luggage pass-through, it is

sufficient to fold the backrest forward, it does not
have to be removed.

- Remove cover and upholstery from front seat backrests

74-1, Front seat cushion cover and padding, removing
and installing
Warning!
Airbag Page 26 / 29

Front Passenger s Seat Occupied

Sensor G128 - 1 - is secured with
seat cushion padding. It is not
possible to remove and install
separately, sensor must be replaced
with upholstery.
Installing
- Press wiring harness in positioning aid

area - 1 - in rear padding channel.
- Press wiring harness in area of -

arrows A and B - from padding.
- Align sensor positioning aid - 3 - with

padding positioning aid - 2 - .
Caution!
Ensure distance from sensor to

Airbag Page 27 / 29
positioning aids - 2 - is constant -

arrows - when doing this.
- Secure aligned sensor - 1 - with right

hand, remove adhesive tape strips - 2 -
and attach sensor to padding.
- Press wiring harness in rear area into

padding opening - arrow - .
Airbag Page 28 / 29
- Connect wiring harness with vehicle

electrical system.
Installing of remaining components is reverse of removal.
- After installing, perform a function check with ignition on.
Components, adapting
Airbag Page 29 / 29
Vehicle Diagnosis, Testing and Information System

VAS 5051
Diagnostic cable VAS 5051/1 or VAS 5051/3
Note:
VAS 5051 A version shown as example only.
Select "Guided Fault Finding" on vehicle diagnosis, testing

and information system VAS 5051 .
After all control modules have been interrogated:
- Press "Go to" button
- Select "Function/Component selection"
- Select "Body"
- "Body Repairs"
- Select "01 - On Board Diagnostic (OBD) capable

systems"
- Select "Airbag"
- Select "Functions"
- Select "Action"
Passenger Occupant Detection System (PODS) (USA only) Page 1 / 26
69 - 5
Passenger Occupant Detection System (PODS)

(USA only)
Note:
Passenger Occupant Detection System (PODS)

controls automatic passenger airbag deactivation.
This equipment is only installed on vehicles released

in the USA.
Safety measures when working on seat occupied

recognition
After every repair on the passenger seat in which the

seat and/or backrest cover was "disengaged" basic
setting on Seat Occupied Recognition Control
Module J706 must be performed. Perform basic
setting with a diagnostic tester that has "Guided
Fault Finding" .
The seat occupied recognition mat must not be

kinked.
A leaking mat must be replaced (repair kit).
The seat occupied recognition pressure hose must

not be kinked.
Seat occupied recognition (repair kit) components

must not fall on hard surfaces.
Seat occupied recognition components must not

come in contact with grease.
There is the danger that the pPassenger Occupant

Detection System (PODS) may be damaged by
sharp objects when working on the seat. It is
necessary to avoid this danger.
The mat, the crease and various covers must be

fitted to be free of folds.
When installing, ensure upholstery and cover are

installed correctly.
Replace all upholstery clips and clip connectors from

cover, ensure it is positioned correctly on seat when
doing so.
System basic setting is only possible at

temperatures between 32 and 104 F (0 and
+40 C).
Make sure that no objects are placed on seat when

performing basic setting.
Use of seat covers, such as cushions or something

similar, impairs seat occupied recognition function
and airbag system effectiveness.
Procedure after an accident with belt pretensioner and/or

airbag deployment
Each time passenger airbag and/or belt pretensioner

on passenger side is deployed, Seat Occupied
Recognition Control Module J706 basic setting must
be performed. Perform basic setting with a
diagnostic tester that has "Guided Fault Finding" .
If the seat rails and/or seat pan must be replaced

after an accident due to deformation, seat occupied
recognition must also be replaced with "seat
occupied recognition repair kit" . Then, Seat
Occupied Recognition Control Module J706 basic
setting must be performed. Perform basic setting
with a diagnostic tester that has "Guided Fault
Finding" .
Passenger Occupant Detection System (PODS),

assembly overview (USA only)
Front seat wiring harness
Seat frame
Seat Occupied Recognition

Control Module J706
Upholstery of front seat cushion
Must not be separated from

mat for seat occupied
recognition
Seat Occupied Recognition Mat
Must not be removed from

pressure hose and
upholstery of front seat
cushion
Insertion profile
Note location
Bracket
White
Repair set components for Passenger Occupant

Detection System (PODS)
If there is a malfunction on a part of the

system, it must be replaced with
components from the repair kit. Repair
set is already matched to characteristics
of vehicle to be repaired and contains the
following components.
Warning!
Never use repair set components

separately.
Upholstery of front seat

cushion
Pressure hose
Seat Occupied Recognition Mat

Pressure Sensor G452

Control Module J706
Front seat wiring harness
Bracket
White
Warning!
Read and follow instructions for use

on package of repair set.
Misapplication may lead to

malfunction of system.
Components of Passenger Occupant Detection System

(PODS), removing (vehicles with manual seat
adjustment)
Warning!
Observe safety precautions when working on seat

occupied recognition 69-5, Safety measures when
working on seat occupied recognition .
Note:
Seat cushion, mat for seat occupied recognition,

control module and pressure sensor must only be
replaced together. Components are complementary
and must not be separated!
Only disconnect wiring harnesses mentioned in the

following description!

