SM 46 PDF

Service
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Workshop Manual
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General body repairs, exterior
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Edition 08.2017
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Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2017 Volkswagen AG, Wolfsburg D4B807A09D2

General body repairs, exterior - Edition 08.2017
Contents
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Lock carrier - service position (vehicles with long front-end) . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Removing and installing lock carrier with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Front wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Assembly overview 01.96 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Renewing insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . V. o.lk.s.w.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.2 Removing lid ► 12.95 . . . . e. d.b. . . . . . . . . . . . . . . . . . . . . . . . . . .gu. a.ra. . . . . . . . . . . . . . . . . . .
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1.3 Installing and adjusting lid ho► 12.95 . . . . . . . . . . . . . . . . . . . . . . . . . . . e. o. . . . . . . . . . . . . . . .
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1.4 Assembly overview 01.96 ss
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1.5 Removing lid 01.96 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.6 Installing and adjusting bonnet 01.96 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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1.7 Removing and installing bonnet catch cable ► 12.95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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1.8 Removing and installing bonnet catch cable and bonnet catch 01.96 ► . . . . . . . . . . . . . . 18
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2 Rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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2.3 Removing and installing bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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2.5 Removing and installing tailgate lock mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.6 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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2.7 Removing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.8 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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1 Rear door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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1.3 Removing and installing door ► 12.95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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1.4 Installing and adjusting door ► 12.95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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1.5 Removing and installing door 01.96 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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1.6 Installing and adjusting door 01.96 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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1.7 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.8 Repairing electric window regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.9 Electric window regulator with convenience function (automatic opening and closing) and
force limitation mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.10 Overcoming resistance with excess force limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.11 Initialising and releasing automatic closing function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.12 Removing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.13 Installing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.14 Removing exterior door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.15 Removing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.16 Removing lock cylinder (front door, side wing door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2 Central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Contents i
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 Assembly overview - central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.3 Removing and installing front door positioning element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4 Removing and installing sliding door lock actuating element . . . . . . . . . . . . . . . . . . . . . . . . 41
2.5 Removing and installing tailgate door lock positioning element . . . . . . . . . . . . . . . . . . . . . . 41
2.6 Removing and installing wing door lock actuating element . . . . . . . . . . . . . . . . . . . . . . . . 42
2.7 Functional check of central locking with radio remote control . . . . . . . . . . . . . . . . . . . . . . 42
2.8 Synchronising keys with radio remote control ► 04.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.9 Removing and installing batteries for key with remote control ► 04.00 . . . . . . . . . . . . . . . . 44
2.10 Adapting ignition keys with radio remote control 05.00 ► . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.11 Adapting a new additional key 05.00 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.12 Synchronising ignition keys with radio remote control 05.00 ► . . . . . . . . . . . . . . . . . . . . . . 50
2.13 Removing and installing batteries for key with remote control (folding type) 05.00 ► . . . . 51
58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

1 Sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.2 Assembly overview ► 12.95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.3 Assembly overview 01.96 ► 03.01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.4 Assembly overview 04.01 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.5 Removing and installing sliding door ► 03.01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.6 Removing and installing sliding door 04.01 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.7 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.8 Adjusting sliding door ► 12.95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.9 Adjusting sliding door 01.96 ► 03.01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.10 Adjusting sliding door 04.01 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.11 Removing and installing central lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.12 Removing and installing exterior door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.13 Removing and installing lock cylinder (sliding door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.14 Assembly overview - guide rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2 Rear wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .w.a.ge. n. A.G. ..V.ol.ks. w. a.g.en. A. G
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2.2 Assembly overview - left wing door . . . . . . . . . . . .b.y V. o.l . . . . . . . . . . . . . . . . . . . . .no. t.g.ua. . . 74
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2.3 Assembly overview - right wing door . . . . . . . .or.is.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.nt.ee 75
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2.4 Removing and installing wing door . . . . . . .s a.u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r76 ac
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2.5 Adjusting wing doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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2.6 Removing and installing door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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2.7 Removing and installing lock operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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2.8 Adjusting lock operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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2.9 Removing and installing interior door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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2.10 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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3 Side wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.2 Assembly overview - side wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.3 Removing and installing wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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3.4 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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1 Sunroof with glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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1.2 Assembly overview - sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

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1.3 Removing sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

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1.4 Installing sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

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1.5 Adjusting height of sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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1.6 Adjusting panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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1.7 Removing and installing electric drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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1.8 Checking electric drive (0 position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

1.9 Checking and adjusting parallel running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.10 Removing sliding headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.11 Installing sunroof sun blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.12 Removing and installing carrier unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.13 Routing and cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2 Servicing glass/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.1 Assembly overview - glass/tilting sunroof . . . . . . . . . . . . . . . .ks. . . . . . . . . . . . . . . . . . . . . . 101
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2.2 Removing glass panel . . . . . . . . . . . . . . . . . . . l.ks. w.a.ge. n. . . . . . . . . . . A. G. d. o.e.s n. . . . . . . . . . . . 101
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2.3 Installing glass panel . . . . . . . . . . . . . . . . e.d.by. V. . . . . . . . . . . . . . . . . . . . . . . . . g.u.ar.a. . . . . . . 102
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2.4 Routing and cleaning water drain hosesthor.i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.ee.o. . . . 103
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3 Tilting/sliding sunroof with glass panel ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . 107
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3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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3.2 Assembly overview - tilting/sliding roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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3.3 Removing and installing tilting/sliding sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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3.4 Removing and installing water collector plate (with sun blind) . . . . . . . . . . . . . . . . . . . . . . 109
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3.5 Removing and installing glass panel for tilting/sliding sunroof . . . . . . . . . . . . . . . . . . . . . . 110
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3.6 Removing and installing electric drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
es, in part or in w
3.7 Checking parallel running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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3.8 Adjusting parallel running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
61 - Convertible roof, hardtop, canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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1 Assembly of convertible roof frame and canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

1.2 Canopy frame for dropside and double cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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1.3 Assembly overview - canopy frame for dropside and double cab . . . . . . . . . . . . . . . . . . . . 113
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1.4 Assembly overview - canopy frame (cab height) for double cab . . . . . . . . . . . . . . . . . . . . 114
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1.5 Assembling convertible roof frame and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
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63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
p
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1 Bumper, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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1.2 Assembly overviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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2 Bumper, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Prote
cted AG.
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122
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.2 Assembly overviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.3 Towing bracket 08.90 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1 Flush bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.3 Assembly overview - flush bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.4 Spacings for flush bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.5 Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.6 Assembly overview - side window and rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1.7 Removing windscreen, undamaged side window and undamaged rear window . . . . . . . . 133
1.8 Removing irreparable side window and rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.9 Installing windscreen, side window and rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.10 Preparing old undamaged window for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.11 Preparing new window for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.12 Preparing body flange and door window flange for glazing . . . . . . . . . . . . . . . . . . . . . . . . 137
1.13 Fitting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.14 Minimum curing period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.15 Touching up paint damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Contents iii
1.16 Cleaning in the event of dirt caused by adhesive sealing material . . . . . . . . . . . . . . . . . . . . 138
1.17 Installing frame (repair profile) (side and rear windows) . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.18 Re-sealing windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2 Windows having threaded connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.2 Assembly overview - side window with intake trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.3 Removing and installing side window with intake trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3 Sliding window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.2 Assembly overviews - sliding window (sliding door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.3 Renewing detent rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3.4 Renewing sealing frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.5 Renewing ledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.6 Renewing moving window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.7 Retrofitting sliding window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

1 Exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.1 Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.2 Exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.2 Assembly overview - radiator grille . Vo►lks12.95
wagen AG .................................... 162
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2.3 Removing radiator grille olks► 08.94 . . . . . . . . . . . .s .no.t .g . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.4 Radiator grille with ed trim frame 09.94 ► . . . . . . . . . . . . r.an. . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.5 Removing and ut installing radiator grille 01.96 ► . . . . . . . . . .or.a . . . . . . . . . . . . . . . . . . . . . . .
ho 166
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3 Cover stripssfor number plate lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
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3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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3.2 Removing and installing for tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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3.3 For removing and installing rear wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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iv Contents
50 – Body - front
1 Body - front
(VRL010811; Edition 08.2017)
1.1 Tools
Special tools and workshop equipment required
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♦ Front end hook - 3370-
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1.2 Lock carrier - service position (vehicles

with long front-end)
1.2.1 Assembly overview
1. Body - front 1
1 - Lock carrier
2 - Adapter - T10235-
❑ With mark -R- for right
side and -L- for left side
of vehicle and -arrows-
for forwards.
❑ The set consists of -2-
adapters and -4- bolts.
3 - Lock carrier - middle part
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– Remove radiator grille ⇒ page 162 .

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– Remove turn signals ⇒ Electrical system; Rep. gr. 94 ; Front

turn signals (long front end) 01.96
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Observe marks -L- for left side and -R- for right side of vehicle and
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-arrows- for forwards on special tool adapter - T10235- .

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– Remove bolts at connection for lock carrier to middle part of

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2 Rep. gr.50 - Body - front

1.2.3 Moving from service position n AG. Volkswagen AG do

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1.3 Removing and installing lock carrier with
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– Remove insulation tray ⇒ page 9 .
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– Unscrew bolts -1- on left and right.
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– Fold radiator and lock carrier out forwards -arrow-.
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– Pull end plate -2- with sleeves -3- off pins -4- on left and right.
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1.3.2 Vehicles 10.91►

1. Body - front 3
– Pull apron -1- off the pins -3- with the aid of a (locally manu‐
factured) hook -2- (approx. 2 mm dia. wire).
– Position hook for front end - 3370- over or under the pin
-arrows-.
1.3.3 Continuation all vehiclesagen AG. Volkswagen AG do

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– Remove turn signals on left and right
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– Remove headlights on leftss and
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right sides (unscrew bolts ac
-arrows-) and separate electrical connectors.
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– Attach radiator to workshop crane - VAS 6100- .
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– Lift radiator with workshop crane.

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– Unbolt cross member -1- with headlight -2-.

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Tightening torque ► 08.93

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Bolt -3- and -4- = 8 Nm

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Tightening torque 09.93 ►

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– Unclip electrical leads from cross member/headlight bracket.

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1. Body - front 5
2 Front wing
2.1 Tools
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2.2 Assembly overview 01.96 ►
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1 - Wings
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❑ Removing ⇒ page 7
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❑ Installing ⇒ page 7
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❑ Features oversized
holes for gap adjust‐
ment between wing,
bonnet and front door.

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– Remove front bumper ⇒ page 118 .

– Remove turn signal ⇒ Electrical system; Rep. gr. 94 ; Front
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turn signal (short front end) 12.95 ⇒ Electrical system; Rep.

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– Unscrew bolts -2- and -3-.

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– Heat wing in area of wheel arch with a hot air blower and pull
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PVC must only be heated lightly and briefly. PVC must not change in colour or blister.
Installing
Before bolting on wing, apply a zinc intermediate layer - AKL 381
035 50- to bolted connection points in area where wheel housing
contacts A-pillar.
2. Front wing 7
The remaining installation steps are carried out in the reverse se‐
quence of removal.
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3 Noise insulation
3.1 Tool
♦ Torque wrench - V.A.G 1331-
3.2 Assembly overview
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2 - Bracket
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❑ Unscrew two hexagon

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❑ Release locking hooks

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7 - Dampers
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❑ Renewing ⇒ page 10
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3. Noise insulation 9
3.3 Renewing insulation
1 - Dampers
❑ On vehicles with an au‐
tomatic gearbox or com‐
pressor for air condition‐
er, damping material
must be removed ac‐
cording to perforation
2 - Clip
3 - Insulation tray
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55 – Bonnet, rear lid

1 Bonnet
1.1 Tools
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1.2 Removing lid ► 12.95
Removing lid 01.96 ►, ⇒ page 15 .
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– Unscrew three bolts -2- (from expanding nut -3-) and carefully
pry out air inlet grille -1-.
ss o
– Pull hose off washer jets, unclip and pull out of bonnet lid.
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– Separate electric connectors for electrically heated washer
mer
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– Turn clips -1- 60° and pull out.

– Remove insulation -2-.
1. Bonnet 11
1.2.2 Continuation all vehicles

– Unclip engine compartment light (W 27) -4- if present.
– Unscrew bolt -3- (a clip as of 09.92) and bolts -2-.
Specified torque of bolts -2- = 8 Nm
– Remove lid lock -1- and detach cable -arrow-.
– Unclip cable on bonnet ⇒ page 18 .
– Unscrew bolts -arrows- at left and right and remove bonnet

-1-.
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1.3 Installing and adjusting lid ► 12.95

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Installing and adjusting lid 01.96 ► ⇒ page 16 .

– Loosely secure bonnet -1- with hinges, align and tighten.
rrectness of i
Specified torque of bolts -arrows- = 8 Nm

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12 Rep. gr.55 - Bonnet, rear lid

– Install lid lock -1-, attach cable -arrow- and clip onto bonnet
⇒ page 18 .
– Clip in engine compartment light (W 27) -4-.
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– Locking eye on lock carrier can be moved -arrow- after loos‐
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1. Bonnet 13
1 - Lid
❑ Adjusting ⇒ page 16
❑ After installing or adjust‐
ing, carry out corrosion
protection measures on
hinges and screws/
bolts.
2 - Lid lock
❑ Removing:
❑ Remove insulation, if fit‐
ted.
❑ Remove bracket for op‐
erating rod. To do this,
press retaining hook to
left.
❑ Unscrew hexagon bolts
and remove lock.
❑ Detach cable.
3 - Bolt
❑ For alignment of lid in
longitudinal direction
4 - Hinge
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spec
(short front end) 12.95

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7 - Clip
❑ To remove and install turn clip 180°.
rrectness of i
8 - Bowden cable
❑ Cable attached.
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10 - Bonnet stay
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11 - Rubber buffer
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14 - Clip
15 - Cd seal
16 - Pop rivet
17 - Bonnet stay holder
18 - Hose
19 - Clip
1.5 Removing lid 01.96 ►
1.5.1 Removing and installing air intake grille 01.96 ►
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Removing lid ► 12.95 ⇒ page 11 .
agen
Prote AG.
– Detach air intake grille at marked positions -arrows-.

– To do this, start from side and release locking lugs with a small
screwdriver.
1. Bonnet 15
– Insert screwdriver at sharp angle in marked openings of air

intake grille when doing this.
1.5.2 Vehicles with bonnet insulation

– Turn clips -1- 60° and pull out.
– Remove insulation -2-.
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– Press locking lug -2- on operating rod s a left in direc‐
retainer sto c
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– Unscrew bolts -3-.
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– Remove bonnet lock -1- and disconnect bonnet lock cable
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-arrow-.
spec
– Unclip bonnet lock cable and windscreen washer system hose
t to the co
(electric wire for heated washer jets when fitted) from the bon‐
net ⇒ Item 7 (page 14) .
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– Unscrew bolts -arrows- at left and right and remove bonnet

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1.6 Installing and adjusting bonnet 01.96 ►

Installing and adjusting lid ► 12.95 ⇒ page 12 .

– Loosely secure bonnet -1- with hinges.

– Align lid and tighten bolts.
Specified torque of bolts -arrows- = 8 Nm
– Then adjust rubber buffers -2- so that bonnet aligns with wings.
– Install bonnet lock -1-, attach cable -arrow- and clip onto bon‐
net ⇒ Item 7 (page 14) .
– Locking eye on lock carrier can be moved -arrow- after loos‐

ening the hexagon nut -1-.
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– Adjust locking eye so that bonnet locks properly when allowed

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to fall from a height of 30 cm without having to be pressed

down. Outer contour must be aligned and there must not be
any play upwards -arrow-.
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1.7 Removing and installing bonnet catch cable ► 12.95 ed
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⇒ page 18 .
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❑ Installing: insert and ro‐
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2 - Bowden cable
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3 - Cable grommet
❑ Bulkhead
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1.8 Removing and installing bonnet catch

cable and bonnet catch 01.96 ►
Removing and installing bonnet catch cable ► 12.95 ⇒ page 18

1 - Sealing grommet
2 - Operating lever
❑ Cable attached.
3 - Bowden cable
❑ Renewing:
❑ Unscrew release lever
and lock, detach cable.
4 - Cable bracket
5 - Bolt
6 - Cable bracket
❑ For carpet only
7 - Locking eye
8 - Hexagon nut
9 - Bolt
10 - Lid lock
❑ Cable attached.
❑ Removing: n AG. Volkswagen AG do
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press retaining hook
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❑ Unscrew bolts and re‐
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❑ Adjusting:
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❑ Adjust in over-sized
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11 - Operating rod to release lock
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12 - Bracket for operating rod

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13 - Locking lug
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1. Bonnet 19
olkswagen AG
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❑ Removing and installing Prote AG.
⇒ page 21
2 - Bolt
3 - Hinge
4 - Sealing plate
5 - Spacer plate
❑ When removing hinge
-3-, do not allow it to
drop into roof pillar
6 - Hexagon nut
7 - Interior release for lid lock
8 - Central locking motor (V 53)
9 - Release for lid lock
❑ Removing with lock cyl‐
inder ⇒ page 25
10 - Lid lock
11 - Countersunk screw
12 - Guide pin
❑ Observe marking for left
-L- and right -R-

13 - Plug
14 - Cross-head screw
15 - Rear window wiper motor -V12-
❑ Removing and installing ⇒ Electrical system; Rep. gr. 92 ; Repairing rear window wash/wipe system for
tailgate
2.3 Removing and installing bonnet

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– Remove tailgate trim panel or remove tailgate moulded trim

panel ⇒ General body repairs, interior; Rep. gr. 70 ; Tailgate
– Disconnect connections for heated rear window, number plate
lighting, rear window wiper motor and central locking motor (if
fitted) and pull all cables out of tailgate.
– Support tailgate.
– Lift retaining clip -1- with screwdriver and pull off gas struts
from ball-head pin on both sides.
2. Rear lid 21
Note
Do not prise retaining clips -1- completely out of the ball socket, otherwise they will be damaged.
– Remove bolts -2- from hinges on left and right and remove
tailgate.
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If a new tailgate is installed, it should be adjusted ⇒ page 22 .
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2.4 Adjusting rear lid
spec
es, in part or in w
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2.4.1 Adjusting height of rear lid
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– Remove passenger compartment moulded headliner ⇒ Gen‐
l purpos
eral body repairs; Rep. gr. 70 ; Roof trim

– Remove gas struts for tailgate ⇒ page 25 .
nform
ercia
– Unscrew guide pin on left and right (-arrow- indicates marking

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– Loosen hexagon nuts -1- of the hinges in the rear of the roof
pillar (do not unscrew completely).
Note
If hexagon nuts -1- are completely removed, it is essential to pre‐

vent hexagon nuts or spacer plates -2- from dropping into roof
pillar.

– Have a second mechanic lift the rear lid so that the outer con‐
tour -arrows- is aligned and tighten hexagon nuts of the hing‐
es.
Specified torque of hexagon nut ⇒ Item 6 (page 20)
2.4.2 Adjusting guide pins

– Pull out cover of guide elements -1- on the left and right after
unscrewing cross-head screw -2-.
– Unscrew guide pin on left and right (-arrow- indicates marking

-L- for left or -R- for right of tailgate).
– Install gas struts.
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– Have a second mechanic carefully close tailgate and check

spec
from inside of vehicle whether guide wedges -1- are pressed

es, in part or in w
t to the co
evenly about 10 – 15 mm forwards -arrow- by guide pins -2-.

– Perform this adjustment on left and right by altering the posi‐
tion of the guide pins at the tailgate and tighten the bolts of the
rrectness of i
guide pins.
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Specified torque for bolt = 8 Nm

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2.4.3 Adjusting striker plate

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– Remove load sill cover.

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2. Rear lid 23
– After slackening bolts -1-, striker plate can be moved in

-direction of arrows-. wage
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– Adjust the striker plate -1- so that the recess of the door lock
with rotary latch is centred -arrows- relative to the striker plate.
rrectness of i
– When slowly closing tailgate from inside vehicle, check posi‐
tioning and adjust accordingly.
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Removing: Prote AG.
– Remove tailgate moulded trim panel or remove tailgate trim

panel ⇒ General body repairs; Rep. gr. 70 ; Roof trim
– If fitted, detach central locking motor (V 53) -1- by unscrewing
bolts -2- and detach relevant linkage -3- at tailgate lock mech‐
anism.
– Pull off linkage for rear lid lock -1- for interior door opener -2-
and child lock -3-.
– Unscrew bolts -4- and remove tailgate lock operating mecha‐
nism.
Specified torque of bolt -4- = 8 Nm
Installing:
Installation is carried out in the reverse sequence of removal.

