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D3E8020B3C2 Body Exterior
D3E8020B3C2 Body Exterior
Repair Manual
Golf 2009 ➤
Body Exterior
Edition 06.2011
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Repair Group
50 - Body Front
55 - Hood, Lids
57 - Front Doors, Central Locking System
58 - Rear Doors
60 - Sunroof
63 - Bumpers
64 - Glass, Window Regulators
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.
Contents
50 - Body Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Bulkhead Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Bulkhead Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Fender Insulation Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Front Fender Overview . . . . . . . . . n. A. G. ..V.ol.ks. w. a.g.en. A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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1.5 Lock Carrier Overview . . . V. o.lk.s.wa. . . . . . . . . . . . . . . . .oe. s.n.ot. . . . . . . . . . . . . . . . . . . . . . . . . 5
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1.6 Lock Carrier Service Position,
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1.7 Noise Insulation Overview
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1.8 Plenum ChambersBulkhead
s Overview . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . 9
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1.11 Underbody Impact Guard Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1.13 Underbody Trim Panel, Rear Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Charge Air Cooler Pressure Hose and Coupling, Disconnecting and Connecting . . . . . . . . 16
3.2 Front Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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3.3 Fender Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4 Lock Carrier with Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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3.5 Plenum Chamber Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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55 - Hood, Lids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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1.3 Hood Locking Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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1.4 Hood Release, Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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1.5 Hood, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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1.6 Hood Latch, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Contents i
Golf 2009 ➤
Body Exterior - Edition 06.2011
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3.10 Rear Lid Adjusting Buffer . . . . . . . . . .ol.ks.w.a.g . . . . . . . . . . . . . . d. o.e.s n. o.t . . . . . . . . . . . . . . . . . 60
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3.11 Rear Lid Gas Strut . . . . . . . . . . s. e.d .by. . . . . . . . . . . . . . . . . . . . . . . . . . .u.ar.an. . . . . . . . . . . . . . 60
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3.12 Rear Lid Hinge . . . . . . . . . . u.th. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ee.o.r . . . . . . . . . .
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3.13 Rear Lid Lock . . . . . . . . . .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . 64
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3.14 Rear Lid Release Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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3.15 Rear Lid Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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3.16 Rear Lid Striker Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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3.17 Rear Lid Unlocking Element with Rearview Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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3.18 Fuel Filler Door Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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3.19 Fuel Filler Door Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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57 - Front Doors, Central Locking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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1.6 Front Door Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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1.8 Insulation Overview, 4-Door Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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1.10 Remote Vehicle Keys, Adaptation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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95
3.1 Cap without Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.2 Cover, 2-Door Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.3 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.4 Door Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.5 Door Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.6 Inner Door Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.7 Inner Window Shaft Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.8 Lock Cylinder Cover Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.9 Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.10 Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.11 Outer Window Recess Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.12 Outer Door Seal, 2-Door Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.13 Outer Door Seal, 4-Door Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.14 Remote Foldable Vehicle Key Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.15 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.16 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
ii Contents
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Body Exterior - Edition 06.2011
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60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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1.1 Installation Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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1.5 Parallel Movement, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.6 Sunroof Glass Panel Drive Zero Position, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.7 Sunroof with Glass Panel Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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1.8 Sunroof with Glass Panel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.9 Sunroof Glass Panel Height, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ss o 168
1.10 Water Drain Hoses, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.1 Front Bumper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.2 Rear Bumper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.1 Front Bumper Overviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.2 Front Bumper Overviews, GTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.3 Front Bumper Overviews, Golf R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.4 Front Bumper Carrier Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.5 Side Guide Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
2.6 Rear Bumper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.7 Rear Bumper Overviews, GTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.8 Rear Bumper Overviews, Golf R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2.9 Rear Bumper Cover Substructure Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.10 Rear Bumper Carrier Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.11 Trailer Hitch Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Contents iii
Golf 2009 ➤
Body Exterior - Edition 06.2011
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2.10 Special Component Overview, Golf R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
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4.1 Anti-Rodent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
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4.2 Drip Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
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4.4 Exterior Rearview Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
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4.6 Rear Wheel Housing Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
4.7 Radiator Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
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4.8 Roof Edge Spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
4.9 Roof Edge Spoiler Retaining Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
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4.13 Sill Panel Extension, GTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
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4.14 Sill Panel Extension, Golf R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
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vi Contents
Golf 2009 ➤
Body Exterior - Edition 06.2011
50 – Body Front
1 Description and Operation
⇒ “1.1 Bulkhead Materials”, page 1
⇒ “1.2 Bulkhead Overview”, page 2
⇒ “1.3 Fender Insulation Component Locations”, page 3
⇒ “1.4 Front Fender Overview”, page 3
⇒ “1.5 Lock Carrier Overview”, page 5
⇒ “1.6 Lock Carrier Service Position, Setting”, page 6
⇒ “1.7 Noise Insulation Overview”, page 8
⇒ “1.8 Plenum Chamber Bulkhead Overview”, page 9
⇒ “1.9 Plenum Chamber Cover Overview”, page 10
⇒ “1.10 Tunnel Bridge Overview”, page 11
⇒ “1.11 Underbody Impact Guard Overview”, page 12
⇒ “1.12 Underbody Trim Panel, Center Overview”, page 13
⇒ “1.13 Underbody Trim Panel, Rear Overview”, page 14
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mer
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Prote AG.