installing .
- Remove front belt latch:
2-door 69-1, Belt latch (2-door), removing and

installing
4-door 69-1, Belt latch (4-door) removing and

installing
- Remove right trim on seat:
Seat without pass-through 72-1, Right seat trim,

Seat with pass-through 72-1, Right trim, removing

and installing (seat with pass-through)
- Remove left trim on seat:
Seat without pass-through 72-1, Left seat trim,

Seat with pass-through 72-1, Left trim, removing

and installing (seat with pass-through)

installing .
- If present, remove mount for seat drawer 72-1, Seat

drawer mount, removing and installing .
- If present, remove connector - 1 - from

Front Passenger s Heated Seat Control
Module J132 .
- If equipped, remove retaining clip - 2 -

.
- Remove retaining clips - 3 - .
- If present, disconnect connector - 4 -

and remove connector from seat frame.
- Disconnect side airbag connector - 5 -

and remove connector from seat frame.
- Remove line clip - 6 - and disconnect

backrest wiring harness from seat
frame.

- Remove cover from upholstery of front seat cushion

(front seat cushion is not removed) 74-1, Front seat
cushion cover and padding, removing and installing .
- Unclip pressure hose - 6 - from

retainers.
- Unclip Seat Occupied Recognition

Pressure Sensor G452 - 5 - from
retainer, when doing this do not
disconnect harness connectors - 3 - or -
4 - at Seat Occupied Recognition
Pressure Sensor G452 and similarly at
Seat Occupied Recognition Control
Module J706 - 2 - .
- Remove bolts - 1 - (1.5 Nm).
- If present, disconnect front seat heating

connector - 3 - .
- Disconnect black Seat Occupied

Recognition Safety Belt Force Sensor
G453 connector - 5 -
- Disconnect yellow Front Passenger s

Safety Belt Switch E25 connector - 4 - .
- If present, disconnect front seat

backrest heating connector - 6 - .
- Cut wiring harness cable ties - 2 - .
- Slide white bracket - 1 - left and

remove from seat frame.
- Remove all connectors from bracket.
Caution!
Do not disconnect connector from

Module J706 .
- Lift upholstery of front seat cushion - 1

- , when doing this do not separate
upholstery of front seat cushion from mat
for seat occupied recognition - 4 - .
- Remove clip - 2 - from seat frame - 5 -

, clip - 3 - must not be removed.
Warning!
Do not damage seals when assembling or

disassembling.

pressure hose, Seat Occupied Recognition
Pressure Sensor G452 and Seat Occupied
Recognition Control Module J706 must not be
separated!
- Remove screws - 1 - (2.5 Nm) and

remove Seat Occupied Recognition
Control Module J706 bracket.
- Remove upholstery of front seat

cushion - 1 - together with mat for seat
occupied recognition - 4 - .
- Thread pressure hose - 6 - , Seat

Occupied Recognition Pressure Sensor
G452 - 7 - , Seat Occupied Recognition
Control Module J706 - 9 - and seat
wiring harness - 8 - through opening -
arrow - on seat frame - 5 - .
Repair set for Passenger Occupant Detection System

(PODS), installing (vehicles with manual seat
adjustment)
Note:
When installing, there must be no wiring harness of

seat heater between upholstery and mat for seat
occupied recognition.
Pressure hose must be routed without kinking.
Stickers with notes on harness connectors must not

be damaged.
After being connected to the vehicle electrical

system, verify that the replaced components can
move easily by moving the seat.
After replacing seat occupied recognition, basic setting of

seat occupied recognition must be performed using
diagnostic tester containing "Guided Fault Finding" .
Warning!
Basic setting must be performed when seat is not

occupied.
Installation is reverse of removal, noting the following:
- Secure insertion profile - 2 - with double-sided tape - 3 -

on seat frame - 1 - as shown.
- Clip pressure hose - 6 - into bracket.

Begin clipping into bracket near Seat
G452 - 5 - and end near connector - 3 -
.
Warning!

disassembling.

Components of Passenger Occupant Detection System

(PODS), removing (vehicles with electric seat
adjustment)
Warning!
Observe safety precautions when working on seat

occupied recognition 69-5, Safety measures when
working on seat occupied recognition .
Note:

control module and pressure sensor must only be
replaced together. Components are complementary
and must not be separated!
Only disconnect wiring harnesses mentioned in the

following description!

installing .
2-door 69-1, Belt latch (2-door), removing and

installing
4-door 69-1, Belt latch (4-door) removing and

installing
- Remove right trim on seat 72-1, Right seat trim,


trim, removing and installing .
- If present, remove seat drawer mount 72-1, Seat

drawer mount, removing and installing

- Disconnect connector - 1 - from backrest adjustment

motor.
- Disconnect connector - 1 - from seat

adjustment motor.
- Remove cable brackets - 2 - and - 3 -

.
- Disconnect backrest adjustment

connector - 4 - and remove connector
from seat frame.
- Remove cable bracket - 5 - .
- If present, remove connector - 6 - from

Front Passenger s Heated Seat Control
Module J132 .
- If equipped, remove retaining clip - 7 -

.
- Disconnect side airbag connector - 8 -

.
- If present, disconnect front backrest

heating connector - 10 - and remove
yellow connector.
Note :
Do not remove white bracket.