2.6 Removing and installing lock cylinder

Removing:
– Remove tailgate moulded trim panel or remove tailgate trim
panel ⇒ General body repairs; Rep. gr. 70 ; Roof trim
– Removing tailgate lock mechanism ⇒ page 24 .
– Remove securing clip -1- and linkage.
– Drive out roll pin -2-.
– Take casting -3- off square head.
– Remove spring.
– Remove lock cylinder with key inserted.
Installing:
2.7 Removing gas strut

– Support tailgate. n AG. Volkswagen AG do
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– Position a small screwdriver beneath spring clip -1-. ised b ran
tee
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– Raise spring clip -1- until spring clip can be movedau over ball ac
socket. ss
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– Pull gas strut off ball-head pin.
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After removing gas strut, slide spring clip -1- back immediately.
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WARNING
hole
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es, in part or in w
Proceed with care if gas strut is reused. Do not lever spring clip
t to the co
completely out of ball socket, as it will otherwise be damaged.
Gas strut will spring out of mounting, causing damage or injury
to operator.
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Specified torque of ball-head pins -2- = 20 Nm

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Specified torque of bolts -3- for bracket -4- = 8 Nm

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2. Rear lid 25
2.8 Releasing gas from gas strut

– Clamp gas strut in vice in area x = 50 mm.
WARNING
Clamp gas strut only within area -x-; otherwise danger of ac‐
cident!
– Saw through cylinder of gas strut within first third of cylinder's

overall length using piston rod end of cylinder as reference
point.
Note
♦ Wear eye protection when sawing.

♦ Cover area of saw cut with a cloth.
♦ Feed oil and cleaning clothes .into existing method of disposal.
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57 – Front doors, door components, central locking
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Assembly overview shows front door with electric window regu‐

lator. Proceed similarly in door without electric window regulator.
1. Rear door 27
1 - Rear door
❑ Installing and adjusting
⇒ page 29
2 - Inner window slot seal gen AG
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Rep. gr. 70 ; Door trim
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3 - Outer window slot seal
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❑ Pushed onto flange.
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4 - Window channel
5 - Door window
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❑ Screwed on.
10 - Exterior door handle
❑ Removing lock cylinder ⇒ page 38
11 - Clip
12 - Bolt
13 - Locking rod
14 - Bolt
15 - Door lock
16 - Pull rod
17 - Clip
❑ For securing and guiding pull rod
18 - Bolt
❑ For securing window lifter rail on window regulator
28 Rep. gr.57 - Front doors, door components, central locking

19 - Bolt
20 - Window regulator
❑ Removing and installing ⇒ page 33
21 - Bolt
22 - Window regulator motor
❑ Removing together with window regulator ⇒ page 33
❑ Window regulator crank drive (front door without electric window regulator) together with window regu‐
lator ⇒ page 33 Volkswa AG. gen AG
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24 - Door arresterss au ra
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25 - Bolt
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26 - Hexagon nut
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wit
, is n
❑ Specified torque: 6.5 Nm
h re
hole
spec
27 - Pin
es, in part or in w
t to the co
28 - Boot
❑ Cover in vehicles without electric window regulator, central locking, etc.
rrectness of i
l purpos
1.3 Removing and installing door ► 12.95

Removing door 01.96 ► ⇒ page 30 .
nf
ercia
orm
1.3.1 Vehicles with central locking, electric

m
atio
om
n in
window regulators, heated exterior mir‐

or c
thi
e
rors and/or door loudspeakers

t
sd
iva
o
r
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o
Removing:
f
en
ng
t.
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op
– Remove door trim: ⇒ General body repairs, interior; Rep. gr. C py
ht. rig
70 ; Removing and installing front door trim with electric win‐ rig ht
py by
dow regulator co Vo
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cted agen
Prote AG.
– Release electrical wiring, separate connections and pull out of
the door.
Continuation all vehicles
– Unscrew hexagon nut -1- and pull out pin.
– Unscrew bolts -2- for upper and lower hinge and remove door.
Installing:
1.4 Installing and adjusting door ► 12.95

Installing and adjusting door 01.96 ► ⇒ page 31 .
1. Rear door 29
– Screw bolts -2- into upper and lower hinge.

– Adjust door within over-sized holes in hinge.
• Front door is adjusted correctly if, when door is closed, gap is
equal around door aperture, door is not proud or set too deep
and contours -arrows- align.
– Tighten bolts -2-, tighten hexagon nut -1- after installing pin.
Specified torques: Hexagon nut -1- = 6.5 Nm
Specified torque: bolt -2- = 55 Nm.
AG. Volkswagen AG d
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erm
ab
ility
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wit
1.4.1 Adjusting striker pin
, is n
h re
hole
spec
– After slackening bolts -1-, striker plate -2- can be moved hor‐
es, in part or in w
izontally and vertically -arrows-.
t to the co
Specified torque: cross-head screws -1- = 19 Nm.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
– Adjust striker plate -1- so that recess of door lock with rotary
p
cum
for
latch engages centrally with striker plate -arrows- (door should

en
ng
t.
yi
not be lifted or pushed downwards).
Co
Cop py
t. rig
gh
The door must not have any play when closed.
ht
pyri by
Vo
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Prote AG.
1.5 Removing and installing door 01.96 ►

Removing door ► 12.95 ⇒ page 29 .

Transporter
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wage doe
General body Vo repairs, exterior - Editions 08.2017
lks not
gu
by ara
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ris
1.5.1 Vehicles with central locking, electric tho eo
au ra
ss c
window regulators, heated exterior mir‐
ce
e
nl
pt
du
rors and/or door loudspeakers
an
itte
y li
erm
ab
Removing:
ility
ot p
wit
, is n
– Remove door trim: ⇒ General body repairs, interior; Rep. gr.
h re
70 ; Removing and installing front door trim with electric win‐
hole
spec
dow regulator
es, in part or in w
t to the co
– Release electrical wiring, separate connections and pull out of
the door.
rrectness of i
– Unscrew hexagon nut -1- and pull out pin.
– Unscrew bolts -2- for upper and lower hinge and remove door. l purpos
nf
ercia
o
Installing:
rm
m
atio
m

o
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or c
thi
te
sd
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m
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ng
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Cop py
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by
cted agen
Prote AG.
1.6 Installing and adjusting door 01.96 ►

Installing and adjusting door ► 12.95 ⇒ page 29 .
1.6.1 Adjusting door gaps to wing, A-pillar and

B-pillar
– Remove door ⇒ page 30 .
– Then loosen bolts -3-, move the hinges, and retighten the
bolts.
Specified torques: Hexagon nut -1- = 6.5 Nm
– Then install door again.
– Screw bolts -2- into upper and lower hinge.
1. Rear door 31
1.6.2 Adjusting door flush to wing, A-pillar and

B-pillar
– Adjust door within over-sized holes in hinge flush so that it is
with wing.
• Front door is adjusted correctly if, when door is closed, gap is
equal around door aperture, door is not proud or set too deep
and contours -arrows- align.
lkswage es n
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– Tighten hexagon bolts -2-. Tighten nut -1- once pin
th is installed.
o tee
or
au ac
Specified torques: Hexagon nut -1- = 6.5 Nm ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
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fo
– After slackening the cross-head screws -1-, the striker pin en

ng
t.
-2- can be moved horizontally and vertically -arrows-. Speci‐
yi Co
op py
fied torque: Cross-head screws -1- = 19 Nm. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Adjust striker plate -1- so that recess of door lock with rotary
latch engages centrally with striker plate -arrows- (door should
not be lifted or pushed downwards).

1.7 Removing and installing window regula‐

tor
olkswagen AG
en AG. V
1.7.1 Window regulator
yV
olks
wag with crank drive
does
not
g
b ua
ed ran
Removing: oris tee
th or
au ac
– Remove doorsstrim: ⇒ General
body repairs, interior; Rep. gr.
70 ; Removing and installing front door trim without electric
ce
le
un
pt
window regulator
an
d
itte
y li
rm
ab
– Unscrew window lifter rail with door window from window reg‐
pe
ility
ulator.
ot
wit
, is n
h re
– Slide door window upward and secure (e.g. with adhesive
hole
tape).
spec
es, in part or in w
t to the co
– Carefully remove window regulator with crank drive from up‐
per opening -arrow-.
rrectness of i
Installing:
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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en
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1.7.2 Electric window regulator

n
t.
yi Co
Cop py
t. rig
Removing:
gh ht
pyri by
Vo
co lksw
by
– Remove door trim: ⇒ General body repairs, interior; Rep. gr. cted agen
Prote AG.
dow regulator
– Unscrew window lifter rail with door window from window reg‐
ulator.
– Slide door window upward and secure (e.g. with adhesive
tape).
– Disconnect connector -arrow A- of motor for window regulator
(V 14 or V 15).
1. Rear door 33
– Unhook securing clip -2- of window regulator on door aperture.

– Remove window regulator with motor from upper opening
-arrow-.
Installing:
1.8 Repairing electric window regulators

dow regulator
– Remove window regulators ⇒ page 33 .
– Remove bolts -1- from joint between window regulator and
regulator motor.
– Disconnect window regulator -2- in direction of -arrow- from
window regulator motor -3-.
– When removing or installing windowAG. Volregulator,

kswagen AGmake sure that
cable drum -2- with cables agen
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does pulled out
ol not
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– Pull assemblyuthcover
o
off housing -1- of cable drum -2- of newe or a
a
window regulator.
ss c
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nl
pt
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itte
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Note
erm
ab
ility
ot p
Surfaces/parts coated with grease must not come into contact

wit
, is n
with dust or dirt. Regrease only with grease G 000 450 02.
h re
hole
spec
es, in part or in w
t to the co
– Pull assembly cover off drive pinion on new motor -1-.

rrectness of i
Note
l purpos
Surfaces/parts coated with grease -2- must not come into contact
with dust or dirt. Regrease with genuine-part grease - G 000 450
nform
ercia
02- only.
m
at
om
ion
c
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or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Join window regulator to window regulator motor in

-direction of arrow- and fasten using all bolts.
– Tighten bolts in the specified order.
Specified torque: 3.5 Nm
Note
Test function before fitting window regulator.
1.9 Electric window regulator with conven‐

ience function (automatic opening and
closing) and force limitation mechanism
Volkswa AG. gen AG
agen does
Now that convenience window regulators olkshave been fitted, win‐
w not
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dow regulators have the following sadditional
ed
b functions: automatic ara
nte
opening and closing and force tlimitation
ho
ri mechanism. eo
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c
ss
1.9.1 Function of window regulator with igni‐
ce
e
nl
pt
tion switched on
du
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itte
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erm
ab
Opening
ility
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wit
Press and briefly hold the front edge of the appropriate button and
, is n
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the window will open fully (automatic window opening).
hole
spec
If the switch is pressed again the window will stop immediately.
es, in part or in w
t to the co
Closing
Lift and briefly hold the front edge of the respective button and the
rrectness of i
window will close fully (automatic window closing).
l purpos
If the switch is pressed or lifted again the window will stop imme‐
diately.
nform
ercia
1.9.2 Function of window regulator with igni‐

m
at
tion switched off

om
ion
c
in t
or
The window regulators can be operated for approx. 10 minutes

his
ate
after switching ignition off, as long as the driver's, front passeng‐

do
priv
er's or sliding door and the tailgate have not been opened.
um
for
en
ng
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Opening
Co
Cop py
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Press and briefly hold the front edge of the appropriate button and
ht
pyri by
Vo
the window will open fully (automatic window opening).
co lksw
by
cted agen
Prote AG.
If the switch is pressed or lifted again the window will stop imme‐
diately.
Closing
Press down the front edge of the button until the window is fully
closed. The window will not close automatically.
If the window in the driver's or front passenger's door is impeded
because of resistance or an obstruction during closing (force lim‐
itation) the window will open immediately.
In this case the window can be closed again only when the ignition
is switched on.
1. Rear door 35
AG. Volkswagen AG d
agen oes
olksw not
V gu
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Note hor eo
aut ra
ss c
♦ The roll-back function prevents the window from closing only
ce
e
nl
pt
from the half closed position.
du
an
itte
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♦ After disconnecting and reconnecting the vehicle battery the
erm
ab
ility
automatic closing and opening features for the driver's and
ot p
front passenger's doors are inoperative.
wit
, is n
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hole
♦ These functions, also known as “initialisation and automatic
spec
lift”, can be reinstated by following the text on page
es, in part or in w
t to the co
⇒ page 36 .
1.10 Overcoming resistance with excess
rrectness of i
force limitation
l purpos
• Prerequisite: automatic opening and closing is initialised (pro‐

grammed)!
nform
ercia
• Ignition switched on.

m
at
om
io
– Close door window with window regulator switch (hold button).
n
c
in t
or
his
e

at
do
riv
because of resistance or obstruction during the closing sequence

p
cum
or
(force limitation intervention) the window will open immediately.

f
en
ng
t.
yi Co
op
– Press window regulator switch again (hold button). C py
t. rig
gh ht
yri
Now the window closes as far as the obstruction and stops.
p by
o Vo
by c lksw
cted agen
– To be able to close window, press and hold button of appro‐
Prote AG.
priate window regulator switch again. The window closes

passed the obstruction without using the excessive force lim‐
itation until 1. the button is released or 2. obstruction detection
(window closed fully) is recognised.
This switch operation must take place within 5 seconds of the
window stopping and without interruption from other functions
(lowering, raising automatically).
• Ignition off
because of resistance or obstruction during the closing sequence
(force limitation intervention) the window will open immediately.
Operations using the interior window regulator switch is now
blocked.
If the ignition is switched on within 1 minute after the windows are
opened and then the button is pressed to close the window within
5 seconds, the process is the same as from the 2nd closure with
ignition on.
1.11 Initialising and releasing automatic clos‐

ing function
1.11.1 From inside using window regulator

switch (perform separately for each win‐
dow)
• Ignition on
• With window open
– Operate "Up" button until window stops at top stop in seal.

– Release button.
– Operate lower button until window stops at bottom stop in seal.
– Release button.
♦ With window closed:
– Operate lower button until window stops at bottom stop in seal.
– Release button. n AG. Volkswagen AG do
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– Operate "Up" button until window dstops by
Vo at top stop in seal. ot g
ua
ran
ir se tee
– Release button. utho
or
a ac
ss
This sequence is performed by user without realisation within the
ce
le
normal operational framework and without realisation of the initi‐

un
pt
an
d
alisation sequence.
itte
y li
erm
ab
1.12 Removing door window
ility
ot p
wit
is n
h re
ole,
70 ; Door trims
spec
– Lower door window fully and unscrew window lifter rail from
t to the co
window regulator.
– Tilt door window forwards and lift it out of window slot.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.13 Installing door window
– Insert door window in door.
– Bolt window lifter rail loosely onto window regulator.
– Use window regulator to move door window all the way up and
then tighten hexagon bolts -1-.
Specified torque: Bolts -1- = 7 Nm.
1. Rear door 37
1.14 Removing exterior door handle

– Unscrew bolts -1- and remove exterior door handle in direction
of -arrow-.
1.15 Removing door lock agen

AG. Volkswagen AG d
oes
olksw not
– Remove door trim: ⇒ General body repairs, interior; Rep. gr. d b y V gu
ara
70 ; Door trims horise nte
eo
ut ra
a
– Removing exterior door handle ⇒ page 38 . ss c
ce
e
nl
– Raise door window fully.
pt
du
an
itte
y li
– Unclip pull rod from retaining clips on inner door panel.
erm
ab
ility
ot p
– Unscrew bolts -1- and remove door lock together with pull rod
wit
, is n
and locking rod.
h re
hole
spec
Specified torque: fillister-head screw -1- = 8 Nm
es, in part or in w
t to the co
1.16 Removing lock cylinder (front door, side
rrectness of i
wing door)
l purpos
– Removing exterior door handle ⇒ page 38 .
nf
ercia
o
rm
m
atio
m
– Remove spring -3-.

o
n in
or c
thi
te
sd
iva
o
r
– Remove lock cylinder -4- with key inserted -5-.

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

2 Central locking
2.1 Tools
♦ Vehicle diagnosis, testing and information system - VAS
5051B-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
2.2 Assembly overview - central locking

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Central locking 39
1 - Front door lock positioning

element
❑ Removing and installing
⇒ page 40
2 - Sliding door lock actuating
element
⇒ page 41
3 - Rear lid lock actuating ele‐
ment
⇒ page 41
4 - Front door lock positioning
element
⇒ page 40 AG. Volkswagen AG d
agen oes
lksw not
5 - Wing door lock actuating el‐ d by
Vo gu
ara
ement orise nte
h eo
❑ Removing and installing aut ra
s c
⇒ page 42 s
ce
le
un
pt
6 - Control unit for central lock‐
an
d
itte
y li
ing remote control
erm
ab
ility
❑ Only on vehicles with
ot p
wit
central locking with ra‐
is n
h re
dio remote control
ole,
spec
❑ Accessible after remov‐
ing dash panel insert
t to the co
rrectness o
cial p
f inform
mer
atio
om
2.3 Removing and installing front door posi‐

n
c
i
or
n thi
tioning element
te
sd
iva
o
pr
cum
r
Removing:
fo
en
ng
t.
yi Co
– Remove door trim: ⇒ General body repairs, interior; Rep. gr. t. Cop py
70 ; Door trims
rig
gh ht
pyri by
Vo
o
by c
– Pull off connector -1- from actuator.
lksw
cted agen
Prote AG.
– Unscrew cross-head screws -2-, unhook connecting rod and
take out positioning element.
Installing:

AG. Volkswagen AG d
agen oes
lksw not
2.4 Removing and installing sliding door
o
byV gu
ara
ed
is nte
lock actuating element
aut
hor eo
ra
ss c
Removing:
ce
e
nl
pt
du
an
– Remove sliding door trim at bottom ⇒ General body repairs,
itte
y li
interior; Rep. gr. 70 ; Door trim .
erm
ab
ility
ot p
– Remove bolts -1- and hang positioning element to side.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c

or
thi
te
sd
a
– Detach connecting rod and remove positioning element.