Note
The bulkhead -1- is bolted and also bonded in with PUR adhesive sealing material -3-.
1 - Bulkhead
❑ Removing:
– Cut through the bead of
adhesive -3- after re‐ agen
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2 - Body Flange ut
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3 - PUR Adhesive Sealant s
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❑ DH 009 100 03
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❑ Bead diameter: width =
erm
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8 mm, height = 10 mm
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spec
⇒ “1.3 Minimum Curing
urposes, in part or in wh
t to the co
4 - Bolt
❑ Tightening specifica‐
rrectne
tion: 25 Nm
❑ Quantity: 10
ss o
cial p
f inform
mer
atio
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n
c
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Cop py
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❑ Installed in front of the
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fillet plate on the fender.
hole
spec
3 - Filler Piece
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t to the co
❑ Glued to the A-pillar with
butyl rubber
❑ The filler piece remains
rrectness of i
attached to the A-pillar
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4 - Butyl Rubber
m
a
Remove the protective film just
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before installing.
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Cop py
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Vo
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by
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Prote AG.
Note
Note
1 - Fender
2 - Bolt
❑ Tightening specifica‐
tion: 6 Nm
❑ A-pillar, quantity: 1
❑ Sill panel, quantity: 2
❑ Wheel housing, quanti‐
ty: 2
❑ Fender brace, quantity:
2
❑ Fender connecting
piece, quantity: 2
3 - Foam Piece
❑ Inserted between the
fender and the upper
front longitudinal mem‐
ber, refer to
⇒ “1.3 Fender Insulation
Component Locations”,
page 3 .
4 - Fillet Plate Insulation
❑ Installed in front of the
fillet plate on the fender,
refer to
⇒ “1.3 Fender Insulation
Component Locations”,
page 3 .
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❑ Spacer -AKL 381 035 olksw not
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6 - Filler Piece s au ra
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❑ Glued to the A-pillar with
ce
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un
pt
butyl rubber.
an
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❑ The filler piece remains attached to the A-pillar when removing the fender. Refer to
erm
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⇒ “1.3 Fender Insulation Component Locations”, page 3 .
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7 - Fender Brace
h re
ole,
8 - Bolt
t to the co
❑ Tightening specification: 6 Nm
❑ Quantity: 2
rrectne
9 - Nut
s
❑ Tightening specification: 6 Nm
s o
cial p
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om
n
c
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fo
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t.
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Cop py
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Vo
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Prote AG.
ce
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un
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6 - Bolt
an
d
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❑ Tightening specifica‐
erm
ab
tion: 8 Nm
ility
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ole,
7 - Angle Bracket
spec
urposes, in part or in wh
❑ Left
t to the co
8 - Retaining Plate
❑ For the left headlamp
rrectne
9 - Guide Piece
s
❑ Left
s o
cial p
f in
10 - Bolt
form
mer
❑ Tightening specifica‐
atio
m
tion: 5 Nm
o
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11 - Air Duct
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12 - Cross Member
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❑ Tightening specification: 60 Nm Prote AG.
18 - Guide Piece
❑ Right
19 - Retaining Plate
❑ For the right headlamp
AG. Volkswagen AG d
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un
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erm
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ole,
spec
urposes, in part or in wh
t to the co
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mer
atio
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n
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sd
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– Remove the upper and lower screw on the headlamp bolts. Cop py
Refer to ⇒ Electrical Equipment; Rep. Gr. 94 ; Removal and
t. rig
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Installation . op Vo
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– Disconnect the release cable from the lock carrier. Refer to
AG.