- Remove cover from upholstery of front seat cushion

(front seat cushion is not removed) 74-1, Front seat
cushion cover and padding, removing and installing .
Caution!
Do not disconnect connector from

Module J706 .
- Unclip pressure hose - 6 - from

retainers.
- Unclip Seat Occupied Recognition

Pressure Sensor G452 - 5 - from
retainer, when doing this do not
disconnect harness connectors - 3 - or -
4 - at Seat Occupied Recognition

Pressure Sensor G452 and similarly at
Module J706 - 2 - .
- Remove bolts - 1 - (1.5 Nm).
- Disconnect black Seat Occupied

Recognition Safety Belt Force Sensor
G453 connector - 1 -
- Disconnect yellow Front Passenger s

Safety Belt Switch E25 connector - 2 - .
- Remove white bracket - 3 - from seat

frame.
- If present, disconnect front seat heating

connector - 3 - .
- If present, disconnect front seat

backrest heating connector - 4 - .
- Cut wiring harness cable ties - 2 - .
- Slide white bracket - 1 - left and

remove from seat frame.
- Remove all connectors from bracket.
- Lift upholstery of front seat cushion - 1

- , when doing this do not separate
upholstery of front seat cushion from mat
for seat occupied recognition - 4 - .
- Remove clip - 2 - from seat frame - 5 -

, clip - 3 - must not be removed.
Warning!
Seat cushion, mat for seat occupied

recognition, pressure hose, Seat
Occupied Recognition Pressure
Sensor G452 and Seat Occupied
Recognition Control Module J706
must not be separated!
- Remove upholstery of front seat

cushion - 1 - together with mat for seat
occupied recognition - 4 - .
- Thread pressure hose - 6 - , Seat

G452 - 7 - , Seat Occupied Recognition
Control Module J706 - 9 - and seat
wiring harness - 8 - through opening -
arrow - on seat frame - 5 - .
Repair set for Passenger Occupant Detection System

(PODS), installing (vehicles with electric seat
adjustment)
Note:
When installing, there must be no wiring harness of

seat heater between upholstery and mat for seat
occupied recognition.
Pressure hose must be routed without kinking.
Stickers with notes on harness connectors must not

be damaged.
After being connected to the vehicle electrical

system, verify that the replaced components can
move easily by moving the seat.
After replacing seat occupied recognition, basic setting of

seat occupied recognition must be performed using
diagnostic tester containing "Guided Fault Finding" .
Warning!
Basic setting must be performed when seat is not

occupied.
Installation is reverse of removal, noting the following:
- Secure insertion profile - 2 - with double-sided tape - 3 -

on seat frame - 1 - as shown.
- Connect pressure hose - 6 - . Brackets

must be reinstalled, from Seat Occupied
Recognition Pressure Sensor G452 - 5 -
to wiring harness connector - 3 - .
Warning!

disassembling.

.
Crash sensors Page 1 / 6
69 - 6
Crash sensors
Front door crash sensors, removing and installing
Note:

Removing
Warning!
Observe safety precautions for working on airbags.
- Remove outer door panel
Repair Manual, Body Exterior, Repair Group 57,
- Separate wiring harness - 1 - from

crash sensor - 3 - .
Installing
Warning!
Rear wheel housing crash sensors (2-door), removing

and installing
Note:

Removing
Warning!

and installing .

installing


and installing
- Press connector lock - 1 - toward rear -

arrow - and disconnect connector - 2 -
from crash sensor - 4 - .
Installing
Warning!
Rear wheel housing crash sensors (4-door), removing

and installing
Note:

Removing
Warning!

and installing .


- Wheel housing trim, 4-door, removing 68-3, Wheel

housing trim (4-door), removing and installing
- Press connector lock - 1 - toward rear -

arrow - and disconnect connector - 2 -
from crash sensor - 4 - .
Installing
Warning!
.
(A5)
Instrument panel
Tools

Instrument panel, removing and installing
Removing

- Remove steering wheel 69-4, Steering wheel,

- Remove side instrument panel covers 68-2, Instrument

- Remove upper trim on A-pillars 70-3, Upper A-pillar


and installing
- Remove glove compartment 68-2, Glove

- Remove center console:

Instrument panel Page 2 / 13


- Remove instrument panel center vent 68-2, Instrument

panel center vent, removing and installing (vehicles with
Climatronic)
Vehicles without Climatronic 68-2, Instrument

panel center vent (vehicles without Climatronic),
Vehicles with Climatronic 68-2, Instrument panel

center vent, removing and installing (vehicles with
Climatronic)
- Remove instrument panel center trim: 68-2, Center

instrument panel trim, removing and installing
Vehicles with radio system
- Remove radio
Vehicles with Navigation
- Remove Navigation display and control head
Vehicles with Climatic or Climatronic
- Remove Climatic or Climatronic mechanism
Repair Manual, Heating Air Conditioning, Repair Group