iv
o
r
rp
cu
o
m
Installing:
f
en
ng
t.
yi Co
op
Installation is carried out in the reverse sequence of removal. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.5 Removing and installing tailgate door

lock positioning element
Removing:
– Remove tailgate trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Tailgate
– Unscrew cross-head screws -2-, unhook connecting rod and
take out positioning element.
Installing:
2.6 Removing and installing wing door lock

actuating element
Removing:
– Remove rear wing door trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Tailgate
– Pull off multi-pin connector from actuator.
– Remove bolts -1-, unhook connecting rod -2- and take out po‐
sitioning element.
Installing:
2.7 Functional check of central locking with

radio remote control
Vehicles 05.98 ► with radio remote control can be locked and
opened without actuating door locks directly. If part of the equip‐
ment, the anti-theft alarm is also activated and deactivated via the
radio remote control. The following is a description of the addi‐
tional functional features compared with central locking without
radio remote control.
The radio transmitter with batteries is housed in the handle of the
vehicle key. The radio receiver is located under the dash panel
inside the vehicle.
The effective range of the radio remote control is 6 - 15 m.
The range depends on various factors (atmospheric conditions,
metallic materials close the vehicle, charge level of the battery in
the key).
n AG. Volkswagen AG d
If the batteries are considerably discharged, only the unlocking olks
wage oes
not
functions will be carried out. The vehicle can no longer bed blocked
yV gu
ara
using the radio remote control and the respective key ocanris no lon‐
e nte
eo
ger be synchronized. auth ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
42
c by lksw
cted agen
Rep. gr.57 - Front doors, door components, central locking Prote AG.
n AG. Volkswagen A
Transporter
G do 1991 ➤
lkswage es n
General
by Vo
body repairs, exterior - Edition
ot g
u 08.2017
ara
ed nte
ris
ho eo
Unlocking: aut ra
c
ss
– To unlock the vehicle, point the key towards the effective range
ce
e
nl
pt
du
of the vehicle and press the open button -1- briefly. Opening
an
itte
y li
of the vehicle and, if necessary, deactivation of the anti-theft
erm
ab
alarm are signalised by the hazard warning lights flashing
ility
ot p
twice.
wit
, is n
h re
Locking:
hole
spec
– To lock the vehicle, press the close button -2- briefly.
es, in part or in w
t to the co
If the close button -2- is pressed for at least one second, the anti-
theft alarm is activated at the same time.
rrectness of i
Locking of the vehicle and activation of the anti-theft alarm are
signalised by the hazard warning lights flashing once. l purpos
When the close or open buttons are pressed the warning lamp
-3- will flash in the key. If this lamp does not flash, the battery in
nf
ercia
o
the key might be discharged. Renew battery if necessary.
rm
m
atio
m
After the battery in the key is changed, it is not necessary to syn‐

o
n in
c
chronise it.
or
thi
te
sd
a
Each time the vehicle is opened and closed via radio remote con‐
iv
o
r
rp
cu
trol, the code is changed.
o
m
f
en
ng
t.
yi
If the sender buttons are operated for more than 50 times outside
Co
op py
of the effective range the system reacts after first pressing the
t. C rig
gh ht
yri
respective button -1- or -2- twice quickly. p by
co Vo
by lksw
cted agen
Prote AG.
2.8 Synchronising keys with radio remote
control ► 04.00
It becomes necessary to synchronise keys with radio remote con‐
trol when:
♦ New additional keys have been purchased for the vehicle (a
total of up to 4 keys is possible) or defective keys have been
renewed
♦ Radio remote control central locking control unit -J276- has
been replaced
or
♦ The complete lock system has been replaced
Always match the new keys to the immobilizer first ⇒ Electrical
system self-diagnosis; Rep. gr. 01 ; Self-diagnosis of immobilizer
Successful synchronisation of a key supersedes the previous
synchronisation (code) of the other keys.
The whole key set (maximum 4 keys) must therefore be re-
synchronised immediately one after the other.
Note
During synchronisation, ensure that no other vehicle with radio

remote control is within 20 m. If this is ignored, it is possible that
the synchronisation of other vehicles may be affected.
– With the first key to be synchronised, switch on the ignition for

a maximum of 3 seconds.
– Switch off ignition and remove the key.
The synchronization of the key must take place within the next 20
seconds.
– Holding the unlock button -1- pressed, press the lock button
-2- three times.
– Release lock -2- button. The warning lamp -3- in the key will
flash five times.
Once the radio receiver has accepted synchronisation of the key,
the vehicle is locked and unlocked again once by the system and
the hazard warning lights are activated accordingly.
After completing the synchronization of a key the other (maximum
of a further three) keys must be synchronised by pressing and
holding the lock button -2- and depressing the unlock button -1-
three times along with the relevant reaction from the system,
within the next 20 seconds for each.
The synchronisation process is terminated when the time limit of
20 seconds is exceeded or the ignition is switched on for at least
5 seconds. If 4 keys are synchronised, the synchronisation proc‐
ess is terminated automatically.
2.9 Removing and installing batteries for

key with remote control ► 04.00
1- Sender unit - upper part (turned-over)
2- Button battery agen
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3- Contact plate ed by ara
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4- Button battery auth ra
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5- Sender unit - lower part
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In the following description the sender unit is called a transmitter

ility
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unit.
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2.9.1 Removing
ss
– Insert a screwdriver in slot between transmitter unit -1- and key

o
cial p
-2-.
inform
mer
– Move screwdriver in direction of -arrow- and unclip transmitter

atio
m
unit from key.

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– Lever the transmitter unit apart at the two retaining lugs

-arrows-.
– Unclip upper battery -1- from the retainers -2- with a screw‐
driver in direction of -arrow-.
– The contact plate -1- has a straight edge. The contact plate
can be removed if the straight edge is turned to a retaining lug.
– The contact plate can also be unclipped with a screwdriver.
– Now unclip the lower battery from the retainers with a screw‐
driver. olksw n AG. V agen AG
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2.9.2 Installing
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Observe polarity and correct position when installing the batter‐

ole,
spec
ies.
t to the co
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mer
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– Place the battery -4- in the sender unit with the positive termi‐
nal upwards (positive terminal is marked in housing).
– Place the contact plate -3- on the battery -4-.
– Place battery -2- onto the contact plate with the positive ter‐
minal upwards and engage both.
– Place sender unit -1- and sender unit -5- together and clip to‐
gether.
– Then clip transmitter unit to the key.
Note
If changing the batteries takes longer than 30 seconds, it will be

necessary to adapt (synchronise) the key(s) ⇒ page 43 . Perform
functional check.
2.10 Adapting ignition keys with radio remote

control 05.00 ►
Note n AG. Volkswagen AG do

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If new or additional
ir se ignition keys are required they must abe
r n
♦ o tee
matched to the
au immobilizer control electronics and the remote
th or
ac
control. ss
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un
pt
♦ The matching procedure must normally be carried out for all

an
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itte
the ignition keys, including the existing ones.

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♦ The number of keys already matched will be displayed when

ot p
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the adaption (matching) function is selected.

is n
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ole,
♦ The adaptation can be interrupted by pressing the C key on

spec
the vehicle diagnosis, testing and information system - VAS

t to the co
5051B- .
rrectne
WARNING
s
The dealership number (workshop code) of the vehicle diag‐

s o
cial p
nosis, testing and information system - VAS 5051B- will be

f in
stored in immobilizer control unit when ignition keys are adap‐

form
mer
ted.
atio
om
n
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2.10.1 Prerequisites:
t
sd
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fo
• All ignition keys present. If no old ignition key is available see

en
ng
t.
“Lost key procedure”, ⇒ Electrical system self-diagnosis; Rep.
yi Co
op py
gr. 01 ; Immobilizer self-diagnosis t. C rig
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• Key fob with covered secret number is available, if not see
co Vo
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“Establishing secret number”, ⇒ Electrical system self-diag‐
agen
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nosis; Rep. gr. 01 ; Immobilizer self-diagnosis
– Insert correct profile ignition key in the ignition lock.
– Connect fault reader ⇒ Electrical system self-diagnosis; Rep.
gr. 01 ; Immobilizer self-diagnosis
– Start self-diagnosis ⇒ Electrical system self-diagnosis; Rep.
gr. 01 ; Immobilizer self-diagnosis

The adaption procedure shown here is only an example.

Indicated on display: Rapid data transfer HELP
Select function XX
– Press keys 1 and 0 (10 selects function “Adaption”).

Indicated on display: Rapid data transfer Q
10 - Adaption
– Confirm entry with Q key.

Indicated on display: Adaption
Enter channel number XX
– Press keys 0 and 0 (all keys are deleted with channel number
00).
Indicated on display: Adaption Q
Erase learned values?

Indicated on display: Adaption ->
Learned values are erased
– Press → button.
Select function XX

10 - Adaption

AG. Volkswagen AG d Enter channel number XX
agen oes
olksw not
– Press keys 0 eand by V1 . (all keys are learnt with channel gu number
ara
d
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01). horis
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Indicated on display: ss c
Adaption Q
ce
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nl
Enter channel number 01

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Indicated on display: Channel 1 Adaption 1

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Key 1 <-1
h re
hole
spec
The top line displays number of keys to be learnt (standard =1).

es, in part or in w
Select number of keys with keys 1 and 3 .

t to the co

rrectness of i
Indicated on display: Channel 1.......Adaption 1

Enter adaption value XXXXX
l purpos
– Press the 0 key four times and then enter the number of all
ignition keys to be matched, including the existing key, (e.g.
nform
ercia
00003); max. possible qty. 4.

m
at

om
ion
c
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or
Indicated on display: number of remote control keys to be learnt.

his
e
Channel 1 Adaption 3 Q
at
do
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Key 3
p
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or

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47
Prote AG.
2. Central locking
Indicated on display: Channel 1 Adaption 3 Q

Save changed value?

Indicated on display: Channel 1 Adaption 3 ->
Changed value stored
Select function XX
– One button must be pressed for at least 1 second on each of

the keys to be learnt (3 keys in above example).
– Switch off ignition and remove ignition key.
– Perform functional check (e.g. 3) of remote control keys.
AG. Volkswagen A n G do
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Note oris tee
th or
s au ac
♦ All 3 keys (see example) can be learnt
s
in one matching se‐
ce
e
nl
quence.
pt
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itte
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♦ 15 seconds must not be exceeded when matching all ignition
erm
ab
keys (pressing a button).
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♦ A successful adaptation can be checked via “Read data block”
h re
function 08, display group number 003. When remote control
hole
spec
key is operated, both first measured values must adopt “OK”
es, in part or in w
status. At same time, last measured value displays sequence
t to the co
number of key (first, second, third, fourth key).
♦ If the remote control key is operated several times, the third
rrectness of i
display - no measured value - will change to “OK”. ⇒ Electrical
system self-diagnosis; Rep. gr. 01 ; Starting self-diagnosis for
l purpos
radio remote control of central locking
nf
ercia
Key adaption is automatically terminated when: orm

m
atio
♦ Number of keys to be matched is reached

om
n in
or c
♦ A button of one of the keys to be learnt is pressed frequently

thi
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♦ Permissible matching period of 15 seconds is exceeded (fault

o
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cu
is stored)
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– Select function 02 “Interrogate fault memory”. If no fault is . Cop py
stored, key adaption is completely successfully.
ht rig
rig ht
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– Press keys -0- and -6- to end the output.
by lksw
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06 End output

Enter address word XX
– Switch off ignition.

– Disconnect connectors to vehicle diagnosis, testing and infor‐
mation system - VAS 5051B- .

2.11 Adapting a new additional key 05.00 ►
2.11.1 With vehicle diagnosis, testing and in‐

formation system - VAS 5051B-
– Connect fault reader ⇒AGElectrical
. Volkswagensystem
AG do self-diagnosis; Rep.
gr. 01 ; Vehicle agen
olkswdiagnosis, testing and information
es n
ot systems
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db a
– Start self-diagnosis
oris
e ⇒ Electrical system self-diagnosis;
ran
tee Rep.
gr. a01
ut ; Starting self-diagnosis for radio remote control
h or of cen‐
a
tral
ss locking c
ce
le
un
pt
Indicated on display:
an
d
Rapid data transfer HELP

itte
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Select function XX
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ab
pe
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Rapid data transfer Q
spec
10 - Adaption
es, in part or in w
t to the co
rrectness of i
Enter channel number XX
– Press keys 0 and 1 .

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Indicated on display: nform Adaption Q

ercia
Enter channel number 01

m

com
tion in
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Channel 1 Adaption 1
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Key 1 <-1 3->

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The top line displays number of keys to be learnt -1-.

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– Press → button. Cop py
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c by lksw Channel 1.......Adaption 1 Q
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– Press the 0 key four times and then press the 1 key.
Indicated on display: number of remote control keys to be learnt. Channel 1 Adaption 1 Q
Key 1 <-1 3->

Indicated on display: Channel 1 Adaption 1 Q
Save changed value?

Indicated on display: Channel 1 Adaption 1 ->
Changed value stored
Select function XX
– Within the next 15 seconds, a button must be pressed once

for at least one second on the remote control key to be learnt.
– Switch off ignition and remove ignition key.
– Perform functional check of remote control key
Note
Initialisation is finished when the 15 seconds have been excee‐

ded, no key station is free or the key was successfully adapted.
2.11.2 Without vehicle diagnosis, testing and

information system - VAS 5051B-
– Insert correct profile (old) ignition key in the ignition lock.
– Switch on ignition.
– Switch off ignition within five seconds.
– Switch ignition back on within five seconds.
– Using the new key (to be adapted) lock the vehicle (e.g. at the AG. Volkswagen AG d
agen
driver's door) mechanically or lock door from the interiorolkswand
oes
not
subsequently depress a button on the remote control by Vwithin 15 gu
ara
ed
seconds. thoris nte
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au ac
– After a pause of more that one second (butsswithin 30 seconds)
ce
depress the button on the remote control a second time.
le
un
pt
an
d
itte
– Adaptation is finished and is confirmed by the vehicle flashing
y li
rm
ab
its lights twice.
pe
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Note
hole
spec
es, in part or in w
t to the co
This adaptation will occupy the next free key station or the fourth
one will be overwritten.
rrectness of i
2.12 Synchronising ignition keys with radio
l purpos
remote control 05.00 ►

Synchronisation can be required when the vehicle does not open
nform
ercia
or close as requested by pressing the remote control buttons, or

m
equivalent faults are registered when the measured value block

a
com
is read. It may be the case that the key code no longer matches tion in
the control unit code. This can happen if the key's sender button
r
te o
thi
is frequently pressed outside the system's effective range.

s
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The vehicle key(s) must then be resynchronised. The synchroni‐

fo
en
g
sation process should not take longer than 15 seconds.

n
t.
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Cop py
– Insert key into ignition lock. ht. rig
rig ht
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– Switch on ignition. by c lksw
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– Switch off ignition within five seconds.
– Switch ignition back on within five seconds.
– Using the new key (to be adapted) lock the vehicle (e.g. at the
driver's door) mechanically or lock door from the interior and
subsequently depress a button on the remote control within 15
seconds.
– After a pause of more that one second (but within 30 seconds)
depress the button on the remote control a second time.

2.13 Removing and installing batteries for

key with remote control (folding type)
05.00 ►
1 - Key with variable code

transponder
2 - Transmitter unit - upper part
3 - LED
❑ When remote control is n AG. Volkswagen AG do
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operated, this LED must olks es n
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light up. d b ua
ran
ir se tee
❑ If LED does not flash autho
or
ac
during remote control ss
operation, the battery is
ce
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un
pt
dead and must be re‐
an
d
itte
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newed.
rm
ab
pe
ility
4 - Battery
ot
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❑ Removing battery
h re
hole
⇒ page 51
spec
es, in part or in w
❑ Installing battery
t to the co
⇒ page 52
5 - Transmitter unit - lower part
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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en
ng
t.
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Cop py
t. rig
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pyri by
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cted agen
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2.13.2 Removing
– Insert a screwdriver in slot between transmitter unit -1- and key
-2-.
– Turn screwdriver -in direction of arrow- to separate transmitter
unit from key.
– Press transmitter unit -1- apart using profile section of key

-2-.
– Unclip battery -1- from the retainers -2- with a screwdriver

-in direction of arrow-.
AG. Volkswagen AG d
agen oes
olksw not
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2.13.3 Installing
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Note polarity and correct position when installing battery.

l purpos
– Lay battery -1- with positive terminal downwards in sender unit

-2- (positive terminal is marked on housing).
nform
ercia
– Engage battery in transmitter body by pressing down lightly.

m
at
om
– Fit cover to transmitter unit (do not damage seal).

on
c
in t
or
– Then clip transmitter unit to the key.

his
ate
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58 – Rear doors, door components

1 Sliding door
1.1 Tools
1.2 Assembly overview ► 12.95
AG. Volkswagen AG d
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pe
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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tion in
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by c lksw
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1. Sliding door 53
1 - Sliding door
2 - Rubber buffer
3 - Bolt
4 - Lower roller guide
5 - Bolt
6 - Centre stop
7 - Remote release mecha‐
nism
8 - Locking rod
9 - Bolt
10 - Catch plate
11 - Bolt
12 - Trim collar
13 - Cross-head screw
14 - Spring
AG. Volkswagen AG d
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15 - Exterior door handle olksw not
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❑ Removing ⇒ page 71 orise nte
h eo
ut ra
16 - Interior operating mecha‐ ss a c
nism
ce
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nl
pt
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17 - Hexagon socket head bolt
itte
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18 - Locking button
, is n
h re
❑ Screwed onto pull rod

hole
spec
es, in part or in w
19 - Bolt
t to the co
20 - Washer
rrectness of i
21 - Upper roller guide

l purpos
22 - Bolt
nf
ercia
orm
m
23 - Window frame
atio
om
❑ Destroyed during removal

n in
or c
thi
e
24 - Sliding door window

t
sd
iva
o
r
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cu
❑ Flush-bonded window: removing and installing ⇒ page 133

o
m
f
en
ng
❑ Repairing optional sliding window ⇒ page 144

t.
yi Co
Cop py
t.
25 - Central lock
rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
26 - Bolt
54 Rep. gr.58 - Rear doors, door components

27 - Hinge
28 - Sealing
29 - Hexagon head and washer combination bolt
30 - Pull rod
❑ Connection from remote mechanism to central lock
1.3 Assembly overview 01.96 ► 03.01
1 - Window frame
❑ Destroyed during re‐
moval
2 - Rubber buffer
❑ Flush-bonded window:
removing and installing
⇒ page 133
❑ Optional sliding window;
repairing ⇒ page 144
4 - Central lock
olkswagen AG
en AG. V
5 - Bolt olks
wag does
not
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❑ Specifiedistorque:
ed
b 19 Nm ara
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6 - Hinge s aut ra
c
s
7 - Sealing
ce
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un
pt
an
d
itte
8 - Bolt
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❑ Qty. 2
pe
ility
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wit
, is n
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hole
9 - Pull rod
spec
es, in part or in w
❑ Connection from remote

t to the co
mechanism to central
lock
rrectness of i
10 - Sliding door
l purpos
nform
ercia
11 - Locking rod
m

com
tio
nism
n in
r
te o
thi
13 - Bolt
s
iva
do
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um
fo
en
ng
t.
14 - Centre stop
yi Co
Cop py
ht. rig
15 - Bolt rig ht
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by c lksw
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Prote AG.
17 - Locking peg
1. Sliding door 55
AG. Volkswagen AG d
agen oes
lksw not
18 - Bolt byV
o gu
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ed
❑ Specified torque: 19 Nm horis nte
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aut ra
19 - Catch plate ss c
ce
le
un
pt
20 - B-pillar
an
d
itte
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21 - Rear right door contact switch (sliding door) -F7-
erm
ab
ility
ot p
22 - Bolt
wit
is n
h re
ole,
spec
23 - Catch plate
t to the co
24 - Bolt
rrectne
25 - Trim collar
s
26 - Bolt
s o
cial p
f
inform
mer
27 - Spring
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
29 - Interior operating mechanism
um
r
fo
en
ng
t.
30 - Locking button
yi Co
Cop py
❑ Screwed onto pull rod ht. rig
rig ht
py by
o Vo
31 - Bolt
by c lksw
cted agen
Prote AG.
32 - Washer
33 - Bolt
35 - Sealing strip
❑ Secured with clips and adhesive
36 - Clip

1 - Window frame
❑ Destroyed during re‐
moval
2 - Rubber buffer
❑ Flush-bonded window:
removing and installing
⇒ page 133
❑ Optional sliding window; AG. Volkswagen AG d
agen
repairing ⇒ page 144 Volksw
oes
not
gu
d by ara
4 - Central lock orise nte
eo
h
ut
ss a ra
c
ce
le
5 - Bolt
un
pt
an
d
itte
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ab
6 - Hinge
ility
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is n
7 - Sealing
h re
ole,
spec
8 - Bolt
t to the co
❑ Qty. 2
rrectne
9 - Pull rod
❑ Connection from remote
s
mechanism to central
s o
lock
cial p
f inform
10 - Sliding door
mer
atio
om
n
c
i
or
n thi
te
sd
a
11 - Locking rod
iv
o
pr
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r
fo

en
ng
t.
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nism
Co
Cop py
t. rig
gh
13 - Bolt
ht
pyri by
Vo
o
by c lksw
❑ Specified torque: 19 Nm Prote
cted AG.
agen
14 - Centre stop
15 - Bolt
16 - Bolt
18 - Locking peg
19 - Bolt
1. Sliding door 57
AG. Volkswagen AG d
20 - Catch plate ksw
agen oes
not
Vol
y gu
21 - B-pillar ise
d b ara
nte
or eo
h
22 - Rear right door contact switch (sliding door) -F7- s aut ra
c
s
23 - Bolt
ce
e
nl
pt
du
an
itte
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erm
ab
24 - Catch plate
ility
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wit
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25 - Bolt
h re
hole
spec
es, in part or in w
26 - Trim collar
t to the co
27 - Bolt
rrectness of i
28 - Spring
l purpos
nform
ercia
m
at
om
ion
c
in t
31 - Locking button
or
his
ate
❑ Screwed onto pull rod
do
priv
cum
or
32 - Bolt
f
en
ng
t.
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❑ Specified torque: 12 Nm t. Cop py
rig
gh ht
33 - Washer yri
p by
co Vo
by lksw
cted
34 - Bolt
agen
Prote AG.
36 - Sealing strip
❑ Secured with clips and adhesive
37 - Clip
1.5 Removing and installing sliding door ►

03.01
Removing:
– Unscrew screw -1- and pull end piece -2- off guide rail.

– Mark position of lower roller guide -arrow-.