AG. Volkswagen AG d
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spec
urposes, in part or in wh
t to the co
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mer
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n
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Cop py
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1.7 Noise Insulation Overview
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Note
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spec
Slight changes may have to be made to removal and installation procedures, depending upon engine installed
es, in part or in w
t to the co
in vehicle.
rrectness of i
1 - Noise Insulation
l purpos
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❑ Removing:
m
at
– Remove the screws
om
io
-2, 3 and 4-.
n
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2 - Bolt
a
do
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cum
❑ Tightening specifica‐
for
en
g
tion: 2 Nm
n
t.
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❑ 4 pieces per side
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3 - Bolt
co Vo
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❑ Tightening specifica‐
Prote AG.
tion: 6 Nm
❑ Quantity: 3
4 - Bolt
❑ Tightening specifica‐
tion: 2 Nm
❑ Quantity: 1
2 - Nut
❑ Tightening specifica‐
tion: 8 Nm
❑ Quantity: 1
AG. Volkswagen AG d
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3 - Seal Volksw
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When installing the plenum cham‐
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ber bulkhead, make sure seal is
an
d
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4 - Plenum Chamber
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5 - Bolt
hole
spec
❑ Tightening specifica‐
es, in part or in w
t to the co
tion: 8 Nm
❑ Quantity: 1
rrectness of i
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a
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tion in
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Cop py
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Prote AG.
AG. Volkswagen AG d
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Prote AG.
Note
2 - Nut
❑ Tightening specifica‐
tion: 20 Nm
❑ Quantity: 4 per tunnel
bridge
3 - Rear Tunnel Bridge
❑ Removing:
– Remove the nuts -2- (2
on each side).
AG. Volkswagen AG d
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tion in
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Cop py
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Prote AG.
Note
Slight changes may have to be made to removal and installation procedures, depending upon engine installed
in vehicle.
ce
❑ The shape may be dif‐
le
un
pt
ferent depending on the
an
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engine versions
erm
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ility
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8 - Bolt
ole,
spec
❑ Tightening specifica‐
urposes, in part or in wh
tion: 70 Nm
t to the co
❑ Quantity: 2
9 - Bolt
rrectne
❑ Tightening specification: 2 Nm
s
❑ Quantity: 8
s o
cial p
f i
10 - Bolt
nform
mer
❑ Tightening specification: 20 Nm
atio
m
❑ Quantity: 6
o
n
c
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Prote AG.
Note
1 - Underbody Cover
❑ Removing:
– Remove the hex nuts
-2-.
2 - Hex Nut
❑ Tightening specifica‐
tion: 1.5 Nm
❑ Quantity: 8
3 - Bolt
❑ Tightening specifica‐
tion: 2 Nm
❑ Quantity: 2
4 - Cover
❑ Locked in the under‐
body
5 - Cover
❑ Removing:
– Remove screws -3-.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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nl
pt
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ate
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Cop py
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Prote
13
AG.
1. Description and Operation
Golf 2009 ➤
Body Exterior - Edition 06.2011
Note
The arrow in the lower left corner of the image shows the direction of travel.
1 - Hex Nut
❑ Tightening specifica‐
tion: 20 Nm
❑ Quantity: 1
2 - Bolt
❑ Tightening specifica‐
tion: 20 Nm
❑ Quantity: 1
3 - Angle Bracket
4 - Expanding Nut
❑ Quantity: 1
5 - Lock Washer
❑ Tightening specifica‐ agen
AG. Volkswagen AG d
tion: 1.5 Nm Volksw
oes
not
gu
by ara
❑ Quantity: 1 rise
d
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6 - Underbody Cover ss au ra
c
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7 - Bolt
un
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an
d
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❑ Tightening specifica‐
y li
rm
ab
tion: 2 Nm
pe
ility
❑ Quantity: 2
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spec
es, in part or in w
t to the co
rrectness of i
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Cop py
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Prote AG.
2 Specifications
Tightening Specifications
Component Tightening Specifications
Fender bolts 6 Nm
Fender nuts 6 Nm
Fender brace bolts 6 Nm
AG. Volkswagen AG d
agen oes
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urposes, in part or in wh
t to the co
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mer
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Cop py
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by lksw
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Prote AG.