87,
Vehicles with heating
- Remove heating mechanism
Repair Manual, Heating Air Conditioning, Repair Group

80,
- Remove steering column trim 68-2, Steering column

- Remove Steering Column Electronic Systems Control

Module J527
- Remove Airbag Spiral Spring/Return Spring With Slip

Ring F138
- Remove Steering Angle Sensor G85
- Remove Turn Signal Switch E2
- Remove Windshield Wiper Switch E
- Remove right trim panel on drivers side 68-2, Drivers

side left trim, removing and installing
- Remove left trim panel on drivers side 68-2, Drivers

side right trim, removing and installing
- Remove instrument cluster

- Remove drivers side footwell cover 68-2, Drivers side

footwell cover, removing and installing
- Remove two bolts - 1 - (9 Nm) from

front passenger airbag.
- Disconnect wiring harness from front

passengers side airbag.
- Remove bolts - 3 - and - 4 - (3 Nm).

- Remove two screws - 2 - (8 Nm)

above tunnel.

- Remove bolts - 1 - , - 2 - and - 3 - (3

Nm).
- Pull instrument panel out of mounts - 1

- in area of juncture to front windshield.
- Depending on vehicle equipment,

disconnect the corresponding wiring
harnesses and remove instrument panel
from vehicle with a second technician.
Note :
When installing instrument panel, make sure that

instrument panel is placed with exact fit into mounts
- 1 - .
Installing
Instrument panel, aligning in vehicle

Instrument panel height is adjusted correctly when there is

no offset between door trim seam - arrow A - and
instrument panel seam - arrow B - .
Height difference between upper edge of door trim - 1 -

and upper edge of instrument panel - 2 - is 3 mm 1 mm.
It is not necessary to change instrument panel position to

increase horizontal gap between door trim and instrument
panel - arrow C - .
- Open door and remove screw - 1 - (2 Nm).
- Hold an appropriately thick cloth at left edge of

instrument panel and close door.
In this way, door trim engages closer to door and the gap
between door trim and instrument panel increases
appropriately. Thus, it is not necessary to align instrument
panel.
Note:
Perform work on passenger side in the same way.
Instrument panel, aligning
Instrument panel can be aligned in height and diagonally to

direction of travel.
- Remove wiper arm
- Remove plenum chamber cover
Repair Manual, Body Exterior, Repair Group 64,

- Pry cover - 1 - out of mounts using trim removal wedge

3409 .

small screw driver.

mounts.
Note :
- Loosen screw - 1 - in plenum chamber 2-3 turns.
- Loosen two screws - 1 - below heating

or A/C mechanism 2-3 turns (9 Nm).
Note :
Additional screws in this area do not need to be

loosened.
- Loosen four screws - 2 - in tunnel area

2-3 turns (20 Nm).
- Loosen nut - 1 - on right side 2-3 turns

(18 Nm).
- Loosen fuse holder screw - 3 - on left

side (2 Nm).
- Loosen two nuts - 4 - 2-3 turns (18

Nm).
Instrument panel, aligning height
Note :
Instrument panel height is set using eccentric screws

- 2 - and - 5 - .
In the zero position, the longer eccentric surface

faces toward outside of vehicle.
Eccentric must not be turned more than 90 out

of zero position.
- Adjust desired instrument panel height

using eccentric screws - 2 - and - 5 - .
Instrument panel, aligning width
- Slide instrument panel into desired

position.
- After aligning in vehicle, secure instrument panel with

specified torque.
Installation of removed components is reverse of removal.

Door trim Page 1 / 9
70 - 2
Door trim
Tools

Pliers 3392
Driver side front door trim, removing and installing
Removing
- Pry upper section of grip shell - 1 -

upward out of mounts in door trim using

disconnect wiring harnesses from upper
section of grip shell.
- Remove two screws - 2 - (1.5 Nm) in

area handle molding area.
- Remove bolt - 3 - and three bolts - 4 -

(2 Nm).
- Disengage door trim from mounts in

lower area using disassembly pliers
3392 .
- Disengage door trim from mounts on

the sides using disassembly pliers
3392 .
- Pull door trim vertically upward out of

window shaft.
- In vehicles with radio system,

disconnect wiring harness from speaker.
- Disconnect door trim wiring harness

from door control module.
- Detach release cable - 5 - from inside

door release mechanism - 6 - .
- Remove screw - 7 - (2 Nm) and pry

mirror triangle cover - 8 - out of mounts
using trim removal wedge 3409 .

disconnect wiring harness from speaker
in cover.
Installing
Note:
Before installing, inspect the securing clips for

Passenger side front door trim, removing and installing
Removing
- Pry upper section of grip shell - 1 - out

of pull handle in door trim using wedge

3409 .

Nm).
- Remove screw - 3 - and three screws -

4 - (2 Nm).

3392 .