– Lower sliding door at front until upper roller guide can be re‐
moved from guide rail.
– Guide back sliding door with aid of second mechanic until

hinge fitting -1- is pushed back out of guide rail -2-.
Installing:
Installation is carried out in the reverse sequence of removal. AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
ss c
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nl
pt
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ab
ility
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1.6 Removing and installing sliding door
hole
spec
04.01 ►
es, in part or in w
Removing: t to the co
– Unscrew screw -1- and pull end piece -2- off guide rail.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Sliding door 59
– Mark position of lower roller guide -arrow-. AG. Volkswagen AG d

agen oes
– Unscrew bolts -1-. olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Lower sliding door at front until upper roller guide can be re‐
moved from guide rail.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
– Guide back sliding door with aid of second mechanic until Cop py
hinge fitting -1- is pushed back out of guide rail -2-.
t. rig
gh ht
pyri by
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Installing:
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1.7 Removing and installing door arrester

Removing:
– Remove step insert and step light (W 23), if fitted
⇒ page 61 .
– Move sliding door to half-opened position.
– Unscrew bolts -1- and remove door arrester -2- from lower
guide channel.
Installing:
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1.8 Adjusting sliding door ► 12.95
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– Remove sliding door moulded trim or sliding door trim at bot‐

hole
spec
tom: Assembly overview - sliding door moulded trim

es, in part or in w
t to the co
1.8.1 Adjusting hinge

– Loosen striker plate -1- by slackening bolts -2-.
rrectness of i
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– Close sliding door and slacken bolt -1- from inside the vehicle.
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– Have a second mechanic lift sliding door and push hinge with
Prote AG.
hexagon bolt -1- and guide lug -2- as far as possible to the
front.
– Tighten bolt -1-.
1.8.2 Adjusting lower roller guide

• Height of sliding door at front is not correct
• Sliding door is not aligned with outer contour of B-pillar.
1. Sliding door 61
Transporter 1991 ➤ . Volkswagen AG
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General body repairs, exterior - Edition 08.2017 Volkswa not
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– If the height of the sliding door is not correct, slacken
ut
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the bolts tee
or
-1- and align the sliding door accordingly -arrow-
ss a ac
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Specified torque: bolt -1- = 19 Nm
nl
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Note
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If the sliding door is not aligned at the front with the outer contour
hole
spec
of B-pillar, adjust with the aid of the bolts -2- as follows:
es, in part or in w
t to the co
rrectness of i
Vehicle without step insert
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– Press plastic cap -1- out of step from underneath.
nf
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Vehicles with step insert
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– Lever out entry light (W 23) -1-, if present, and pull off con‐
Prote AG.
nectors.
– Unclip step insert -1- on outside -arrows- and lift upwards out
of retaining clips -2- in installation position.

– Slacken bolts -2-, push sliding door against roller guide -1-
-arrow- and tighten only the bolt at the door side.
– Carefully close sliding door.
– Slowly slacken screw at door side while a second mechanic
on the outside says when the sliding door is aligned with the
outer contour of the B-pillar. Then tighten the screw again.
– Open sliding door and tighten both cross-head screws -2-.
1.8.3 Adjusting upper roller guide

• Front upper edge of sliding door is not aligned with outer con‐
tour of B-pillar.
– Loosen bolt -1- and move upper roller guide -2- against brack‐
et -3- -arrows- until front top of sliding door aligns with outer
contour of B-pillar.
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– After bolts -2- have been slackened, striker plate -1- can be
un
pt
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moved horizontally -arrow-.

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– Adjust striker plate -1- so that recess of central lock engages

inform
with rotary latch centrally in relation to striker plate -arrows-.

mer
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• The door must not be raised upwards or pushed downwards.

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The sliding door must not have any play when closed.
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1. Sliding door 63
1.9 Adjusting sliding door 01.96 ► 03.01

tom ⇒ General body repairs, interior; Rep. gr. 70 ; Door trim
1.9.1 Adjusting hinge

– Loosen striker pin -1- by unscrewing bolts -2- slightly.
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– Close sliding door and slacken bolts -1- from inside the vehi‐ ss
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– Have a second mechanic lift sliding door and push hinge link
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– If the height of the sliding door is not correct, slacken the

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Vehicle without step insert

– Press plastic cap -1- out of step from underneath.

Vehicles with step insert
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– Lever out entry light (W 23) -1-, if present, and pull off con‐
es, in part or in w
nectors.
t to the co
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– Unclip step insert -1- on outside -arrows- and lift upwards out
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of retaining clips -2- in installation position.
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Continuation all vehicles t. C rig
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Prote AG.
– Slacken bolts -2-, push sliding door against roller guide -1-
-arrow- and tighten only the bolt at the door side.
– Carefully close sliding door.
– Slowly slacken screw at door side while a second mechanic
on the outside says when the sliding door is aligned with the
outer contour of the B-pillar. Then tighten the screw again.
– Open sliding door and tighten both bolts -2- to specified torque
of 19 Nm.
1. Sliding door 65

tour of B-pillar

– After slackening the cross-head screws -2-, the striker pin
-1- can be moved horizontally -arrow-.
– Adjust striker pin -1- so that recess of central lock engages

with rotary latch centrally
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• The door must
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1.9.5 Adjusting locking pegs

• When installing ensure that points of locating lugs face in‐
rrectness of i
wards to vehicle interior.

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– Loosen bolts -1- until locating peg -2- can be moved.
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– Slowly close sliding door and check position of locating lugs
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-1- to catch plates -2- - locating lugs must be parallel to catch
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plates.
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– Open sliding door and tighten bolts -1-
spec
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t to the co
Specified torque for bolts -1-: 19 Nm
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1.10 Adjusting sliding door 04.01 ►

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– Remove trim for roller guide and front frame and cover for
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sliding door adjustment ⇒ General body repairs, interior; Rep. co Vo
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gr. 70 ; Assembly overview - sliding door moulded trim cted agen
Prote AG.
1.10.1 Adjusting door closure force

• A distance of approx. 1 - 2 mm must exist between catch plate
and B-pillar pressure plate (visual check) when the door is
closed.
If this is not the case, perform the following procedures in the se‐
quence described:
– Adjust hinge fitting ⇒ page 68 .
– Adjust lower roller guide ⇒ page 68 .
– Adjust upper roller guide ⇒ page 68 .
– Adjusting striker pin ⇒ page 69 .
– Adjust locating pegs ⇒ page 69 .
– Adjust rubber buffer ⇒ page 70 .
1. Sliding door 67
Transporter 1991 ➤ gen AG
. Volkswagen AG
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General body repairs, exterior - Edition 08.2017 y Volk not
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1.10.2 Adjusting hinge au
t or
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ss
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– Close sliding door and slacken bolts -1- from inside the vehi‐
nl
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cle.
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– Have a second mechanic lift sliding door and push hinge link
ility
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with bolts forwards as far as possible.
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– Tighten bolts -1-.
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– Remove locating peg on sliding door side.
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– If the height of the sliding door is not correct, slacken the

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screws -1- and align the sliding door accordingly -arrow-.
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Note
– Slacken screws -2-, push sliding door -arrow- against roller

guide -1- and tighten both screws lightly.
– Carefully close the sliding door and check the seating of the
door from the outside.
– If necessary, repeat procedure until the sliding door aligns with
the outer contour of the B-pillar.
– Carefully open the sliding door and tighten both bolts -2-.

tour of B-pillar.

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– After slackening the screws -2-, the striker pin -1- can be
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t to the co
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– Adjust striker pin -1- so that recess of central lock engages
om
n
with rotary latch centrally in relation to striker pin -arrows-.
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When the sliding door is closed there must be a projection of ap‐

fo
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prox. 1 - 2 mm to the C-pillar and no play (wind noise).

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1.10.6 Adjusting locking pegs

– Install locating peg on sliding door side.
• When installing ensure that points of locating lugs face in‐
wards to vehicle interior.
– Loosen bolts -1- until locking peg -2- can be moved.
1. Sliding door 69
AG. Volkswagen AG d
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Transporter 1991 ➤ d by ara
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General body repairs, exterior - Edition
ut
ho 08.2017 eo
ra
s a c
s
– Slowly close sliding door and check position of locating lugs
ce
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nl
pt
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-1- to catch plates -2- - locating lugs must be parallel to catch
an
itte
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plates.
erm
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ility
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– Close sliding door completely, so that locating pegs are ad‐
wit
, is n
justed.
h re
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– Open sliding door and tighten bolts -1-
spec
es, in part or in w
t to the co
– Carefully close sliding door again to check whether locating
pegs are sliding into catch plates centrally.
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1.10.7 Adjusting rubber buffers.
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– The rear upper and lower rubber buffers must be set by screw‐ yri
gh by
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ing in or out so that they only contact the sliding door lightly.
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– The rubber buffers must not be used to adjust the door.
AG.
1.11 Removing and installing central lock

Removing:
– Unhook pull rod -1- from remote actuator -2-.

– Remove central lock -1- by unbolting bolts

⇒ Item 5 (page 57) .
– Unhook pull rod -2- from central lock -1-.
Installing:
Torque specification for bolt ⇒ Item 5 (page 57)
1.12 Removing and installing exterior door

handle
Removing:
– Unscrew bolts -2- to detach door interior opener -1- and re‐
move upwards.
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– Unscrew bolts -1-, unhook pull rod -2- and push remote re‐
lease mechanism to side. h re
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spec
es, in part or in w
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– Remove bolt -1- and detach spring -2-.

thi
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– Remove exterior door handle.

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Installing:
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Installation is carried out in the reverse sequence of removal. ht. rig
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Prote AG.
1. Sliding door 71
olkswagen AG
en AG. V
Transporter 1991 ➤ ksw
ag does
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Vol
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Specified torque of bolts
ss -1-
a = 8 Nm ra
c
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spec
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Prote AG.

(sliding door)
Removing:
– Removing exterior door handle ⇒ page 71 .
– Pull out roll pin -1-.
Installing:

1.14 Assembly overview - guide rail
Note
To remove the guide rail, the sliding door ⇒ page 58 and, if necessary, rear side panel trim or moulded trim on
sliding door side must be removed. ⇒ General body repairs, interior; Rep. gr. 70 ; Pillars and side panel trims
1 - Guide rail
❑ Removing:
❑ Unscrew end piece -4-
and slacken hexagon
nuts -2-.
2 - Hexagon nut
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❑ Specified torque: gen AG
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1. Sliding door 73
2 Rear wing door
2.1 Tools
2.2 Assembly overview - left wing door

Assembly overview - right wing door ⇒ page 75 .
1 - Rear left wing door

2 - Bolt AG. Volkswagen AG d
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❑ For attaching hinge to d by V gu
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3 - Top hinge ss c
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4 - Seal
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5 - Door arrester
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6 - Bolt
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spec
7 - Bottom hinge
t to the co
8 - Washer
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❑ For attaching wing door

to hinge
ss o
10 - Left rear window wiper mo‐

cial p
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tor (V 92)
form
mer

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⇒ Electrical system;
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Rep. gr. 92 ; Rear win‐

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(rear wing doors) ⇒

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13 - Rivet
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14 - Door lock

15 - Bolt
16 - Operating rod
17 - Operating lever
18 - Bolt
19 - Seal
20 - Grommet
21 - Buffer stop
2.3 Assembly overview - right wing door

Assembly overview - left wing door ⇒ page 74 .
1 - Rear right wing door

2 - Grommet
3 - Bolt
4 - Top door lock
❑ Removing ⇒ pagel wage
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Vo ot gu
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5 - Top operating ris rod
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❑ With ball
s a joint
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6 - Locking button
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7 - Trim collar
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❑ Removing:
h re
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❑ Remove bolts -9- and

spec
take off door handle to

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t to the co
the outside
9 - Bolt
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❑ Qty. 2
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10 - Bolt
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❑ 8 Nm
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11 - Locking rod
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12 - Lock mechanism
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13 - Operating rod
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14 - Interior door handle C py
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15 - Stop strip Prote AG.
16 - Rivet
17 - Door lower lock
2. Rear wing door 75

18 - Bolt
19 - Lower operating rod
❑ With ball joint
20 - Right rear window wiper motor (V 93)
❑ Removing and installing ⇒ Electrical system; Rep. gr. 92 ; Rear window wash/wipe system (rear wing
doors)
❑ For attaching wing door to hinge
22 - Washer
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23 - Bolt yV
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❑ For attaching hinge to D-pillar
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24 - Seal ss
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25 - Bottom hinge
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26 - Bolt
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27 - Door arrester
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spec
28 - Top hinge
t to the co
2.4 Removing and installing wing door
rrectne
Removing:
ss o
cial p
f in
Note
form
mer
atio
m
The description refers to the hinged door on the rear right. Re‐
o
n
c
moval of the rear left wing door is a mirror image.

or
n thi
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sd
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– Remove rear right wing door trim ⇒ General body repairs,

um
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fo
interior; Rep. gr. 70 ; Tailgate

en
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– Disconnect wiring for rear window wiper motor, window heat‐
C py
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door.
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– Remove door arrester trim (if fitted) ⇒ General body repairs,
interior; Rep. gr. 70 ; Removing and installing rear right side
wall moulded trim (long wheelbase)
– Unscrew bolts -1- from top and bottom hinge.
– Unhook door arrester and remove wing door.
Installing:

2.5 Adjusting wing doors
2.5.1 Adjusting lower striker plates
Note
Adjustment work should be performed first on the left wing door

and then on the right wing door. The aid of a second mechanic is
required.
– Unscrew load sill cover.

– Removing rear roof pillar trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Pillars and side panel trims
The striker plates -2- and -3- can be moved -arrows- after the bolts
-1- have been slackened.
– Detach left striker plate -2-.
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– Close left wing door. In doing so, striker
ss a plate -1- is aligned by ra
c
pin -2-.
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– Press wing door from the outside against the vehicle and tight‐
itte
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en bolt -3-.
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– Open wing door and tighten second bolt.

wit
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Specified torque of bolts -3- = 20 Nm h re

hole
spec
es, in part or in w
• Wing door must lock properly when closing without any addi‐ t to the co
tional force being required and must not have any play
rrectness of i
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– Detach right striker plate -3-.

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– Close right wing door with left wing door closed. In doing so,
striker plate -1- is aligned by pin -2-.
– Push right wing door onto vehicle from outside until both wing
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– Tighten bolt -3-. edb ara
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– Open right wing door andaut tighten second bolt. ra
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2.5.2 Adjusting upper striker plate
spec
es, in part or in w
t to the co
– Loosen top striker plate -1- by slackening bolts -2-.
– Close both wing doors.
rrectness of i
– Push right wing door in upper area outwards or inwards until
both wing doors align with outer contour.
l purpos
nform
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• When closing the right wing door (left wing door closed), the
upper and lower door locks must lock fully without any play
m
at
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and without additional force being required
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2.6 Removing and installing door locks

t.
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2.6.1 Left wing door lock
cted agen
Prote AG.
Removing:
– Remove release lever by unscrewing bolt -1- and unhook op‐
erating rod -2-.
– Unscrew bolts -1- and remove door lock -2- together with op‐
erating rod -3-.
Installing:

n AG. VolkswaTransporter
gen AG 1991 ➤
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Generaly Vbody
olks repairs, exterior - Editionnot08.2017
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2.6.2 Right wing door lower lock tho eo
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Removing:
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interior; Rep. gr. 70 ; Rear right wing door trim
ility
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– Detach operating rod -1- on door lower lock -2-.
is n
h re
ole,
– Unscrew bolts -3- and remove door lower lock.
spec
t to the co
Note
rrectne
After installing the door lock, check lock operating mechanism,
ss
adjust if necessary ⇒ page 80 .
o
cial p
f inform
mer
Installing:
atio
m

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2.6.3 Right wing door upper lock

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– Unclip ball joint -1- at the lock operating mechanism -2-. Prote AG.
– Remove ball joint (with clip) from operating rod.
– Unscrew bolts -1- and remove upper door lock -2- together
with operating rod -3- upwards.

Note
♦ When installing, push operating rod -1- through the window

member from below until thegoperating
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♦ After installing the
or
isedoor lock, check lock operating mechanism,
ran
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au
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Installing:
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2.7 Removing and installing lock operating
is n
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mechanism
spec
t to the co
Removing:
rrectne
– Unclip ball joints -1- of operating rods and operating rod of
s
interior door handle -2-.
s o
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atio
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– Remove bolts -1- and remove exterior door handle.
AG.
– Unscrew bolt -2- and remove lock operating mechanism -3-

from wing door.
Installing:
Specified torque for bolts -1- and -2- = 8 Nm
2.8 Adjusting lock operating mechanism
Note
Perform the adjustment on the rear right wing door in the opened
position. The top and bottom locks should be carefully blocked
using a screwdriver or another suitable tool.
• When actuating the exterior door handle, both door locks must
engage at the same time. If the door locks can be heard to
open at different times, the following described adjustment
must be performed.

– Unclip ball joint -1- at the lock operating mechanism -2- (figure
shows ball joint for door upper lock).
– Turn ball joint -1- on the operating rod (thread) so that the ef‐
fective length of the operating rod becomes greater or smaller.
• Extending the operating rod “retards” unlocking of the door
lock while shortening it causes “premature” locking.
– Adjust the length of both operating rods so that both door locks
are unlocked reliably and simultaneously.
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2.9 Removing and installing interior door
o tee
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Removing:
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– Detach operating rod -1- at the lock operating mechanism.
hole
spec
– Lever out retaining lug -2- with screwdriver and push interior
es, in part or in w
t to the co
door handle -3- out of bracket in wing door -arrow-.
Installing:
rrectness of i
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– Removing exterior door handle ⇒ page 75 . t. C rig
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Installing:

3 Side wing door
3.1 Tools
. Volkswagen AG
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3.2 Assembly yoverview - side wing odoor
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1 - Side wing door
ss
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⇒ page 83
an
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❑ Installing and adjusting

erm
ab
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⇒ page 84
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2 - Operating rod
h re
ole,
spec
3 - Door lock
t to the co
4 - Lock cylinder
rrectne
❑ Removing:
❑ Remove exterior door
s
handle -5-, drive out roll

s o
pin -6- and remove lock

cial p
f in
cylinder with key inser‐

form
mer
ted ⇒ page 38 .
atio
m

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❑ Removing:
te
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❑ Unscrew bolts -7- and

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remove exterior door

fo
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handle.
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6 - Roll pin opyri
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7 - Bolt
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8 - Bolt
9 - Operating rod
10 - Fastener
❑ Removing:
❑ Drive pin through
spreader clip
❑ Installing:

❑ Press in pin sufficiently until it is flush with the top edge of the clip
11 - Angle lever
12 - Operating rod
13 - Bottom hinge
14 - Bolt
❑ 2 each at top and bottom
15 - Locking rod
17 - Top hinge
18 - Trim collar
19 - Locking button
❑ Screwed on.
3.3 Removing and installing wing door
3.3.1 Removing
Vehicles with central locking
. Volkswage
gen AG
– Detach cable grommet -1- from B-pillar,kpull
swa connection -2- out does no
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of B-pillar and separate. by
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Continuation all vehicles ut
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– Unscrew hinge covers on soutside of B-pillar.
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– Lift retaining pin -1- and detach door retaining strap -2-.
rrectness of i
– Unscrew bolt -3- from the top and bottom hinges and remove
door.
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3. Side wing door 83

3.3.2 Installing and adjusting wing door

– Install bolts -3- in upper and lower hinge.
– Adjust wing door within over-sized holes in. V
hinge.
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– Adjust striker plate ⇒ page 84y.Volks not
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• Side hinged door is adjusted correctly if, in closed state, gap
t to the co
is equal around door aperture, door is not proud or set too
deep and contours -arrows- align.
rrectness o
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– Join connector and insert in B-pillar as well as cable grommet Cop py
(only vehicles with central locking).
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– Lift retaining pin -1- and attach door retaining strap -2-. by c lksw
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– After slackening bolts -1-, striker plate -2- can be moved hor‐
izontally and vertically -arrows-.