2. Specifications 15
Golf 2009 ➤
Body Exterior - Edition 06.2011
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or
– Attach the pressure hose -3- into the coupling
aut
h -1- in eo
ra
-direction of arrow-. ss c
ce
e
nl
pt
– Push the clip -2- all the way through.
du
an
itte
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erm
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ility
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Note
wit
, is n
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hole
♦ If the clip cannot be pushed all the way through, this mean the
spec
t to the co
Removing
orm
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n in
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Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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au ra
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un
pt
an
d
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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
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nform
mercia
tio
thi
do
cum
fo
t.
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⇒ “4.5 Front Wheel Housing Liner”, page 311 .
Co
Cop py
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– Remove the bumper cover bracket. Refer to yri
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⇒ “2.5 Side Guide Overview”, page 195 .
c by lksw
cted agen
Prote AG.
– Remove the foam piece between the fender and the longitu‐
dinal member. Refer to item 3 ⇒ Item 3 (page 4) .
– Remove the fillet plate insulation from the wheel housing. Re‐
fer to item 4 ⇒ Item 4 (page 4) .
– Remove the bolts -2-.
– Remove the nut -3-.
– Remove the fender -1-.
Installation
Note
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urposes, in part or in wh
t to the co
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mer
atio
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n
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Cop py
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Removing and installing the left fender brace is described here.
erm
ab
Removing and installing the right fender brace is identical.
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Removing
ole,
spec
urposes, in part or in wh
t to the co
⇒ “4.1 Front Bumper Cover”, page 211 .
– Remove bolts-2- and remove fender brace -1-.
rrectne
Installation
ss o
cial p
f inform
mer
atio
om
n
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– Align the fender brace and the fender to the hood and bumper. Cop py
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Refer to ⇒ Body Repair; Rep. Gr. 00 ; Specification .
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Tightening Specifications
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Prote AG.
Note
♦ The lock carrier is a safety-relevant component and for this reason it may not be serviced.
♦ If damaged, replace the lock carrier.
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erm
ab
ility
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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
his
do
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en
ng
t.
– Drain the coolant and disconnect the coolant lines. Refer to ⇒
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Engine Mechanical; Rep. Gr. 19 ; Removal and Installation . t. C rig
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– Disconnect the lines on the condenser. Refer to ⇒ Heating,
co Vo
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cted
Ventilation and Air Conditioning; Rep. Gr. 87 ; Removal and
agen
Prote AG.
Installation .
– Together with a second technician, remove the -T 10093- on
the left and right longitudinal members -2- and remove the lock
carrier with attachments -1-.
WARNING
Note
♦ Never hang the condenser and the hydraulic fluid cooler on the lines.
♦ Never bend the condenser lines or the hydraulic fluid lines.
Installation
G. Volkswagen AG d
– Reset the lock carrier. Refer to ⇒ page 7a.gen A
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Install in reverse order of removal.ised b ara
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• Make sure that all plug- and a hose connections are corrected
u ra
c
ss
installed when re-assembling.
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nl
pt
du
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itte
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tween the fenders. Refer to ⇒ Body Repair; Rep. Gr. 00 ;
erm
ab
Specifications .
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hole
spec
Removing
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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or c
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Cop py
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co lksw
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Prote AG.
– Remove the seal -2- from the plenum chamber cover -1-.
Caution
– Lift off the plenum chamber cover -1- along the edge of the
windshield by hand.
– Starting at the edge of the windshield -6- and working up, pull
the plenum chamber cover -1- out of the retainer -5-.
– Remove the plenum chamber cover -1- from the vehicle.
Installation
Caution
AG. Volkswagen AG d
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es, in part or in w
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Prote AG.
AG. Volkswagen AG d
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Note
ss c
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an
♦ New windshields have a insert in the binding profile. Remove the insert before installing the plenum chamber
d
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cover.
erm
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♦ Press the plenum chamber cover lightly by hand into the binding profile. Never force hit it or use a tool to
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install it.
h re
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spec
urposes, in part or in wh
tainer -5-.
s
– Press the seal -2- onto the plenum chamber cover -1-.
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Prote
cted AG.
agen 3. Removal and Installation
Golf 2009 ➤
Body Exterior - Edition 06.2011
4 Special Tools
Cartridge Heater -V.A.G 1939-
Cartridge Gun -V.A.G 1628-
Torque Wrench -V.A.G 1783-
Guide Rod -T 10093-
Torque Wrench -V.A.G 1331-
Torque Wrench -V.A.G 1332-
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es, in part or in w
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c
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ate
do
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by
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Prote AG.