3392 .

window shaft.

disconnect wiring harness from speaker.
- Disconnect door trim wiring harness

from door control module.
- Disengage release cable - 6 - from

interior door mechanism - 7 - .
- Remove screw - 8 - (2 Nm) and pry

mirror triangle cover - 9 - out of mounts
using trim removal wedge 3409 .

disconnect wiring harness from speaker
in cover.
Installing
Note:

Rear door trim, removing and installing
Note:
Removal and installation is described for the right

rear door trim panel. Removal and installation of the
left rear door trim panel is performed in the same
manner.
Removing
Only vehicles with manual window regulators
- Remove window crank 70-2, Manual window crank,

- Pry upper section of grip shell - 1 - out

of pull handle in door trim using wedge
3409 .

Nm).

3392 .

3392 .

window shaft.

disconnect wiring harnesses from door
trim.

- Detach release cable - 5 - from inside

door release mechanism - 6 - .
Installing
Note:

Manual window crank, removing and installing
Removing
- Press circlip - 1 - forward in direction of

travel - arrow - and remove window
crank - 2 - from drive mechanism - 3 - .
Installing
Note :
After installation, window crank on right side of

vehicle must stand at "5:00" position when window is
closed.
After installation, window crank on left side of vehicle

must stand at "7:00" position when window is
closed.
This corresponds to a - 30 angle - position.

Deviation of window cranks to each other must be 6

max.
Pillar and side trim Page 1 / 13
70 - 3
Pillar and side trim

Upper A-pillar trim, removing and installing
Note:

manner.
Removing
- Remove airbag emblem - 1 - and

remove screw - 2 - (4 Nm).
- Remove trim in area of mounting clip -

3 - from mounts - arrow A - .
- Remove trim from door seal tubing.
- Pull trim out of front mount - arrow B -

.
- Remove trim in rear area from

instrument panel - arrow C - .
Note :
When re-installing, airbag emblem - 1 - must be

replaced.

Installing
Driver side lower A-pillar trim, removing and installing
Removing

2-door 68-3, Sill panel trim (2-door), removing and

installing

installing

- Remove hood operating lever - 1 -
Repair Manual, Body Exterior, Repair

Group 55,
- Remove clip - 2 - .
- Remove trim from body - arrow A - .
- Pull trim out of mount - arrow B - .
Note :
Before installation, clip - 2 - must be checked for

damage and replaced if necessary.
Installing
Passenger side lower A-pillar trim, removing and

installing
Removing


installing

installing
- Remove side instrument panel cover on front passengers

installing
Note :
For the sake of illustration, instrument panel is not

- Remove trim from body - arrow A - .

- Pull trim out of mount - arrow B - .
Installing
Upper B-pillar trim, removing and installing
Note:

manner.
Removing

Note :

replaced.
- Pull trim in lower area out of mounts in

body - arrow A - .
- Pull trim out of top mount - arrow B - .
4-door vehicles
- Remove lower B-pillar trim 70-3, Lower B-pillar trim,

- Remove belt anchor from front seatbelt 69-1, Front

seat belts (4-door), removing and installing
2-door vehicles

and installing .
- Remove anchor rail from seat belt 69-1, Front seat

belts (2-door), removing and installing
All vehicles
- Pull seat belt through trim opening.
Installing
Note :
When installing, driver for belt height adjuster - 4 -

and button in trim - 3 - must be located in the same
position.
Before installation, clip must be checked for damage

and replaced if necessary.
- Installation is performed in the reverse

order of removal.
Lower B-pillar trim, removing and installing
Note:

manner.
Removing
- In vehicles with interior monitoring system, switch ignition

off.
- Remove upper B-pillar trim. Belt anchor or belt anchor

rail do not need to be removed from front seat belt 70-3,
Upper B-pillar trim, removing and installing .
- Remove trim - 3 - from door seal

tubing.
- Remove trim from mounts in body in

area of guide - 2 - .
- In vehicles with interior monitoring

system, disconnect wiring harness from
sensor.
Installing
C-pillar trim, removing and installing
Note:


manner.
Removing
4-door vehicles

and installing .


2-door vehicles

Upper B-pillar trim, removing and installing

and installing .

installing

and installing
All vehicles

compartment, removing and installing .

and installing

Note :

replaced.
- Remove nut - 3 - (1.5 Nm).
- Loosen trim from threaded pins in nut -

3 - - arrow A - .
- Remove trim from mounts - arrow B -

- Remove trim upward out of mounts in

body - arrow C - .
Installing
Note:

Side trim (2-door), removing and installing

Note:

Removing
- Remove upper B-pillar trim. Belt anchor rail does not

need to be removed from front seat belt 70-3, Upper B-
pillar trim, removing and installing .

and installing .

installing
- Remove cover cap - 1 - from mounts

and remove screw - 2 - (2 Nm).
- Remove sill panel trim from mounts in

side trim in lower area.
- Remove side trim from mounts in body.