– Adjust the striker plate -1- so that the recess of the door lock
with rotary latch is centred -arrows- relative to the striker plate.
3.4 Removing and installing door lock

Removing:
– Remove side wing door trim ⇒ General body repairs, interior;
– Removing exterior door handle ⇒ Item 5 (page 82)
– Detach central locking motor (V 97), if fitted, by unscrewing
the cross-head screws -2- and detach operating rod at central
locking motor.
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– Detach operating rod -1- for interior lock.au To do this, release
t or
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spreader clips -2- if necessary (push through pin). ss ce
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– Unscrew bolts -1- and take out door lock downward.

– Detach pull rod at door lock.
nform
ercia
Installing:
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3. Side wing door 85

60 – Sunroof
1 Sunroof with glass panel
1.1 Tools
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1.2 Assembly overview - sliding/tilting sunroof
erm
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86 Rep. gr.60 - Sunroof

1 - Glass panel for sliding/tilting

sunroof (single pane safety
glass)
❑ Removing sliding/tilting
sunroof glass panel
⇒ page 88 .
❑ Installing sliding/tilting
sunroof glass panel
⇒ page 88 .
❑ Adjusting sliding/tilting
sunroof glass panel
⇒ page 89
2 - Panel seal
❑ Adjusting panel seal
⇒ page 90
❑ Seal joint is in centre of
right side section
❑ Treat panel seal clamp‐
ing channel with water
as lubricant before fit‐ AG. Volkswagen AG d
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3 - Trim frame hor eo
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❑ Removing trim frame ss c
⇒ page 88 , Removing
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sliding/tilting sunroof
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glass panel.
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4 - Sliding headliner
wit
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❑ Removing sunroof sun
h re
hole
blind ⇒ page 94
spec
es, in part or in w
❑ Installing sunroof sun
t to the co
blind ⇒ page 96
5 - Carrier unit
rrectness of i
carrier unit ⇒ page 96
l purpos
❑ If required, guide channels may only be greased with special grease - G 000 450 02- , otherwise correct
operation cannot be guaranteed. nform
ercia
6 - Crank for emergency operation

m
at
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❑ Clipped into electric drive

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7 - Bolt (microencapsulated)
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ate
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❑ Qty. 2
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❑ Always use new bolts.

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❑ Specified torque: 3 Nm Cop py
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8 - Bolt py by
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9 - Electric drive Prote AG.
❑ Removing and installing electric drive ⇒ page 90

❑ Checking electric drive (0 position) ⇒ page 91
10 - Wind deflector
❑ Open glass panel to rear, unscrew wind deflector and unhook on left and right
11 - Velcro fastener
❑ Bonded to trim frame and glass panel frame
12 - Bolt
1. Sunroof with glass panel 87

13 - Clamping washer
❑ With centring pins
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1.3 Removing sliding/tilting sunroof glass ris nte
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– Move glass panel to “closed” position.
an
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– Slide sunroof sun blind -1- towards rear.
ility
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– Slide trim frame -2- to rear (clipped in at front, also secured
, is n
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with Velcro tape -3- and guided at rear by pegs).
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
– Remove screws -2- (three cross-head screws with clamping
om
io
washers -1- on each side).
n
c
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– Lift out glass panel upwards.

at
do
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– Pull out trim frame (if required) towards front and upwards out
for
en
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of roof aperture.
n
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by lksw
cted agen
Prote AG.
1.4 Installing sliding/tilting sunroof glass

panel
Glass panel must be installed in 0 position (glass panel closed).
– Check and if necessary adjust parallel running ⇒ page 93 .

– Fit sliding/tilting sunroof glass panel from above and fit bolts
-2- with clamping plates -1-. Ensure the centralizing pins -3-
on the back of the clamping plate is seated correctly.
Note
♦ After successful height adjustment tighten bolts.

♦ If both centring pins -3- have broken off, renew the clamping
washer -1-.
– Perform height adjustment ⇒ page 89 .

Volkswa AG. gen AG
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– Check and, if necessary,
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adjust seating of panel
es n
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⇒ page 90 . ised b ara
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– Push trimauframe
t
towards front and clip in. or
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Only lift up trim frame at front when securing clips.
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– Check that sliding/tilting sunroof functions correctly.
spec
t to the co
1.5 Adjusting height of sliding/tilting sunroof
glass panel rrectne

s

s o
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form

mer
atio
m
– Check and if necessary adjust parallel running ⇒ page 93 .

o
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– Loosen all six screws of glass panel (floating alignment in roof

te
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aperture).
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– Adjust height of glass panel at front and rear on both sides as

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– When doing this, only tighten the front and rear screws on each
ht
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side respectively. Specified torque: 5 Nm by c lksw
cted agen
Prote AG.
Front panel adjustment:

1- Roof frame
2- Glass panel
-a- = 1 mm lower than roof frame
-Arrow- = Forwards

Rear panel adjustment:

1- Roof frame
2- Glass panel
-b- = 0+1 mm higher than roof frame
-Arrow- = Forwards
– Tighten glass panel centre bolts.
Specified torque: 5 Nm
– Push trim frame towards front and clip in.
Note
wage
Only lift up trim frame at front when securing clips. yV
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1.6 Adjusting panel seal ss
a ac
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pt
– Check that tension between panel seal -1- and roof frame
du
an
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-2- is uniform all around using a 0.3 mm thick strip of card‐
y li
erm
ab
board, for example, a business card (gap a = 0.3 mm).
ility
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– It must be possible to pull the paper strip through between the
, is n
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panel seal and roof frame under significant tension.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– If the pre-tension is insufficient, the panel seal can be pushed

apart with a wedge -1-, or if the pre-tension is excessive push‐
m
at
ed together.
om
ion
c
in t
r
– To adjust the panel seal remove the glass panel -2-

o
his
te
⇒ page 88 .
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Prote AG.
1.7 Removing and installing electric drive
Note
If vehicle has a security-coded radio, obtain anti-theft code before

disconnecting battery.
– Disconnect earth strap from battery.

– Pull off beading -1- in area of the electric drive cover.

– Push retaining lugs -2- in direction of travel with a screwdriver
(or similar) and unhook.
– Swing cover -1- for electric drive downwards -arrow- and de‐
tach from retainers -2-. en AG. V
olkswagen AG
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– Disconnect connector -1-.
– Unscrew electric drive. Renew micro-encapsulated screws
-2- during installation. Bolt -3- can be reused.
rrectness of i
l purpos
Note
nform
ercia
Before installing the electric drive check and, if necessary, adjust

m
parallel running ⇒ page 93 . a

com
tion in
r
te o
– Check electric drive for 0 position ⇒ page 91 and install in

thi
s
iva
this position.
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1.8 Checking electric drive (0 position)

t.
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AG. Volkswagen AG d
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If electric drive is renewed, it must be installed in 0 position (slid‐
h re
hole
ing/tilting sunroof glass panel closed).
spec
es, in part or in w
– Connect electric drive wiring harness connector to sliding/tilt‐

ing sunroof wiring harness. t to the co
– Operate switch -1- and count rotations of drive pinion -2-: The
rrectness of i
0 position of the electric drive is between the end switch-off

points -A- and-B-. The end switch-off point -B- is obtained by
l purpos
turning drive pinion clockwise and the end switch-off point

-A- by turning it anti-clockwise.
nf
ercia
-A- End switch-off point, panel tilting function = 3 turns to -0- po‐
rm
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-B- End switch-off point, panel sliding function =∼17 turns to 0

hole
spec
position
es, in part or in w
t to the co
1.9 Checking and adjusting parallel running

rrectness of i
1.9.1 Checking
l purpos

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ercia

m

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Retaining hooks (with roller) -1- must be engaged in the guide

rails.
Note
Engagement of the retaining hooks is audible as the sliding/tilting

sunroof moves from the “open” position (pushed back) to the
“closed” position. If parallel running is set correctly, engagement
occurs on both sides simultaneously.
Pins -1- must be within the marks (notches) -arrows-.

If this is not the case, adjust parallel running as follows:
1.9.2 Adjusting
– Removing glass panel for sunroof ⇒ page 88 .
– Remove electric drive ⇒ page 90 .
AG. Volkswagen AG d
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Retaining hooks (with roller) -1- must be engaged in the guide Vol
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spec
t to the co
– Only move rear guides with pins -1- from front to rear between
rrectne
notches -arrows-.
– Install electric drive (0 position) at this position ⇒ page 90 .
ss o
– Install sliding/tilting sunroof glass panel ⇒ page 88 .

cial p
f inform
mer
atio
om
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1.10 Removing sliding headliner
ht
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– Removing glass panel for sunroof ⇒ page 88 .
AG.

– Pull out trim frame towards front and upwards out of roof aper‐
ture.
– Unscrew guide -1- from sliding sunroof (qty. 3 on both sides)
and pull out from guide channels of carrier unit towards front.
AG. Volkswagen AG d
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– Unhook spring -1- from guide -2- on both sides using a narrow
ce
le
un
assembly lever, suitable screwdriver or similar -arrow A-.
pt
an
d
itte
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– Spring -1- cannot be seen when installed. (It is possible to slide
rm
ab
pe
the guide piece -2- in direction of -arrow B-).
ility
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– Push sunroof sun blind back as far as possible against direc‐
h re
hole
tion of travel -arrow B- without springs -1- engaging again.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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– Lift sunroof sun blind -1- and pull out towards front and up‐
wards out of roof aperture.

Transporter 1991 ➤ AG. Volkswagen AG d
agen oes
V olk-swEdition 08.2017 not
g y ua
db ran
rise tee
1.11 Installing sunroof sun blind s au
tho or
ac
s
– Insert sunroof sun blind -2- from above in roof aperture. Insert
ce
le
un
pt
slides -1- on both sides in guide channels and screw to sunroof
an
d
itte
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sun blind. Always use new bolts (micro-encapsulated). erm
ab
ility
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ole,
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t to the co
rrectness o
– Push sunroof sun blind against direction of travel -arrow B-
cial p
f in
until springs -1- engage in guide parts -2- automatically.
form
mer
atio
– Insert trim frame from above in assembly unit.
om
n
c
i
– Install sliding/tilting sunroof glass panel ⇒ page 88 .
or
n thi
te
sd
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pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.12 Removing and installing carrier unit
1.12.1 Removing

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Move glass panel -1- to “closed” position for removal.

– Guide O-ring or cable under beading ⇒ page 98
– Remove electric drive ⇒ page 90 .
– Remove passenger compartment moulded headliner ⇒ Gen‐
eral body repairs; Rep. gr. 70 ; Roof trim
– Pull off water drain hoses -arrows- from assembly unit.
– Remove hexagon bolts -4- and lift carrier unit -2- out of vehicle
with help of second mechanic.

1.12.2 Installing
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Place assembly unit on rear mounting in vehicle and swing

upwards (three locating pins -3- must engage in mounting
holes).
– Screw on assembly unit.
Specified torque for bolts -4-: 7.5 Nm
– Installing beading ⇒ page 99
Guiding O-ring under beading
– Guide O-ring or cable -3- between moulded headliner -2- un‐
der beading -1- -arrow-.

Installing beading
– Pull out O-ring or cable and guide beading over moulded
headliner -arrow-.
1.13 Routing and cleaning water drain hoses
1.13.1 Caravelle and Kombi models with slid‐

ing/tilting sunroof
Note
Ensure that water can drain downwards when routing water drain
hoses.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 - Front frame drain

2 - Adapter
3 - B-pillar
4 - Front water drain hose lkswage es n
o ot g
yV ua
❑ Covered with foam tube ir se
d b ran
tee
o
❑ Water drain hose and auth or
ac
foam tube are taped to‐ ss
ce
le
gether with textile rein‐
un
pt
forced adhesive tape in
an
d
itte
y li
lower area -B- to pre‐
erm
ab
vent movement. -a- =
ility
ot p
200 mm
wit
is n
h re
❑ To clean, blow through
ole,
spec
with compressed air
from front frame drain
t to the co
-1-
5 - Securing clip
rrectne
6 - D-pillar
s
7 - Rear water drain hose
s o
cial p
f
❑ Is covered with foam
inform
rubber in the area of the
mer
D-pillar
atio
m

o
n
c
i
or
n
with compressed air
thi
te
from rear frame drain
sd
iva
o
r
-8-
p
cum
r
fo
en
ng
8 - Rear frame drain

t.
yi Co
Cop py
.
9 - B-pillar grommet
t rig
gh ht
pyri by
Vo
co
10 - Grommet
by lksw
cted agen
Prote AG.
❑ Rear water drain is be‐
hind the bumper cover

2 Servicing glass/tilting sunroof
2.1 Assembly overview - glass/tilting sunroof
1 - Glass panel
2 - Seal
3 - Profile frame
❑ Secured with rivets
4 - Bolt
5 - Securing ring agen
AG. Volkswagen AG d
oes
olksw not
V
6 - Seal ed by gu
ara
ris nte
o
7 - Rotary handle aut
h eo
ra
ss c
ce
le
un
pt
❑ Routing and cleaning
an
d
itte
y li
⇒ page 103
erm
ab
ility
ot p
9 - Frame
wit
is n
h re
10 - Seal
ole,
spec
11 - Support
t to the co
12 - Grommet
13 - Front water drain hose
rrectne
❑ Routing and cleaning
⇒ page 103
ss o
14 - Washer
cial p
f inform
15 - Bolt
mer
atio
m
16 - Rivet
o
n
c
i
or
n thi
17 - Hinge
te
sd
va
❑ Is hooked into mounting

i
o
pr
cum
r
-11-.
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c
2.2 Removing glass panel
lksw
cted agen
Prote AG.
– Turn latching screw -arrow A- in the middle of the rotary handle

-1- (with glass panel closed) approx. 1/4 turn with a screw‐
driver to left or right until the glass panel unlatches.
– Turn rotary handle -1- to the right until glass/tilting sunroof is
tilted open; when doing this, lift glass panel slightly so that it
does not latch in again.
– Push securing lever -arrow B- upwards.
– Detach glass panel and pull out from mountings with hinges.
2. Servicing glass/tilting sunroof 101

wage es n
Transporter 1991 ➤ yV
olks ot g
b ua
ir se
d - Edition 08.2017 ran
tee
tho
u or
a ac
2.3 Installing glass panel
ss
ce
le
un
pt
an
d
itte
y li
1 - Profile frame
erm
ab
ility
ot p
2 - Seal
wit
is n
h re
ole,
3 - Hinge
spec
4 - Glass panel
t to the co
❑ Installing:
❑ Installing: hook glass
rrectne
panel into mountings
-7- with hinges -3- and
allow to drop into the
ss
latch
o
cial p
f inform
5 - Seal
mer
atio
6 - Roof trim
om
n
c
i
or
n
7 - Support
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.4 Routing and cleaning water drain hoses
2.4.1 Panel van and Kombi model with glass/tilting sunroof in cab
Note
Ensure that water can drain downwards when routing water drain hoses.

with compressed air
-1-
3 - A-pillar
D-pillar
with compressed air
-6- AG. Volkswagen AG d
agen oes
ksw
5 - B-pillar by
Vol not
gu
ara
ed
is nte
6 - Rear frame drain tho r eo
au ra
s c
7 - D-pillar s
ce
e
nl
pt
du
8 - Securing clip
an
itte
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erm
ab
9 - Grommet
ility
ot p

wit
, is n

h re
hole
spec
10 - A-pillar cover
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Servicing glass/tilting sunroof 103

2.4.2 Panel van and double cab with glass/tilting sunroof in cab
AG. Volkswagen AG d
agen oes
Note olksw not
y V gu
d b ara
rise nte
o
Ensure that water can drain downwards when routing
auth water drain hoses. eo
ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
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is n
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with compressed air
ole,
spec
-1-
t to the co
3 - A-pillar
4 - B-pillar
rrectne
5 - Adapter
ss o
6 - Moulded hose
cial p
f inform
mer
atio
m

o
n
c
i
or
n
❑ Covered with foam tube
thi
te
sd
a
❑ Water drain hose and

iv
o
pr
c
foam tube are taped to‐
um
r
fo
en
ng
t.
yi Co
forced adhesive tape in Cop py
t. rig
gh ht
yri
p by
co Vo
by lksw
200 mm Prote
cted AG.
agen

with compressed air
-7-
9 - B-pillar cover
10 - A-pillar cover

2.4.3 Vehicles with glass/tilting sunroof in passenger compartment
Note

2 - Adapter
3 - B-pillar
❑ Water drain hose and
foam tube are taped to‐
forced adhesive tape in
200 mm
with compressed air
-1-
5 - Securing clip
6 - D-pillar
D-pillar
with compressed air
from rear frame drain AG. Volkswagen AG d
agen oes
ksw
-8- byV
ol not
gu
ara
ed
is nte
8 - Rear frame drain hor eo
aut ra
s c
9 - B-pillar cover s
ce
e
nl
pt
du
10 - Grommet
an
itte
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erm
ab
ility

ot p
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
105
co Vo
by lksw
cted
2. Servicing glass/tilting sunroof
agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Transporter 1991 ➤ ut
ho eo
ra
a
ss c
ce
le
un
pt
2.4.4 Vehicles with glass/tilting sunroof in cab and passenger compartment
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
with compressed air
nform
ercia
-1- m
a
com
tio
3 - A-pillar
n in
r
te o
thi
4 - Y-branch
s
iva
do
r
rp
c
um
fo
en
ng
t.
yi
6 - B-pillar
Co
Cop py
ht. rig
7 - Front frame drain rig ht
py by
co Vo
by lksw
8 - Adapter
cted agen
Prote AG.

10 - Securing clip
11 - D-pillar
D-pillar
with compressed air
from the rear frame
drains -5- and -9-
13 - Grommet
14 - B-pillar cover
❑ Water drain hose and foam tube are taped together with textile reinforced adhesive tape in lower area
-B- to prevent movement. -a- = 200 mm
❑ To clean, blow through with compressed air from front frame drain -7-
16 - A-pillar cover

3 Tilting/sliding sunroof with glass pan‐

el
3.1 Tools
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
3.2 Assembly overview - tilting/sliding roof
es, in part or in w
t to the co
1 - Glass panel for tilting/sliding
rrectness of i
sunroof
l purpos
⇒ page 110
❑ Checking parallel run‐
nform
ercia
ning ⇒ page 111

m
at
❑ Adjusting parallel run‐
om
ion
ning ⇒ page 111
c
in t
or
his
e
❑ Adjusting the height of

at
do
riv
the glass panel is not

p
cum
or
possible
f
en
ng
t.
yi Co
2 - Threaded sleeve t. Cop py
rig
gh
❑ For securing glass pan‐
ht
pyri by
Vo
el
o
by c lksw
cted agen
Prote AG.
3 - Bush
❑ For securing glass pan‐
el
4 - Guide plate
5 - Bolt
6 - Spring for retaining hook
7 - Frame for tilting/sliding sun‐
roof
8 - Sealing strip
❑ Sponge rubber
9 - Hexagon nut
❑ Specified torque: 4.5
Nm
❑ Secured with locking flu‐
id - D 185 400 A2-
3. Tilting/sliding sunroof with glass panel 107

10 - Countersunk screw
Nm
❑ Secured with locking fluid - D 185 400 A2-
11 - Guide roller
12 - Clamping frame
13 - Bolt
14 - Sun blind
❑ Part of water collector plate
15 - Water collector plate
❑ ⇒ page 109 Removing and installing ⇒ page 109
16 - Cover
17 - Crank for emergency operation
18 - Bolt
19 - E-drive
❑ Removing and installing ⇒ page 111
3.3 Removing and installing tilting/sliding

sunroof
AG. Volkswagen AG d
Removing: ksw
agen oes
not
ol
yV gu
– Remove upper B-pillar trims ⇒ General bodyised repairs, interior;
b ara
nte
Rep. gr. 70 ; Pillars and side panel trim
ut
hor eo
a ra
s c
– Remove A-pillar trim ⇒ General body
s repairs, interior; Rep. ce
e
gr. 70 ; Pillar and side panel trim

nl
pt
du
an
itte
y li
– Unscrew brackets -1- for sun visors and disconnect connec‐
erm
ab
tors for mirror lighting.

ility
ot p
wit
, is n
– Prise out front interior light -W- -2- and separate connection
h re
-arrow-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
– Unclip cover strip -1-.

m
atio
om
– Lever out moulded headliner from beading in area of tilting/

n in
or c
sliding roof aperture using a plastic wedge.

thi
te
sd
iva
– Remove front seat area moulded headliner downwards.

r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Unscrew bolts -2- (qty. eleven) and remove water collector

plate -1- (with sun blind) downwards.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Remove bolts -1- and pull electric drive -2- off frame.
t to the co
– Unscrew bolts -3- (qty. ten) and remove clamping frame -4-
downwards.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Remove frame with glass panel upwards.

f
en
ng
t.
yi Co
op
Installing: C py
t. rig
gh ht
yri
p by
co Vo
by lksw
cted agen
Prote AG.
3.4 Removing and installing water collector

plate (with sun blind)
Removing:
– Remove upper B-pillar trims ⇒ General body repairs, interior;
Rep. gr. 70 ; Pillars and side panel trim
– Remove A-pillar trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Pillar and side panel trim
– Unscrew brackets -1- for sun visors and disconnect connec‐
tors for mirror lighting.
– Prise out front interior light -W- -2- and separate connection
-arrow-.


– Lever out moulded headliner from beading in area of tilting/
sliding roof aperture using a plastic wedge.
– Remove front seat area moulded headliner downwards.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u
– Unscrew bolts -2- (qty.
ss a eleven) and remove water collector ra
c
plate -1- (with sun blind) downwards.
ce
le
un
pt
an
d
Installing:
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
3.5 Removing and installing glass panel for
ss o
cial p
f
tilting/sliding sunroof
inform
mer
atio
om
3.5.1 Removing
c
i
or
n thi
te
sd
a
– Removing tilting/sliding sunroof ⇒ page 108 .

iv
o
pr
cum
r
fo
– Remove hexagon nuts -1- on left/right and bolts -2- on left/right

en
ng
t.
yi
(threads are coated with locking fluid, in cases of repair use D
Co
op py
185 400 A2).
t. C rig
gh ht
pyri by
Vo
o
– Pull glass panel off left/right guide plates.
c by lksw
cted agen
Prote AG.
3.5.2 Installing
– Check front seals -arrow- for damage and renew if necessary.
– Press left and right guide plates at sides onto frame of sliding/
tilting sunroof.
• Roller must be in guide plate. ⇒ Item 11 (page 108)
– Place glass panel onto guide plates and align them so there
is an even gap all the way around. Apply locking fluid - D 185
400 A2- to thread and screw on glass panel with guide plates.
Specified torque: Hexagon nut = 4.5 Nm, bolt = 2.5 Nm.

3.6 Removing and installing electric drive

Tilting/sliding roof closed
– Remove cover from drive unit.
– Remove bolts -1-, separate electrical connection and remove
electric drive -2-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
3.7 Checking parallel running ed
ris nte
ho eo
aut ra
– Open tilting/sliding roof. ss c
ce
e
nl
pt
– Measure distance -a- between glass panel and frame edge on
du
an
itte
left and right-hand side.
y li
erm
ab
ility
1- If the distance -a- is the same, then the parallel running is
ot p
OK.
wit
, is n
h re
hole
2- If the distance -a- varies, then the parallel running must be
spec
adjusted.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
3.8 Adjusting parallel running
orm
m
atio
– Open tilting/sliding roof.
om
n in
or c
– Remove cover from drive unit. thi

te
sd
iva
– Loosen fillister-head screws -1- and detach electric drive.

o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
Note
C py
ht. rig
rig ht
py by
co Vo
The drive pinion must no longer be in mesh with the cables.
by lksw
cted agen
Prote AG.

– Push glass panel -1- by hand up to rear stops.

– Screw on electric drive and clip in cover again.
– Close tilting/sliding sunroof and check function.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
112
co Vo
by lksw
cted
Rep. gr.60 - Sunroof
agen
Prote AG.
61 – Convertible roof, hardtop, canopy

1 Assembly of convertible roof frame
and canopy
1.1 Tools
AG. Volkswagen AG d
♦ Pop rivet pliers - VASol5072-
ksw
agen oes
not
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db ara
ir se nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
1.2 Canopy frame for dropside and double

rrectness of i
cab
l purpos
nform
ercia
Note
m
a
com
♦ The rails are supplied in a length of 2864 mm only, which cor‐

tion in
responds to the dimensions for the dropside with long wheel‐

r
te o
thi
base.
s
iva
do
r
♦ For the short wheelbase dropside the rail must be shortened

rp
cum
fo
to 2464 mm.
en
ng
t.
yi Co
op
♦ For double cab vehicles the rails must be shortened to a length
C py
t. rig
gh
of 2094 mm.
ht
pyri by
Vo
co lksw
by
♦ Perform corrosion protection measures at interfaces and holes
cted agen
Prote AG.
of shortened pipes.
1.3 Assembly overview - canopy frame for

dropside and double cab
Assembly overview - canopy frame (cab height) for double cab
⇒ page 114 .
1. Assembly of convertible roof frame and canopy 113

1 - Front right cross strut

2 - Front upper strut section
❑ Connect to front left
-10- and front right -1-
cross struts and bolt to‐ AG. Volkswagen AG d
gether. agen oes
olksw not
V y gu
db ara
3 - Pipe rests orise nte
th eo
❑ Bolt together
s au front upper ra
c
strut section
s
-2- and rear
ce
le
upper strut section -5-

un
pt
an
d
itte
y li
4 - Rear right cross strut
erm
ab
ility
ot p
5 - Rear upper strut section
wit
is n
h re
6 - Countersunk head bolt
ole,
spec
M6×30
t to the co
7 - M6 speed nut
8 - Rear left cross strut
rrectne
9 - Rubber buffer
❑ Push into the hole in the
ss
rear left -8- and rear
o
cial p
f
right -4- bow
inform
mer
10 - Front left cross strut atio

m
11 - Rubber buffer
o
n
c
i
or
n thi
❑ Press into existing holes

te
sd
a
of front cross strut on left

iv
o
pr
-10- and right -1-

um
r
fo
en
ng
t.
yi
12 - M8 hexagon nut
Co
Cop py
t. rig
gh
13 - M8×22 hexagon bolt
ht
pyri by
Vo
o
by c lksw
14 - Strut
cted agen
Prote AG.
❑ Bolted to front left -10-
and front right -1- cross
strut
1.4 Assembly overview - canopy frame (cab

height) for double cab
Assembly overview - canopy frame for dropside and double cab
⇒ page 113 .
114 Rep. gr.61 - Convertible roof, hardtop, canopy

AG. Volkswagen AG d
agen oes
1 - Front right cross strut olksw not
y V gu
d b ara
2 - Front upper strut section rise nte
tho eo
u ra
❑ Connect to front left ss a c
-18- and front right -1-
ce
le
un
pt
cross struts and bolt to‐
an
d
itte
gether.
y li
rm
ab
pe
ility
3 - Pipe rests
ot
wit
, is n
❑ a = 2094 mm
h re
hole
spec
4 - Centre right cross strut
es, in part or in w
t to the co
5 - Centre upper cross strut
section
❑ Connect to centre left
rrectness of i
-17- and centre right -4-
bows and bolt together
l purpos
6 - Right support pipe
nform
ercia
❑ Is bolted to centre right

bow -4- and rear bow
m
a
upper part -12-
com
tion in
r
te o
7 - M6×45 hexagon bolt
thi
s
iva
do
8 - B6 spring lock washer
r
rp
cum
fo
en
g
9 - M6 hexagon nut
n
t.
yi Co
Cop py
10 - Ladder rest assembly
t. rig
gh ht
yri by
❑ Is supplied as replace‐ cop Vo
by lksw
cted
ment part subdivided in‐
agen
Prote AG.
to ladder support, rub‐
ber strap and buckle for
rubber strap
❑ Only for German Post
Office vehicles
11 - Spacer tube
12 - Rear upper strut section
13 - Countersunk head bolt M6×30
14 - Speed nut
15 - Left support pipe
❑ Bolted to centre left cross strut -17- and rear upper cross strut section -12-.
16 - Rubber buffer
❑ Push into the holes in the centre left bow -17- and centre right bow -4-
17 - Centre left cross strut
18 - Front left cross strut
19 - Rubber buffer
❑ Press into the holes in the front left -18- and right -1- bows
20 - M8 hexagon nut
21 - M8×22 hexagon bolts
22 - Strut
❑ Is bolted to front left -18- and front right -1- bows

1.5 Assembling convertible roof frame and

cover
– Place frame (four mechanics required) onto the load platform.
– Position bow -1- into the corners of the load platform so that
the outer edge of the foot -2- is in the centre of the floor frame
-arrow-.
– Mark holes (9 mm ∅) -3- and drill.
– Deburr holes in drop side flange -4-.
Note n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
ed ra
Areas at which paintwork or was damaged should be repaired, and ntee
is
corrosion protection smeasures should be carried out as neces‐
th or
au ac
sary. s
ce
le
un
pt
an
d
itte
y li
– Loosely screw canopy frame to load area floor.
erm
ab
ility
ot p
1- M8×40 hexagon bolt
wit
is n
h re
2- Washer A8,4
ole,
spec
3- M8 hexagon nut
t to the co
4- Protector plate
5- Self-tapping screw ( -B3- .5 x 9.5)
rrectnes
Note
s o
cial p
f inform
Both rear cross strut feet must be covered with foot deflector plate
mer
-4- for reasons of safety.

atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
– Secure front left and right cross struts to drop side with secur‐ gh ht
yri by
ing bracket -1-, hexagon bolt ( -M8- × 22) -2- and hexagon nut cop Vo
by lksw
-M8- -3-.
cted agen
Prote AG.
– Remove bolt -4- on left and right.

– Fit canopy on convertible roof frame and secure.
116 Rep. gr.61 - Convertible roof, hardtop, canopy

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Secure canopy stay -1- on front left and right with hexagon bolt
l purpos
( -M6- × 26) -2- and washer ( -B6- .5 × 21 × 2) -3-.

– Mark, drill and deburr holes (∅ 4.1 mm) -4- for water deflector
nform
ercia
plate -5- at front left and right.

m
♦ Lower hole a = 15 mm, b = 18 mm

a
com
tion in
♦ Water deflector plate serves as a template for centre and up‐

r
te o
thi
per hole -5-.

s
iva
do
r
rp
– Touch up paint damage.

um
fo
en
ng
t.
yi Co
Cop py
t. rig
Note opyri
gh by
Vo
ht
by c lksw
cted
Areas at which paintwork was damaged should be repaired, and corrosion protection measures should be
agen
Prote AG.
carried out as necessary.
– Secure front right and front left water deflector plates -5- with
pop rivets - N 900 978.01- .

63 – Bumpers
1 Bumper, front
1.1 Tools
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
1.2 Assembly overviews
ility
ot p
wit
, is n
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hole
spec
1.2.1 Assembly overview ► 12.95
es, in part or in w
t to the co
Assembly overview - long front end 01.96 ► ⇒ page 119
Assembly overview - short front end 01.96 ► ⇒ page 120
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
118 Rep. gr.63 - Bumpers

AG. Volkswagen AG d
1 - Cover agen oes
olksw not
byV gu
ara
2 - Bolt rised
nte
ho eo
❑ Qty. 2 aut ra
c
ss
ce
e
nl
pt
du
an
3 - Bumper, front
itte
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erm
ab
❑ Removing:
ility
❑ drive through/pull out ot p
wit
, is n
pins -4- and pull bumper
h re
hole
parallel out of the guides
spec
-5-.
es, in part or in w
t to the co
❑ Installing:
❑ push bumper parallel
onto the guides -5- and
rrectness of i
locate by driving in pins
l purpos
-4- flush.
4 - Pin
nf
ercia
o
5 - Guide
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.2.2 Assembly overview - long front end 01.96 ►

Assembly overview ► 12.95 ⇒ page 118
1. Bumper, front 119

Assembly overview - short front end 01.96 ► ⇒ page 120
1 - Cover
❑ Material: PP/EPDM
❑ When dismantling, first‐
ly remove the radiator
grille with trim frame
⇒ page 166 .
❑ Removing:
-3- on left and right.
❑ Pull off cover parallel
from guide sections in
forwards direction.
❑ Installing:
❑ Note centre attachment
-arrow-.
2 - Bolt ksw
age es n
y Vol ot g
❑ Qty. 4 ed
b ua
ran
ris tee
❑ Specified torque:aut6 Nm
ho
or
ac
ss
3 - Bolt
ce
e
nl
pt
du
❑ Qty. 2
an
itte
❑ Specified torque: 1.2 y li

erm
ab
Nm ility
ot p
wit
, is n
4 - Impact absorber h re
hole
spec
❑ When removing, the
es, in part or in w
right half of the impact

t to the co
absorber must be re‐

leased first and then the
left half
rrectness of i
5 - Guide
l purpos
❑ To remove/install bump‐
er, pull out or push in
nf
ercia
parallel to guides at left

or
and right.
m
m
atio
m
6 - Spreader rivet
o
n in
or c
thi
e
7 - Hexagon bolt
t
sd
iva
o
r
❑ Qty. 4
rp
cu
o
m
f
en
ng
❑ Specified torque: 1.5 Nm yi

t.
Co
op py
8 - Bracket for bumper
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.2.3 Assembly overview - short front end 01.96 ►


Assembly overview - long front end 01.96 ► ⇒ page 119
1 - Cover
❑ Removing:
❑ Prise out covers -9-, re‐
move bolts -10- and
bolts -8- on left and right.
❑ Pull cover off parallel
forwards out of the
guides -3-. AG. Volkswagen AG d
agen oes
ksw
2 - Bracket for bumper by
Vol not
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ara
ed
is nte
3 - Guide hor eo
aut ra
❑ To remove and install, ss c
pull out/push in cover
ce
e
nl
pt
du
-1- parallel to guide ele‐
an
itte
y li
ments (left and right).
erm
ab
ility
ot p
4 - Spreader rivet
wit
, is n
h re
5 - Pop rivet
hole
spec
6 - Bracket for bumper
es, in part or in w
t to the co
7 - Guide
8 - Bolt
rrectness of i
❑ Qty. 2
l purpos

Nm
nform
ercia
9 - Cover
m
❑ Qty. 2
at
om
ion
c
10 - Hexagon head and wash‐
in t
or
his
e
er combination bolt
at
do
riv
❑ Qty. 2
p
cum
for
en
g

n
t.
yi Co
Nm t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Bumper, front 121

2 Bumper, rear
2.1 Tools
AG. Volkswagen AG d
agen oes
olksw not
V gu
by
♦ Torque wrench rise-
d V.A.G 1332- ara
nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
2.2 Assembly overviews

l purpos
nf
ercia

orm
m
atio
m
Assembly overview 01.96 ► ⇒ page 124

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
d by
V
Transporter
gu
ar 1991 ➤
ris General body repairs, exterior - Editionan08.2017
e
tee
ho
aut or
ac
ss
1 - Bumper, rear
ce
e
nl
pt
du
an
2 - Cover
itte
y li
erm
ab
3 - Screw with washer
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
5 - Pin
❑ Spare part consists of
rrectness of i
-5- and -6-.
6 - Fastener l purpos
❑ Spare part consists of
nf
ercia
-5- and -6-.
orm
m
7 - Bracket
atio
om
n in
c
8 - Hexagon head and washer

or
thi
e
combination bolt
t
sd
iva
o
r
❑ Specified torque: 110

rp
cu
o
m
Nm
f
en
ng
t.
yi Co
op
9 - Pin
C py
t. rig
gh ht
yri by
10 - Guide
op Vo
by c lksw
cted agen
❑ To remove/install bump‐ Prote AG.
er, pull out or push in
parallel to guides on left
and right.
11 - Sealing disc
2. Bumper, rear 123

2.2.2 Assembly overview 01.96 ►

1 - Cover
❑ Removing:
bolts -8- on left and right.
❑ Pull rear cover out of
side guides -6- com‐ agen AG. Volkswagen AG do
plete with carriersV-3-. olks
w es n
ot g
by ua
❑ Remove bolts ir se -9- and
d ran
tee
pull coverauoff carrier with
tho
or
ac
bracketsss -3-.
ce
le
❑ Installing:
un
pt
an
d
itte
❑ Note centre attachment
y li
erm
ab
-arrow-.
ility
ot p
wit
2 - Impact absorber
is n
h re
ole,
❑ When removing, the
spec
right half of the impact
absorber must be re‐
t to the co
leased first and then the
left half
rrectne
3 - Carrier with bracket
4 - Grommet
ss o
cial p
5 - Fastener
f inform
mer
6 - Guide
atio
m
❑ To remove and install,

o
n
c
pull out/push in cover

i
or
n thi
e
-1- parallel to guide ele‐

t
sd
va
ments (left and right).

i
o
pr
cum
r
fo

en
ng
t.
yi Co
op
❑ Specified torque: 95 Nm C py
t. rig
gh ht
yri by
8 - Bolt -T25- cop Vo
by lksw
cted agen
❑ Qty. 2 Prote AG.
9 - Bolt -T30-
2.3 Towing bracket 08.90 ►
2.3.1 Installation instructions
Note
♦ Depending on manufacturer, slight differences are possible

when referring to assembly overview.
♦ Information on electrics can be found under ⇒ Towing mode
current flow diagram workshop manual .

General
AG. Vobody
lkswagrepairs,
enA exterior - Edition 08.2017
n G do
wage es n
Volks ot g
by ua
ed ran
WARNING oris tee
th or
au ac
ss
The towing bracket is a safety component and must only be
ce
le
un
installed by specialist personnel.
pt
an
d
itte
y li
All modifications to and conversions on the towing bracket are
erm
ab
prohibited, they lead to the expiry of General Type Approval.
ility
ot p
wit
is n
Refer to manufacturer's assembly instructions for tightening
h re
torques for other towing brackets. ole,
spec
Underbody protection (if fitted) in area of towing bracket con‐
t to the co
tact surfaces must be removed.
Corrosion protection measures must be carried out on bare
rrectne
metal body areas.
Adherence to the standard, approved fastening points is re‐
ss
quired.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
1 - Towing bracket
iv
o
pr
cum
r
❑ Display of towing brack‐

fo
en
ng
et depending on manu‐
t.
yi Co
op
facturer C py
ht. rig
rig ht
❑ A towing bracket with py by
co Vo
rigid ball hitch is shown.
by lksw
cted agen
Prote AG.
❑ Installation is identical
for a towing bracket with
removable ball hitch.
❑ The removable ball
hitch is stored in a sep‐
arate container in the
luggage compartment.
2 - Bolt
❑ Qty. 3 on each side
❑ Towing bracket -
07.07.17- (made by PE‐
KA) Transporter/bus
08.90 ► specified tor‐
que: 105 Nm
❑ Towing bracket - 707
092 101- (made by
Votex) for bus/Trans‐
porter 09.90 ► high-
loader dropside and
four-wheel drive speci‐
fied torque: 95 Nm
❑ Towing bracket - 707
092 101 A- (made by
Votex) for bus/Trans‐
porter 09.90 ► low-load‐
er dropside specified
torque: 100 Nm
2. Bumper, rear 125

64 – Glazing
1 Flush bonded windows
1.1 Tools
Special tools and workshop

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
♦ Removal kit for flush bonded windows - V.A.G 1474 A-

ate
do
priv
♦ Suction lifter - V.A.G 1344-

um
for
en
ng
t.
♦ Cutting tool - V.A.G 1351-
yi Co
Cop py
t. rig
♦ Windscreen removal kit - V.A.G 1755-
gh ht
pyri by
Vo
co lksw
by
♦ Hand-cartridge gun - V.A.G 1628- cted agen
Prote AG.
♦ Cartridge heating unit - V.A.G 1939-
126 Rep. gr.64 - Glazing

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
♦ Electric cutter - V.A.G 1561 A-

wit
is n
h re
ole,
♦ Blade - V.A.G 1561/2-

spec
♦ Blade - V.A.G 1561/8-

t to the co
♦ Blade - V.A.G 1561/10-

rrectne
♦ Blade - V.A.G 1561/19-

♦ Double cartridge gun - VAS 5237-
ss o
1.2 Materials
cial p
f inform
mer
♦ 2-pack glass adhe‐ DA 004 600 A2

atio
m
sive
o
n
c
i
or
n thi
e
♦ 1-pack glass adhe‐ DH 009 100 03

t
sd
va
sive
i
o
pr
cum
r
fo
en
ng
♦ Activator D 181 801 A1

t.
yi Co
Cop py
t. rig
gh
♦ Glass and paint pri‐ D 009 200 02
ht
pyri by
Vo
o
mer
c by lksw
cted agen
Prote AG.
♦ Cleaning solution D 009 401 04
1. Flush bonded windows 127