disconnect wiring harness from speaker -
3- .
- In vehicles with interior monitoring

system, disconnect wiring harness from
sensor.
Installing
Note:
Before installing, check securing clips for damage

and replace if necessary.
Rear lid trim Page 1 / 3
70 - 4
Rear lid trim

Tools

Pliers 3392
Rear lid trim, removing and installing
Removing
- Remove two screws - 1 - from handle

recess (2 Nm).
- Remove trim from mounts in rear lid

using disassembly pliers 3392 . Start
from lower edge of rear lid.
- Remove rear lid trim - 2 - on both sides

from window frame trim - 3 - .
- Remove trim in centering pin area - 4 -

and - 5 - from mounts in rear lid.
Installing
Note:

Window frame trim, removing and installing
Removing
- Remove rear lid trim 70-4, Rear lid trim, removing and
installing
- Using pliers 3392 , remove trim at

sides from mounts in lid.
- Pull trim on upper edge out of mounts.
- Remove trim in centering pin area - 1 -

and - 2 - from mounts in rear lid.
Installing
Note:

Luggage compartment trim Page 1 / 5
70 - 5
Luggage compartment trim

Luggage compartment cover side storage compartment,
Note:

Removing
2-door vehicles
- Remove upper B-pillar trim. Belt anchor rail does not

need to be removed from front seat belt 70-3, Upper B-

and installing .

installing

and installing
4-door vehicles

and installing .


All vehicles
- Remove lock carrier cover from catches

in compartment transition area.

Nm).
- Remove compartment - 3 - from

mounts.

compartment.
Installing
Note:

Luggage compartment side trim, removing and installing
Note:


Removing
- Remove floor covering from vehicle.
2-door vehicles

Upper B-pillar trim, removing and installing .

and installing .

installing

and installing
4-door vehicles

and installing .


All vehicles
- Remove rear lock carrier cover 70-5, Rear lock carrier

cover, removing and installing

- Remove the two bolts - 1 - (8 Nm) and

remove the anchor point - 2 - .
- Remove five press buttons - 3 - and

remove trim from vehicle.
Rear lock carrier cover, removing and installing
Removing
- Remove floor covering from vehicle.
- Disengage cover from body in lower

area - arrow A - .
- Remove cover from side mounts - 1 -

and - 2 - in body.
- Pull cover upward from lock carrier -

arrows B - .
Installing
Note:

Roof trim Page 1 / 9
70 - 6
Roof trim
Tools
Electric cutter V.A.G 1561 A
Release lever T10039
Roof end strip, removing and installing

Removing
- Open rear lid.
- Remove roof end strip - 1 - down out

of mounts in roof crossmember and rear
lid seal molding.
Note :

Installing
Headliner, removing and installing
Removing

and installing
- Remove upper a-pillar trim 70-3, Upper A-pillar trim,


2-door only

and installing .

installing

and installing
4-door only

and installing .


All vehicles


installing
Vehicles with sunroof

- Push the wedge T10039/1 between

frame - 1 - and headliner - 2 - .
- Using the release lever T10039/1 ,

separate the frame in - direction of the
arrow - from the headliner, the whole
way around.
All vehicles
- Remove right and left sun visors - 1 -

68-2, Sun visor, removing and
installing
- Remove right and left roof grab handles

- 2 - and - 3 - 68-4, Grab handles
(roof), removing and installing
- Lower molded headliner slightly and

(depending on vehicle equipment)
disconnect wiring harnesses from molded

headliner.
- Remove molded headliner from vehicle

through rear lid.
Installing
Roof insulation/reinforcement, removing and installing
Removing
Warning!


- Remove sun visors 68-2, Sun visor, removing and

installing
- Remove roof grab handle 68-4, Grab handles (roof),


and installing
- Remove upper a-pillar trim 70-3, Upper A-pillar trim,


2-door only

and installing .

installing

and installing
4-door only

and installing .


All vehicles


- Remove trim on C-pillars 70-3, C-pillar trim, removing

and installing
- Remove molded headliner 70-6, Headliner, removing

and installing
Note:
A Lupo is shown as an example in the following

illustrations. Removal and installation of
insulation/reinforcements is same in Golf.
- Cut roof insulation/reinforcements - 1 -

in direction of travel in strips approx. 6
cm wide - 2 - using a carpet knife.
- Pull off strips - 2 - from roof.
- Cut back adhesive residue - 3 - using

electric cutter V.A.G 1561 A and cutting
blade V.A.G 1561/20 - 4 - .
Note :
If paint structure was damaged while removing roof

insulation/reinforcements, paint damage must be
repaired in accordance with specifications in
Repair Manual Paint .
Installing
Note:
Processing instructions of adhesive must be

observed when installing roof
insulation/reinforcements.
- Apply adhesive D 190 MKD A3 to

insulation/reinforcements using cartridge
gun V.A.G 1628 .
- Apply adhesive in beads on

insulation/roof reinforcement.
- Dimension - a - = 58 2 mm
- Dimension - b - =25 5 mm
- Transport roof insulation/reinforcements

into vehicle through rear lid and press on
to roof over the entire surface.
(A5)
Front seat covers and padding

Tools
Pliers 3392
Engine and transmission holder VAS 6095
Fixture for seat repair VAS 6136