♦ Primer applicator D 009 500 25
♦ Adhesive remover D 002 000 10
♦ Cutting cord 357 853 999 A
♦ Mixing nozzle D 000 000 000
Note
Observe instructions for use on the information sheet provided by

the manufacturer.
AG. Volkswagen AG d
agen oes
olksw not
Use double cartridge gun - VAS 5237- to apply 2-pack
d byV adhesives. gu
ara
ise nte
r
Heat 1K glass adhesive, according to manufacturer's
ut
ho instructions, eo
ra
using cartridge heater - V.A.G 1939- and
s apply using hand-car‐
s a c
tridge gun - V.A.G 1628- .
ce
e
nl
pt
du
an
Small cartridge, 110 ml, only for sealing and/or when a 400 ml
itte
y li
erm
double cartridge alone is not sufficient.
ab
ility
ot p
Minimum curing period ⇒ page 138 .
wit
, is n
h re
1.3 Assembly overview - flush bonded windows
hole
spec
es, in part or in w
t to the co
1 - Windscreen
❑ Assembly overview
rrectness of i
⇒ page 131
l purpos

nf
ercia
o
2 - Front side panel window/
rm
m
sliding door
atio
om
❑ Assembly overview n in
or c
⇒ page 133
thi
te
sd
iva

o
r
rp
cu
o

f
en
ng
t.
yi Co
op
3 - Rear side panel window C py
ht. rig
rig ht
❑ Assembly overview py by
co Vo
⇒ page 133
by lksw
cted agen
Prote AG.
4 - Rear wing door window
⇒ page 133
5 - Rear lid window
⇒ page 133
6 - Cab backwall window
⇒ page 133

7 - Side panel window/double cab
❑ Assembly overview ⇒ page 133
1.4 Spacings for flush bonded windows
1.4.1 Windscreen
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
♦ a = 3… 4 mm all around
o
cial p
f inform
♦ b = 1… 2 mm all around
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
129
by c lksw
cted
1. Flush bonded windows
agen
Prote AG.
1.4.2 Side window and rear window
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
130
op Vo
by c lksw
Rep. gr.64 - Glazing Prote
cted AG.
agen
1.4.3 Rear wing door window AG. Volkswagen AG d

agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ c = 7… 8 mm
1.5 Windscreen
1.5.1 Repair
Note
Before renewing windscreen, explore possibilities of repairing

damage to glass. ⇒ General Information; Body Repairs, General
Body Repairs ; Working process - windscreen repair

1 - Windscreen
❑ Re-sealing ⇒ page 139
❑ Remove and install inte‐
rior mirror ⇒ General
Rep. gr. 68 ; Interior mir‐
ror
❑ Bonding retaining plate
for interior mirror ⇒
interior; Rep. gr. 68 ; In‐
terior mirror; Bonding
retaining plate for interi‐
or mirror
2 - PUR adhesive sealant
❑ Bead cross section:
width = 8 mm; height =
13 mm AG. Volkswagen AG d
agen oes
olksw not
❑ Minimum curing d b period
y V gu
ara
⇒ page 138 ri.se nte
ho e t or
au ac
3 - Windscreen
ss surround
ce
e
❑ One-piece - destroyed
nl
pt
du
an
during removal
itte
y li
erm
ab
❑ Mount on window be‐

ility
ot p
fore applying adhesive

wit
, is n
bead
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.6 Assembly overview - side window and rear window
1 - Side window/rear window agen

AG. Volkswagen AG d
oes
olksw not
❑ Removing: d by V gu
ara
ise nte
❑ Destroys side window thor eo
⇒ page 133 ss au ra
c
❑ Destroys rear window
ce
le
un
pt
⇒ page 135
an
d
itte
y li
erm
ab
ility
❑ Minimum curing period ot p
wit
is n
⇒ page 138 .
h re
ole,
❑ Re-sealing ⇒ page 139
spec
2 - PUR adhesive sealant
t to the co
❑ Bead cross section:
width = 8 mm; height =
rrectne
13 mm
❑ Minimum curing period
s
⇒ page 138 .
s o
cial p
f
3 - Windscreen surround
inform
mer
❑ Removing:
atio
m
❑ Cover window flange at

o
n
c
bottom with textile-rein‐
i
or
n thi
e
forced adhesive tape.

t
sd
iva
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❑ Cut open window frame

p
cum
r
fo
and pull off window us‐
en
ng
t.
yi
ing long-nose pliers.
Co
Cop py
t. rig
❑ Mount on window be‐ yri
gh by
ht
fore applying adhesive cop Vo
by lksw
bead
cted agen
Prote AG.
❑ A repair profile is availa‐
ble for subsequent re‐
pairs, see item -4-.
❑ If a window is replaced
then always use a
standard seal
4 - Frame (repair profile)
❑ Yard goods (cut to length)
❑ Use, e.g. for paintwork repairs without removing window.
❑ Refer to replacement parts programme in Kassel for part numbers.
1.7 Removing windscreen, undamaged

side window and undamaged rear win‐
dow
WARNING
When removing windscreen, ensure without fail that protective

goggles and leather gloves are worn.

Note
The reel -V.A.G 1654- can also be used to remove a windscreen.
– To remove windscreen, unbolt windscreen wipers and pull off

windscreen aerial connection.
– Remove interior mirror ⇒ General body repairs, interior; Rep.
gr. 68 ; Interior mirror
– To remove rear window, pull off rear window heater connec‐
tion.
– Pull window frame completely off window.
– Mask off window cut-out with textile reinforced adhesive tape.
– Push awl - V.A.G 1474 A- through sealing bead from inside of
vehicle. agen
AG. Volkswagen AG d
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ed ran
ris tee
Note tho or
au ac
ss
Use the awl to puncture the windscreen in the area of the lower
ce
e
nl
pt
du
radii on the left or right.
an
itte
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erm
ab
ility
– Thread cutting cord - 357 853 999 A- into awl and pull towards
ot p
the inside through the adhesive material.
wit
, is n
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hole
spec
es, in part or in w
Note
t to the co
♦ Two mechanics are required to cut out the window.
rrectness of i
♦ The prescribed method for cutting out a window must be ad‐
hered to without fail.
l purpos
♦ Do not cut out the window with sawing motions as this will
cause considerable heat generation in the wire, causing it to
nf
ercia
snap. The wire can also break if it is kinked or looped.

orm
m
atio
om
– Secure cutting cord - 357 853 999 A- to awl - V.A.G 1474 A-

n in
or c
-1- using thread ends (inside vehicle).

thi
te
sd
iva
– Secure cutting cord - 357 853 999 A- to pull handle - V.A.G

o
r
rp
cu
o
1351/1- -2- using thread ends (outside vehicle).

m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Insert awl - V.A.G 1474 A- -1- into the adhesive sealing com‐
pound and hold in direction -arrow A-.
– Pull cutting cord - 357 853 999 A- through evenly in direction
-arrow B- as far as the stopping point -3- using pull handle -
V.A.G 1351/1- -2-.
– Pull cutting cord - 357 853 999 A- with awl - V.A.G 1474 A-
-1- approx. 100… 150 mm inwards, insert awl - V.A.G 1474 A-
-1- back in adhesive sealant and hold. Continue cutting until
next stop.
– Cut out window all around.
1.8 Removing irreparableswside

agen window and
AG. Volkswagen AG d
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WARNING ss c
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nl
pt
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♦ When working with the electric cutter, mask off the window
an
itte
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cut-out with textile reinforced adhesive tape.
erm
ab
ility
ot p
♦ Always wear safety goggles and leather gloves.
wit
, is n
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hole
spec
– Protect body and interior from glass splinters.
es, in part or in w
– Pull off window frame completely. t to the co
– Remove pieces of glass up to adhesive sealing material.

rrectness of i
l purpos
nf
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m
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thi
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– Cut off adhesive sealing compound -1- (with remaining glass)

o
m
f
en
ng
with electric cutter - V.A.G 1561 A- and knife blade - V.A.G

t.
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op
1561/9- (with stop roller). C py
t. rig
gh ht
yri
– Cut through adhesive sealant in corner areas with a suitable
p by
o Vo
by c lksw
knife if necessary. Prote
cted AG.
agen

1.9 Installing windscreen, side window and

rear window
Preparing old undamaged window for glazing ⇒ page 136 .
Preparing new window for glazing ⇒ page 136 .
Preparing body flange for glazing ⇒ page 137 .
Installation instructions ⇒ page 137 .
Minimum curing period ⇒ page 138 .
1.10 Preparing old undamaged window for

glazing
AG. Volkswagen AG d
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Note rised
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♦ If installing an undamaged window, cut back residual adhesivess c
ce
le
seal to 1…2 mm, being careful not to damage primer and ce‐
un
pt
ramic coating using, electric cutter - V.A.G 1561 A- and knife
an
d
itte
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blade, U-shape - V.A.G 1561/3- shortly before installing win‐
rm
ab
dow.
pe
ility
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, is n
♦ Remaining material serves as adhesion base for newly ap‐
h re
plied adhesive sealing compound.
hole
spec
es, in part or in w
t to the co
WARNING rrectness of i
Do not prime adhesion surface, do not activate and do not treat

with cleaning solution. Keep bonding surface free of dirt and
l purpos
grease.
nform
ercia
Exception: if bonding is not performed immediately after cutting

m
back, the remaining residual material must be activated with ac‐

com
tion in
tivator - D 181 801 A1- .

r
te o
thi
– Mount window surround on window.

s
iva
do
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cum
fo
en
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1.11 Preparing new window for glazing

n
t.
yi Co
Cop py
ht. rig
– Clean window edge all around to width of 30 mm with cleaning rig ht
py by
solution - D 009 401 04- and rub dry with lint-free cloth. co Vo
by lksw
cted agen
Prote AG.
– Mount window frame -1- on window.
WARNING
Ceramic coating on window is not primer! The glass must be

primed before the adhesive sealing material is applied. Use
only primer - D 009 200 02- !
– Using applicator - D 009 200 02- -3-, apply primer - D 009 500
25- -2- evenly in one pass.
♦ Allow to air dry for approx. 10 minutes.

1.12 Preparing body flange and door window

flange for glazing
– Cut back remaining material on body flange using electric cut‐
ter - V.A.G 1561 A- and knife blade, U-shape - V.A.G 1561/3-
to 1 … 2 mm just before re-bonding.
Note
Remaining material serves as adhesion base for newly applied

adhesive sealing compound. Keep adhesive surface clean and
free of grease. olks
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WARNING ss
au ra
c
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un
pt
Do not permit activator to come into contact with the paintwork,
an
d
itte
or the paint surface will be damaged.
y li
erm
ab
ility
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wit
is n
Exception:
h re
ole,
spec
If bonding is not performed immediately after cutting back, the
remaining residual material must be activated with activator - D
t to the co
181 801 A1- .
♦ If the window flange has been repaired or partially renewed,
rrectne
the area concerned must be cleaned and primed again after
painting.
ss o
1.13 Fitting instructions
cial p
f inform
mer
– Apply adhesive material to primed area -1- or to trimmed seal‐
atio
m
ant bead, holding double cartridge gun - VAS 5237- at right

o
n
c
angle to window.
i
or
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te
sd
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WARNING cum
r
fo
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ng
t.
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Window must be installed within 10 minutes, or adhesive prop‐ Cop py
t. rig
erties of glass adhesive will be impaired. gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
♦ With help of two suction cups - V.A.G 1344- , install glass pane
in window aperture, align to centre and press in onto the spac‐
ing lip.
♦ Secure windscreen during curing period with window adjusters
- 443 845 631 A- .
♦ Replace any stickers (e.g. for airbag).
♦ Use adhesive tape to secure rear window in position while
curing.
♦ Secure side window glass in position with adhesive tape dur‐
ing curing process.
♦ If the adhesive bead is too thick and the adhesive expands
onto the area of the window heater the excess adhesive must
be removed.

1.14 Minimum curing period
WARNING
. Volkswagen AG
Special standards must be adhered to when replacing wage bonded
n AG does
windows. One of these standards is, for example, Volks that a freshly not
gu
by ara
bonded windscreen must comply with the ris safety requirements,
ed nte
even in an accident, following the minimum
au
tho
prescribed curing eo
ra
period. ss c
ce
le
un
pt
an
d
itte
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The minimum curing period for the 2-pack adhesive - DA 004 600
rm
ab
A2- is 3 hours for all windows.
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ility
ot
wit
, is n
The minimum curing period for the 1-pack adhesive - DH 009 100
h re
03- is 16 hours for all windows.
hole
spec
es, in part or in w
Minimum curing period is the time from bonding the window until
t to the co
vehicle may be used. During this time, the vehicle must stand on
a level surface at room temperature (at least 15°C).
rrectness of i
WARNING
l purpos
Vehicle is safe to use only after curing period is completed.
nform
mercia
a
1.15 Touching up paint damage
com
tion in
r
te o
thi
• If paintwork is damaged, paint structure must be restored ac‐
s
iva
cording to specifications in ⇒ “Paint” manual.
do
r
rp
cum
fo
1.16 Cleaning in the event of dirt caused by en

ng
t.
yi Co
op
adhesive sealing material
C py
t. rig
gh ht
pyri by
Vo
o
– Use of the adhesive remover - D 002 000 10- as a cleaning
c by lksw
cted agen
agent is recommended. Safety precautions must be observe Prote AG.
for all work procedures.
WARNING
When cleaning freshly installed glass from the inside in the ve‐
hicle, do not press glass outwards.
– First clean painted surface as much as possible using a dry

cloth. Remove residue with adhesive remover - D 002 000 10- .
– Cleaning plastic trim: allow adhesive sealant to cure (approx.
one hour) and then peel off.
1.17 Installing frame (repair profile) (side and

rear windows)
Repair profile is available for side windows and rear windows.
The standard frame was removed for paintwork repairs.
– Spray cleaning solution - D 009 401 04- (functions as lubricant)
onto outer edge of window.

– Starting from bottom, position repair profile in centre of window

-arrow A- and attach to window cut-out -arrow B-.
– Cut repair profile approx. 4 mm longer.
– Apply cyanoacrylate adhesive - AMV 195 KD1 01- to cut of

repair profile -arrow-.
AG. Volkswagen AG d
agen oes
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un
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ility
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– Attach end of repair profile -arrow A- as well.
is n
h re
ole,
– Push together ends of seal -arrow B- and press together for a
spec
few seconds.
t to the co
– Then attach rest of seal completely to window cut-out.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
1.18 Re-sealing windows

thi
te
sd
iva
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pr
– Perform a water test.

um
r
fo
en
ng
t.
yi
– Visual check from inside
Co
Cop py
ht. rig
– Blow unsealed area dry and clean. rig ht
py by
co Vo
by lksw
– Windscreen can only be re-sealed in area of A-pillars and on cted agen
Prote AG.
roof from inside.
– Rear windows and side windows can be re-sealed all around
from inside.
– Allow adhesive sealant material to flash off.

Note
The small cartridge - DH 009 100 03- (110 ml) is recommended

for touch-up work.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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nl
pt
du
an
itte
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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orm
m
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om
n in
or c
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sd
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Cop py
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rig ht
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by lksw
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Prote AG.

2 Windows having threaded connec‐

tions
2.1 Tools
2.2 Assembly overview - side window with intake trim

n AG. Volkswagen A age G do
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b
ed ran
Note horis tee
t or
au ac
ss
To remove the side window, the mouldings and parts of the luggage compartment ventilation must first be
ce
e
nl
removed.
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Windows having threaded connections 141

1 - Hexagon nut
❑ Qty. 13
Nm
2 - Side window with intake trim
❑ With studs for bolting to
vehicle
⇒ page 142
AG. Volkswagen AG d
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d by ara
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nl
pt
du
an
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erm
ab
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
2.3 Removing and installing side window

l purpos
with intake trim

nf
ercia
Removing:
orm
m
atio
– Depending on equipment variant and need, remove seats or

om
n in
bench seats and remove loading/bed board ⇒ General body

or c
repairs; Rep. gr. 70 ; Removing loading/bed board ⇒ General

thi
te
sd
a
body repairs; Rep. gr. 72 ; Passenger compartment seats

iv
o
r
rp
cu
o
– Remove roof pillar trim ⇒ General body repairs; Rep. gr. 70 ;

f
en
ng
t.
yi
Pillars and side panel trims; Removing and installing rear roof
Co
op py
pillar trim t. C rig
gh ht
pyri by
– Removing B-pillar upper trim on sliding door side ⇒ General
o Vo
by c lksw
cted
body repairs; Rep. gr. 70 ; Pillar and side panel trim; Removing
agen
Prote AG.
and installing B-pillar upper trim on sliding door side
– Remove C-pillar trim on sliding door side ⇒ General body re‐
pairs; Rep. gr. 70 ; Pillar and side panel trim; Removing and
installing C-pillar trim on sliding door side
– Remove D-pillar trim ⇒ General body repairs; Rep. gr. 70 ;
Pillar and side panel trim; Removing D-pillar trim (vehicles with
passenger compartment ventilation or air conditioning)
– Removing rear side panel moulded trim on sliding door side
(vehicles with passenger compartment ventilation or air con‐
ditioning): ⇒ General body repairs; Rep. gr. 70 ; Pillar and

side panel trim; Removing and installing rear side panel moul‐
ded trim on sliding door side (vehicles with passenger com‐
partment ventilation or air conditioning)
– Separate connector -1-.
– Lift air duct -2- and swivel out of air intake -3- -arrow-.
– Pull air duct -2- downwards out of moulded headliner.
– Remove bolts -1- and remove intake duct -2-.
AG. Volkswagen AG d
agen oes
olksw not
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ed
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ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Unscrew hexagon nuts -1- and remove side window from ve‐
l purpos
hicle.
Installing:
nf
ercia
Install in reverse order.

rm
m
atio
m
Maintain specified torque of hexagon nuts (2.2 Nm)

o
n in
or c
thi
• You must ensure that air guide seals are seated correctly.
te
sd
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Cop py
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rig ht
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Prote AG.
2. Windows having threaded connections 143

Transporter 1991 ➤ agen
AG. Volkswagen AG d
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General body repairs, exterior - Edition
by
V 08.2017
ol not
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3 Sliding window
ac
ss
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un
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Note
ab
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ility
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wit
♦ Sliding windows are available in different versions depending , is n
h re
on the equipment level of the vehicle. However, with the ex‐
hole
spec
ception of the partition wall sliding window, their fundamental
es, in part or in w
design is the same.
t to the co
♦ Sliding windows in side wall, sliding door or side wing door are
bolted on. The partition wall sliding window is secured by
rrectness of i
means of a profile section.
l purpos
♦ If the fixed window is damaged, the complete sliding window

must be renewed.
nform
ercia
♦ The following descriptions are based on the sliding window of

the sliding door. Apply the same instructions accordingly for
m
a
work on the other sliding windows.
com
tion in
r
te o
thi
3.1 Tools
s
iva
do
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cum
fo
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ng
t.
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op
♦ Torque wrench - V.A.G 1783- C py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
3.2 Assembly overviews - sliding window

(sliding door)

Note
To remove sliding window (sliding door), it is first necessary to remove sliding door moulded trims. ⇒ General
body repair overview, interior; Rep. gr. 70 ; Door trim

AG. Volkswagen AG d
1 - Frame agen oes
olksw not
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❑ With studs for bolting to d by ara
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sliding door ut
hor eo
a ra
s c
2 - Seal s
ce
e
nl
pt
❑ Bonded with frame
du
an
itte
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3 - Fixed window
erm
ab
ility
ot p
❑ If broken, renew com‐
wit
, is n
plete sliding window
h re
hole
spec
4 - Hexagon flange nut
es, in part or in w
❑ 1.5 Nm
t to the co
❑ Cap nut on vehicles
without moulding
rrectness of i
5 - Ledge
l purpos
❑ Bonded with adhesive

sealant (black) - D 476
KD2 M2-
nform
ercia

m
at
om
io
6 - Sealing frame
n
c
in t
or
❑ Shorten new sealing
his
ate
do
riv
frame if necessary.
p
cum
or

f
en
ng
t.
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op
KD2 M2-
C py
t. rig
gh ht
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p by
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by c lksw
cted agen
7 - Handle
Prote AG.
8 - Bolt
9 - Spring
10 - Pin
11 - Support
12 - Carrier
13 - Detent rail
❑ Shorten new detent rail if necessary
❑ Bonded with adhesive sealant (black) - D 476 KD2 M2-
14 - Moving window
15 - Guide
❑ For left and right
❑ Use only as a set.
16 - Guide profile
❑ Shorten new guide channels if necessary
17 - Seal
18 - Cover plate
19 - Clamping bar
3.2.2 Assembly overview 06.94 ►

3. Sliding window 145

Note
1 - Frame
sliding door
2 - Seal
3 - Fixed window
❑ If broken, renew com‐ agen
AG. Volkswagen AG d
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4 - Hexagon flange nut orise nte
eo
h
ut
❑ Specified torque: 1.5 ss a ra
c
Nm
ce
le
un
pt
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d
itte
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without moulding
erm
ab
ility
ot p
5 - Ledge
wit
is n
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ole,
spec
KD2 M2-
t to the co
6 - Sealing frame
rrectne
frame if necessary.
s
s o
cial p
f in
KD2 M2-
form
mer
atio
om
n
c
7 - Handle
i
or
n thi
te
❑ Bonded on
sd
iva
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cum
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8 - Detent rail
fo
en
ng
t.
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❑ Shorten new detent rail
Co
op py
if necessary
. C rig
ht ht
rig by
py
❑ Bonded with adhesive co Vo
by lksw
sealant (black) - D 476 KD2 M2-
cted agen
Prote AG.

9 - Moving window
10 - Guide
❑ Use only in pairs
11 - Guide profile
12 - Clamping bar

3.2.3 Assembly overview ► 05.94 - with fly screen

Note
1 - Frame
sliding door
2 - Seal
3 - Fixed window
4 - Hexagon nut
Nm
without moulding
5 - Ledge
KD2 M2-
6 - Fly screen
❑ Clipped in from inside lkswage es n
o ot g
byV ua
d
7 - Sealing frame o
ir se
ran
tee
th or
❑ Shorten new sealing au ac
ss
frame if necessary.
ce
le
un
pt

an
d
itte

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rm
ab
KD2 M2-
pe
ility
ot

wit
, is n
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8 - Handle
hole
spec
es, in part or in w
9 - Bolt
t to the co
10 - Spring
11 - Pin
rrectness of i
12 - Support
l purpos
13 - Carrier
nform
ercia
14 - Detent rail
m
❑ Shorten new detent rail if necessary

com
tion in

r
te o
thi

s
iva
do
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cum
15 - Moving window
fo
en
ng
t.
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Co
Cop py
t. rig
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pyri by
Vo
co lksw
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cted agen
Prote AG.

16 - Guide
17 - Guide profile
18 - Seal
19 - Cover plate
AG. Volkswagen AG d
agen oes
20 - Clamping bar Volksw not
gu
by ara
d
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3.2.4 Assembly overview 06.94 ► - with fly screen ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
Note
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
1 - Frame
l purpos
sliding door
2 - Seal
nform
ercia

m
a
com
tio
3 - Fixed window
n in
r
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thi
s
iva
do
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cum
fo
4 - Hexagon nut
en
ng
t.
yi Co
op
❑ Specified torque: 1.5 C py
t. rig
Nm
gh ht
pyri by
Vo
co
by lksw
cted agen
without moulding
Prote AG.
5 - Ledge
KD2 M2-
6 - Fly screen
❑ Clipped in from inside
7 - Sealing frame
frame if necessary.
KD2 M2-
8 - Handle
❑ Bonded on
9 - Detent rail
❑ Shorten new detent rail
if necessary

10 - Moving window
11 - Guide
12 - Guide profile
13 - Clamping bar
3.3 Renewing detent rail
3.3.1 Removing detent rail

– Depending on equipment variant and need, remove seats or
bench seats ⇒ General body repair overview, interior; Rep.
gr. 70 ; Pillars and side trim ⇒ General body repair overview,
interior; Rep. gr. 72 ; Passenger
agen
compartment
AG. Volkswagen Aseats
G do
w es n
olks o
– Unscrew hexagon flangeed b nuts -1- or cap nuts -2- and remove
yV t gu
ara
sliding window from
ho
ri vehicle.
s nte
e t or
au ac
– Open sliding window
ss fully.
ce
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pt
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spec
t to the co
– Unscrew bolt -1- from handle -2- and remove spring -3-.
rrectne
– Remove handle.
ss o
– Unscrew revealed hexagon bolts, then remove retainer and

cial p
f i
cover plate from sliding window.

nform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Detach detent rail -1- from frame -arrow- by tapping or levering

and remove.
3.3.2 Installing detent rail

– Clean groove in frame of sliding window.
– Shorten new detent rail to the required size, if necessary
Note
The paint should be built up again and corrosion protection meas‐

ures should be performed, if necessary.
– Clean detent rail with cleaning solution - D 009 401 04- and
dry with a lint-free cloth.
. Volkswagen AG
gen AG
– Insert detent rail with adhesive
Vol
kswsealant (black) - D 476esKD2
a do
not
M2- and fix in place withedtextile reinforced adhesive tape during
by gu
ara
curing period. horis nte
e t or
au ac
• Curing time is about
ss 8 hours.
ce
e
nl
pt
– Mount locking element, check function of sliding window and

du
an
itte
install in vehicle.
y li
erm
ab
ility
3.4 Renewing sealing frame

ot p
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, is n
h re
hole
spec
3.4.1 Removing sealing frame

es, in part or in w
t to the co
– Depending on equipment variant, remove necessary trims and

seats or bench seats. ⇒ General body repair overview, inte‐
rrectness of i
rior; Rep. gr. 70 ; Pillars and side panel trims ⇒ General body
repair overview, interior; Rep. gr. 72 ; Passenger compart‐
l purpos
ment seats
– Removing detent rail ⇒ page 149
nf
ercia
or
– Lever out sealing frame -1- from frame of sliding window or

m
m
atio
pull out with aid of pliers.

om
n in
or c
thi
te
sd
iva
o
r
rp
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o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
3.4.2 Installing sealing frame

– Clean groove in frame of sliding window.

– Shorten new sealing frame to required size as necessary.
Note

ures performed as necessary.
– Clean sealing frame with cleaning solution - D 009 401 04- and
– Insert sealing frame with adhesive sealant (black) - D 476 KD2
M2- and allow to cure under tension.
• Curing time is about 8 hours
3.5 Renewing ledge
3.5.1 Removing ledge

ment seats
n AG. Volkswagen A ge G do
swa es n
– Removing
by sealing frame ⇒ page 150
Vol
k ot g
ua
d ran
ir se
– Detachtho ledge -1- from fixed window -2- by knocking tee
or e.g. with
a
ss
alocally
u
manufactured wooden or plastic wedge. ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
3.5.2 Installing ledge

l purpos
– Clean fixed window with cleaning solution D 009 401 04 and

nform
ercia

m
– Insert new ledge with adhesive sealant (black) - D 476 KD2

at
om
io
M2- .
n
c
in t
or
his
e
• Curing time is about 8 hours.

at
do
priv
3.6 Renewing moving window

um
for
en
ng
t.
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Cop py
t. rig
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3.6.1 Removing moving window
pyri by
Vo
co lksw
by
cted agen
Prote
AG.

ment seats
– Removing sealing frame ⇒ page 150

– Spread frame of sliding window -arrows- and cut out moving

window -1-.
3.6.2 Installing moving window

– Clean adhesion surface of the sliding window and clamping
bar with cleaning solution - D 009 401 04- and dry a with lint-
free cloth.
– Bond clamping bar to moving window with adhesive sealant
(black) - D 476 KD2 M2- .
• Curing time is about 8 hours.
– Adapt guide profiles, shorten if necessary.
Note

– Bond guide elements in guide profiles.

– Clean guide profiles and adhesion surfaces of the sliding win‐
dow with cleaning solution - D 009 401 04- and dry a with lint-
free cloth.
– Bond guide channels to the sliding window with n Aadhesive seal‐
G. Volkswagen AG
ing compound (black) - D 476 KD2 M2- lks. wage does
not
Vo gu
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• Curing time is about 8 hours ed nte
oris eo
th
au ra
– Install sealing frame ⇒ install detent rail page
ss 150 and c
⇒ page 150 and re-seal fixed window with adhesive sealing
ce
e
nl
pt
compound (black) - D 476 KD2 M2- .

du
an
itte
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erm
3.7 Retrofitting sliding window

ab
ility
ot p
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, is n
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hole
Note
spec
es, in part or in w
t to the co
♦ Sliding windows of various types can be installed in the sliding

door, in the side wall of the Transporter or the double cab and
in the side wing door of the double cab instead of the flush-
rrectness of i
bonded window.
l purpos
♦ The description is for one side only from which the essential
points can be derived from the other side as a mirror image.
nform
ercia
♦ Depending on equipment variant, remove necessary trims and

m
at
om
ion

c
in t
or
ment seats
his
ate
do
priv
cum
or
– Removing flush-bonded window ⇒ page 133

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
152
co Vo
by lksw
Rep. gr.64 - Glazing cted agen
Prote AG.
– Cut away remaining adhesive sealing material.

Transfer respective measurements to window frame of vehicle
and make centre punch marks:
1- Sliding door ⇒ page 153
2- Side panel ⇒ page 154
3- Side wing door ⇒ page 156
4- Side panel (double cab) ⇒ page 157
– Drill holes (∅ 7.5 mm)wand
agen deburr.
AG. Volkswagen AG d
oe
ks s no
Vol t
– If needed, rework
ed holes with a round file so that siderawindow
by gu
a
will fit. horis nte
e t or
au ac
ss
ce
e
nl
Note
pt
du
an
itte
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erm
ab
ility
ot p
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, is n
h re
hole
– After completing the painting/corrosion protection measures,
spec
insert sliding window and secure with screws.
es, in part or in w
t to the co
3.7.1 Right sliding door
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.

(left is mirror image)
Note
Front outer edge and upper edge of sliding door are used as ref‐
erence points. Arrow points in direction of travel.
Dimensions:
a = 55 mm
b = 510 mm
c = 140 mm
d = 337 mm
e = 237 mm
f = 260 mm
g = 80 mm
h = 1060 mm
i = 82 mm
k = 1146 mm
l = 267 mm
m = 350 mm
3.7.2 Left side panel
AG. Volkswagen AG d
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olksw not
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d b ara
rise nte
tho eo
au ra
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ce
le
un
pt
an
d
itte
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erm
ab
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ot p
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is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
(right is mirror image)

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Note Cop py
ht. rig
rig ht
py by
Front edge of B-pillar and roof edge are used as reference points.
co Vo
by lksw
cted
Arrow points in direction of travel.
agen
Prote AG.
Dimensions:
a = 52 mm
b = 510 mm
c = 135 mm
d = 340 mm
e = 310 mm
f = 107 mm
g = 1118 mm
h = 122 mm
i = 335 mm
k = 350 mm

3.7.3 Right wing door, double cab
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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h
aut ra
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nl
pt
du
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itte
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ab
ility
ot p
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hole
spec
(left is mirror image)
es, in part or in w
t to the co
Note
rrectness of i
Rear outer edge and upper edge of sliding door are used as ref‐
erence points. Arrow points in direction of travel.
l purpos
Dimensions:
nform
ercia
a =
m
52 mm
at
om
io
b = 510 mm
n
c
in t
or
his
e
c = 138 mm
at
do
riv
d = 340 mm
p
cum
for
en
g
e = 265 mm
n
t.
yi Co
op
f = 85 mm
C py
t. rig
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yri
g = 560 mm p by
o Vo
by c lksw
cted
h = 565 mm
agen
Prote AG.
i = 267 mm

k = 200 mm
3.7.4 Double cab left side wall
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
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nl
pt
du
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erm
ab
ility
ot p
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, is n
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hole
spec
(right is mirror image)

es, in part or in w
t to the co
Note
rrectness of i
Front edge of B-pillar and roof edge are used as reference points.
l purpos
Arrow points in direction of travel.
Dimensions:
nform
mercia
a = 55 mm
at
om
ion
b = 510 mm
c
in t
or
his
e
c = 143 mm
at
do
riv
d = 340 mm
p
cum
for
en
g
e = 310 mm
n
t.
yi Co
op
f = 110 mm
C py
ht. rig
rig ht
g = 615 mm
py by
co Vo
by lksw
cted
h = 122 mm
agen
Prote AG.

. Volkswagen AG
gen AG does
swa
Transporter y V1991 ➤
olk not
gu
b ara
General ris body repairs, exterior - Edition 08.2017
ed
nte
ho eo
aut ra
s c
i s = 620 mm
ce
e
nl
pt
k = 335 mm
du
an
itte
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l = 200 mm
erm
ab
ility
ot p
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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m
f
en
ng
t.
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.

en AG. Vexterior
olkswa gen- AEdition
G 08.2017
ag does
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y Vol gu
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ed
66 – Exterior equipment ris nte
tho eo
au ra
c
ss
ce
e
nl
pt
1 Exterior mirror
du
an
itte
y li
erm
ab
ility
ot p
wit
1.1 Tool
, is n
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hole
spec
es, in part or in w
t to the co
♦ Removal lever - 80 - 200-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
♦ Torque wrench - V.A.G 1331- t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.2 Exterior mirror
1. Exterior mirror 159

1 - Mirror housing
⇒ page 160
2 - Bolts
❑ Qty. 3
3 - Mirror glass
⇒ page 160
WARNING
Always wear safety
gloves when removing
and installing mirror
glass.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
1.2.2 Removing and installing rear view mirror

ility
ot p
wit
, is n
Removing:
h re
hole
spec
Remove bolts -2- and remove exterior rear view mirror -1-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.
160 Rep. gr.66 - Exterior equipment

AG. Volkswagen AGGeneral body repairs, exterior - Edition 08.2017
agen does
olksw not
Installing: yV gu
db ara
rise nte
o eo
Installation is carried
aut out in the reverse sequence of removal.
h
ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing and installing mirror glass

• Rear view mirror -1- removed
– First lever off mirror glass -3- at bottom, then at top with re‐
moval lever - 80 - 200- .
– Place mirror housing -1- down on a work surface. Clip mirror
glass -3- in vertically and centrally using even pressure.
1. Exterior mirror 161

2 Trim
2.1 Tools
♦ Front end hook - 3370-
2.2 Assembly overview - radiator grille ► 12.95
1 - Radiator grille
2 - Seal
❑ Self-adhesive
3 - Trim
❑ Removing: Remove ra‐
diator grille agen
AG. Volkswagen AG d
oes
⇒ page 163 and unclip olksw not
V gu
by
from the rear. rised ara
nte
ho eo
4 - Company emblem aut ra
ss c
❑ Clipped
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2.3 Removing radiator grille ► 08.94
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv

p
cum
for
en
g
– Tip radiator grille -2- forward -arrow- and unhook from the
n
t.
yi Co
op
mounting holes. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Trim 163
2.4 Radiator grille with trim frame 09.94 ► n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
d ran
ir se
2.4.1 Assembly overview o tee
th or
au ac
ss
ce
le
un
pt
1 - Radiator grille with trim
an
d
itte
y li
frame
erm
ab
ility
ot p
⇒ page 164
wit
is n
h re
2 - Bolt ole,
spec
3 - T-pin
t to the co
4 - Securing clip
5 - Spray nozzle
rrectne
6 - Front-end hook - 3370-
ss o
cial p
f
Note
inform
mer
The radiator grille with trim frame
atio
m
must first be removed before the ra‐

o
n
c
i
diator can be folded forward.
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.4.2 Removing and installing

Removing:
– Pull out spray jets -5- (if fitted) on the left and right side.
– Hook front-end hook - 3370- -6- into trim frame (under head‐
light).

agenGeneral body Arepairs,
oes exterior - Edition 08.2017
AG. Volkswagen G d
olksw not
y V gu
– Pull radiator grille with trim frame -1- ed b the T-pins -4- on left
off
ara
ris nte
and right sides. ut
ho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Installing:
Damaged securing clips -4- must be replaced before installing the
radiator grille with trim frame -1-.
– Clip-in radiator grille with trim frame -1- simultaneously on the
right and left sides.
2. Trim 165
2.5 Removing and installing radiator grille 01.96 ►
1 - Upper radiator grille

❑ Radiator grille: material
ASA
❑ Upper radiator grille is
clipped to trim frame.
❑ Removing radiator grille
with trim frame:
pull off upper radiator
grille with trim frame.
2 - Bolt
3 - Upper trim frame
❑ Remove together with
upper radiator grille
❑ Painted in body-colour.
4 - Rubber mounting
5 - Bolt
olkswagen AG
en AG. V
6 - Release lever ksw
ag does
not
y Vol gu
❑ Is required to release
ise
db ara
nte
the corners. uthor eo
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7 - Lower trim frame
s
ce
le
un
pt
❑ Remove together with

an
d
itte
lower radiator grille

y li
rm
ab
❑ Painted in body-colour.
pe
ility
ot
wit
, is n
8 - Lower radiator grille

h re
hole
❑ Radiator grille: material

spec
ASA
es, in part or in w
t to the co
❑ Lower radiator grille is

clipped and screwed to
trim frame.
rrectness of i
❑ Removing radiator grille

l purpos
with trim frame:

❑ Remove turn signals and side mountings with release levers -6-. Remove combi-screws -5-. Pull off
radiator grille with trim frame forwards.
nform
ercia
9 - Company emblem
m
a
com
tio
❑ Clipped into radiator grille

n in
r
te o
thi
s
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do
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fo
en
ng
t.
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Prote AG.

3 Cover strip for number plate lighting
3.1 Tools
wage
♦ Torque wrench - V.A.G 1783- olks es n
ot g
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d ran
ir se tee
tho
u or
a ac
ss
ce
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un
pt
an
d
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ab
ility
ot p
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is n
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ole,
spec
t to the co
3.2 Removing and installing for tailgate
rrectne
Removing:
ss o
– Remove tailgate moulded trim or remove tailgate trim. ⇒ Gen‐
cial p
f in
eral body repairs, interior; Rep. gr. 70 ; Tailgate
form
mer
atio
om
n
c
i
or
n thi
te
sd
a
Note
iv
o
pr
cum
r
fo
en
ng
Bolts -2- are at the same time used for securing the tailgate lock
t.
yi Co
mechanism ⇒ page 24 . Cop py
t. rig
gh ht
pyri by
Vo
o
– Unscrew bolts -3- and unclip cover strip -1-.
c by lksw
cted agen
Prote AG.
Installing:
3.3 For removing and installing rear wing

door
Removing:
Installing:
3. Cover strip for number plate lighting 167

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2017 Volkswagen AG, Wolfsburg D4B807A09D2

55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.6 Installing and adjusting bonnet 01.96 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.7 Removing and installing bonnet catch cable ► 12.95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.7 Removing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.3 Removing and installing door ► 12.95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.6 Removing and installing door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

2.7 Removing and installing lock operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

2.8 Adjusting lock operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

2.9 Removing and installing interior door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2.10 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

3 Side wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

3.4 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

1 Sunroof with glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

1.2 Assembly overview - sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

1.3 Removing sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

1.4 Installing sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

1.5 Adjusting height of sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1.8 Checking electric drive (0 position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3.7 Checking parallel running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

61 - Convertible roof, hardtop, canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

1.5 Assembling convertible roof frame and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1 Bumper, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

3.2 Removing and installing for tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

3.3 For removing and installing rear wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

1.2 Lock carrier - service position (vehicles

1.2.1 Assembly overview

1.2.2 Moving to service position

– Remove radiator grille ⇒ page 162 .

– Remove turn signals ⇒ Electrical system; Rep. gr. 94 ; Front

-arrows- for forwards on special tool adapter - T10235- .

– Remove bolts at connection for lock carrier to middle part of

– Pull middle part of lock carrier -5- forwards.

2 Rep. gr.50 - Body - front

1.2.3 Moving from service position n AG. Volkswagen AG do

– Fold radiator and lock carrier out forwards -arrow-.

1.3.1 Vehicles ► 09.90

– Unscrew bolts -1- on left and right.

1.3.2 Vehicles 10.91►

1.3.3 Continuation all vehiclesagen AG. Volkswagen AG do

– Lift radiator with workshop crane.

4 Rep. gr.50 - Body - front

– Unbolt cross member -1- with headlight -2-.

Tightening torque ► 08.93

Bolt -3- and -4- = 8 Nm

Tightening torque 09.93 ►

– Unclip electrical leads from cross member/headlight bracket.

❑ With small washer

6 Rep. gr.50 - Body - front

2.2.1 Removing and installing front wing

– Remove front bumper ⇒ page 118 .

turn signal (short front end) 12.95 ⇒ Electrical system; Rep.

gr. 94 ; Front turn signal (long front end) 01.96