Front seat covers and padding Page 2 / 14
Front seat cushion cover and padding, removing and

installing
Note:
Removal and installation of the components is

described for the left-hand seat. The same
instructions apply for removal and installation of
components for right seat.
Warning!
If the upholstery, front seat cushion on front

passengers side is replaced, Front Passengers Seat
Occupied Sensor G128 also must always be replaced
69-4, Front Passenger s Seat Occupied Sensor
G128 , removing and installing
Removing

installing
2door 69-1, Belt latch (2-door), removing and

installing
4door 69-1, Belt latch (4-door) removing and

installing



installing


All vehicles
- Remove front seat drawer mount 72-1, Seat drawer

mount, removing and installing

- Remove profile - 1 - from receptacle.
- Disengage retaining straps - 2 - from

seat on both sides.
- Disengage profiles - 3 - from mounts

on both sides of seat.
- Disengage profile - 4 - from mount on

front side of seat.
- Roll cover upward on outer sides

around circumference.
- Using a small screwdriver, unclip

profiles - 1 - for cover out of mounts - 2
- in upholstery.
- In vehicles with seat heater, disconnect

wiring harness - 3 - from seat frame.
- Remove the cover - 4 - and padding -

5 - from the seat frame - 6 - .
Installing
Front bucket seat cushion cover and padding, removing

and installing
Note:

Removing

installing
- Remove front left bucket seat trim 72-1, Left bucket

seat trim, removing and installing

installing

installing
- Remove front right bucket seat trim 72-1, Right bucket

- Remove front bucket seat backrest 72-1, Front bucket

seat backrest, removing and installing

- Loosen profile - 1 - from mount - 2 - in rear area of seat

base .
- Loosen Velcro strip on both sides - 1 - .
- Loosen surrounding profile - 2 - on seat pan - 3 - .

- Loosen all Velcro strips - 1 - on cover from depression in

upholstery - 2 - .
- Remove upholstery from bucket seat.
Installing
Front seat backrest cover and padding, removing and

installing
Note:

Removing

installing



All vehicles

- Attach the backrest to the fixture for seat repair VAS

6136 .
- Press corresponding button in headrest

guide and pull headrest - 1 - out of
backrest.
2-door only
- Remove operating knob - 2 - .
- Position a screwdriver in - direction of

arrow - and pry trim - 3 - out of mount.
Note :
When installing, securing spring - 4 - must be

removed from lever - 5 - and replaced.
Only vehicles with manual lumbar

adjustment
- Remove lumbar support adjusting

wheel - 6 - using disassembly pliers
3392 .
All vehicles
- Disengage backrest profile - 7 - on

both sides.
- Release profile - 8 - from mount - 9 -

.
- Loosen side profile - 1 - and - 2 - from

mounts and fold back side of cover
upward.
- Remove plate - 3 - from backrest.
- Open side profile - 4 - and disengage

tension wire - 5 - .
- Open side profile - 7 - and disengage

tension wire - 6 - .
- Fold cover - 5 - upward.
- Using a small screwdriver, unclip

profiles - 1 - for cover out of mounts - 2
- in upholstery.
- Disengage tension wire - 4 - on both

sides from upholstery wire - 3 - .
- Remove headrest guides 72-1,

Headrest guides, removing
- Remove the cover - 5 - and padding -

6 - from the seat frame - 7 - .
Installing
Front bucket seat backrest, removing and installing
Note:

Removing

installing
- Remove front left bucket seat trim 72-1, Left bucket


installing

installing
- Remove front right bucket seat trim 72-1, Right bucket

- Remove front bucket seat backrest 72-1, Front bucket

seat backrest, removing and installing
- Press left trim - 1 - on upper edge

downward.
- Then remove trim from mounts in area

of the two catches - arrows - .
- Remove right trim - 2 - in the same

way.
- Remove surrounding cover profile - 3 -

in side area of backrest from mount - 4 -
.
- In lower area of backrest, remove

profile - 5 - from mount.
- Loosen all Velcro strips - 1 - on cover

from depression in upholstery - 2 - .
- Remove upholstery from backrest

frame.
Installing

Cover and upholstery for rear seats Page 1 / 6
74 - 2
Cover and upholstery for rear seats

Seat bench cover and upholstery, removing and
installing
Removing

and installing .
- On the underside of the seat bench,

detach all cover profiles - arrows - seat
frame.
- Release respective Velcro strap - 1 - in

area of belt latches.
- Roll up cover on the sides.

- Using a small screwdriver, press apart

side ribs of mounts - 1 - and pull out grip
channels - 2 - .
- Release cover - 3 - and upholstery - 4

- from seat frame - 5 - .
Installing
Cover and cushion for backrest, removing and installing
Note:
Removal and installation of components is described

for right backrest. The same instructions apply for
removal and installation of components for left
backrest.
Removing
Only vehicles with pass-through
- Remove storage unit with center armrest 74-2,

Storage unit with center arm rest, removing and installing
All vehicles

and installing .

installing
Headrest removal
- To remove headrest - 1 - , depress tab

on headrest mount.
- Locate small hole on opposite headrest

mount and insert a small screwdriver to
release headrest from guide.
- Remove headrest - 1 - completely.
Continued removal of cover and

cushion for backrest
- Press corresponding button in headrest

guide and pull headrest - 1 - out of
backrest.
- Press side locking mechanisms -

arrows - and release belt extraction
panel - 2 - from mounts.
Note :
Belt extraction panel - 2 - has a one-time locking

mechanism and therefore must be replaced when
installing.
- Press side locking mechanisms inward

and pull cover - 3 - out of backrest.
- Using a screwdriver, pry all profiles - 4

- out of mounts - 5 - on rear side of
backrest along the circumference.
- Roll up cover on the sides.
- Using a small screwdriver, press apart

side ribs of mounts - 1 - and pull out grip
channels - 2 - .
- Release cover - 3 - and upholstery - 4

- from backrest frame - 5 - .
Installing
Storage unit with center arm rest, removing and

installing
Removing
- Remove upholstery insert - 1 - beneath

center armrest.
- Open storage unit - 2 - and remove

two bolts - 3 - (9 Nm).
Installing

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Volkswagen Golf V: Lock carrier Page 1 / 6

Required special tools, workshop equipment, testing and

 Guide rod T 10093

 Torque wrench 550 Nm V.A.G 1331

 Torque wrench 40200 Nm V.A.G 1332

Lock carrier service position, assembly overview

 Lock carrier with attachments

 Removing and installing

 Service position 50-1,

Performing service position

- Remove front bumper 63-1, Front

- Disengage hood release cable in

- In vehicles with charge air cooler,

- Remove signal horn - 4 - with bracket

Repair Manual, Electrical Equipment,

- Unscrew bolts - 3 - at left and right

- Screw in guide rod T 10093 at left and

- Remove bolts - 2 - at left and right on

- Lock carrier - 1 - can be pulled toward

Resetting service position

Installation is performed in the reverse order of removal.

- Center lock carrier on side rails and between fenders

Repair Manual, Body Collision Repair, Repair Group 00,

 Make sure that pressure hoses for charge air cooler

 Hoses and lines must not be pinched.

Releasing pressure hoses

- Disengage connector coupling - 1 - and disconnect

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

- When re-connecting pressure hoses, make sure that

Lock carrier with attachments, removing and installing

- Perform service position of lock carrier

- Disconnect the electrical harness

- Drain coolant and disconnect coolant

Repair Manual, 2.0 Liter 4-Cyl. 4V

- Disconnect condenser lines

Repair Manual, Heating Air

- With a second technician, unscrew

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

 Do not hang condenser and hydraulic oil cooler on

 Lines for condenser and hydraulics must not be

Installation is performed in the reverse order of removal.

 Make sure that all plug and hose connections are

- Center lock carrier on side rails and between fenders

Repair Manual, Body Collision Repair, Repair Group 00,

Special tools, testers and auxiliary items required

 Torque wrench 210 Nm V.A.G 1783

 Heat gun V.A.G 1416

Front fender, assembly overview

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

 removing and installing

 Qty. 2, side member

 Qty. 2, wheel housing

 Qty. 2, fender brace

 Qty. 3, fender connecting

 Loosely inserted between

 Removing and installing

 Molded foam part

 Qty. 1, at fender connecting

Fender, removing and installing

 Removing and installing is described only for the left

- Remove front bumper 63-1, Front

- Remove wheelhousing liners 66-1,

- Unscrew guide profile Item - 10 -

Guide rod T 10093

Torque wrench 550 Nm V.A.G 1331

Torque wrench 40200 Nm V.A.G 1332

Lock carrier with attachments

Removing and installing

Service position 50-1,

Make sure that pressure hoses for charge air cooler

Hoses and lines must not be pinched.

Do not hang condenser and hydraulic oil cooler on

Lines for condenser and hydraulics must not be

Make sure that all plug and hose connections are

Torque wrench 210 Nm V.A.G 1783

Heat gun V.A.G 1416

The illustration shows the left side. The right side is

removing and installing

Qty. 2, side member

Qty. 2, wheel housing

Qty. 2, fender brace

Qty. 3, fender connecting

Loosely inserted between

Removing and installing

Molded foam part

Qty. 1, at fender connecting

Removing and installing is described only for the left

Removing and installing is described only for the left

Torque wrench 210 Nm V.A.G 1783

Slight changes may have to be made to removal and

- Arrow - points in direction

Torque wrench 210 Nm V.A.G 1783

The illustration shows the left side. The right side is

- Arrow - points in direction

Rear underbody cover

Only installed on the left

Torque wrench 210 Nm V.A.G 1783

Plenum chamber bulkhead

Seal for plenum chamber

Ensure seal is seated

Torque wrench 550 Nm V.A.G 1331

Pry lever - RMV outside mirror 80-200

Removing and installing

Adjusting 55-1, Hood,

Adjusting 55-1, Hood,

Removing and installing

Removing and installing

Adjusting 55-1, Hood,

Venting gas 55-1, Gas-

Secured to interior hood with