4. Special Tools 25
Golf 2009 ➤
Body Exterior - Edition 06.2011
55 – Hood, Lids
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ility
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spec
urposes, in part or in wh
t to the co
rrectness o
cial p
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mer
atio
om
n
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Prote AG.
1 - Hood
❑ Removing and instal‐
ling, refer to
⇒ “3.1 Hood”,
page 42 .
❑ Adjusting, refer to
⇒ “1.5 Hood, Adjusting”,
AG. Volkswagen AG d
page 31 . ksw
agen oes
not
Vol
by gu
2 - Striker Pin ised ara
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3 - Center Seal s aut ra
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4 - Side Seal
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itte
5 - Adjusting Buffer
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ab
wit
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6 - Hinge
spec
urposes, in part or in wh
ling, refer to
⇒ “3.4 Hood Hinge”,
page 47 .
rrectne
❑ Adjusting, refer to
⇒ “1.5 Hood, Adjusting”,
ss
page 31 .
o
cial p
f in
7 - Hood Lock
form
mer
8 - Nut
atio
om
❑ Tightening specifica‐
c
i
or
n thi
tion: 22 Nm
te
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❑ 2 pieces per side
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9 - Spray Nozzles
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❑ Removing and instal‐ Prote
cted AG.
agen
1 - Right Seal
❑ Removing: pull it off the
hood.
❑ Installing: press the
clips into the hood.
2 - Center Seal
❑ Removing: pull it off the
hood.
❑ Installing: press the
clips into the hood.
3 - Left Seal
❑ Removing: pull it off the
hood.
❑ Installing: press the
clips into the hood.
4 - Hood
5 - Clip
❑ Check for damage be‐
fore installing and re‐
place if necessary. en AG. V
olkswagen AG
ag does
ol ksw not
6 - Clip yV gu
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❑ Check for ho damage be‐
ris nte
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s aut and re‐ ra
c
places if necessary.
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un
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an
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ab
ility
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spec
urposes, in part or in wh
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mer
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28
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Rep. Gr.55 - Hood, Lids cted agen
Prote AG.
Golf 2009 ➤
Body Exterior - Edition 06.2011
1 - Hood Lock
❑ Lid lock removal and in‐
stallation, refer to
⇒ “3.6 Hood Latch”,
page 51 .
❑ Adjusting, refer to
⇒ “1.6 Hood Latch, Ad‐
justing”, page 32 .
2 - Release
❑ From the hood lock to
the cable coupling.
❑ Clipped into the cable
coupling.
3 - Release Coupling
❑ The cable coupling is lo‐
cated above the driver
side headlamp.
❑ Disconnecting, refer to
⇒ “1.4 Hood Release,
Disconnecting”,
page 30 .
4 - Release
❑ From the cable coupling
to the actuator lever.
5 - Actuating Lever
❑ Removing and instal‐
ling, refer to
⇒ “3.7 Hood Release
Lever”, page 54 .
6 - Striker Pin . Volkswagen AG
gen AG does
❑ Removing, ol swa to
krefer not
V gu
⇒ “3.8edHood
by Striker Pin”, ara
nte
page
thoris
56 . eo
u ra
❑ ss aAdjusting, refer to c
⇒ “1.6 Hood Latch, Adjusting”, page 32 .
ce
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un
pt
an
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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
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rrectness of i
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nform
mercia
a
com
tion in
r
te o
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s
iva
do
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29
cop Vo
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Prote
cted AG.
agen 1. Description and Operation
Golf 2009 ➤
. Volkswagen AG
Body Exterior - Edition 06.2011
swa
gen AG does
k not
Vol gu
d by ara
1.4 Hood Release, Disconnecting
e nte
ris
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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t.
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Cop py
t. rig
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pyri by
Vo
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by
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Prote AG.
Note
♦ Make sure the grommets -4 and 5- are secure when installing the release cable -3-.
♦ Make sure the cable coupling is correctly connected together when installing the release cable -1-.
Note
♦ The vehicle must be standing on the ground when adjusting the hood.
♦ The left and right buffers -2- are not for adjusting. They stabilize the hood -1-.
♦ The hood is properly adjusted when there is an overall even gap dimension when closed, it is not too far
inward or outward and contours align.
♦ The hood must latch without much force into the hood lock.
♦ Do not remove the nuts, just loosen them.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
aut ra
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e
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ility
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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
nf
ercia
orm
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atio
om
n in
or c
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– Remove the hood catch -3-. Refer to co Vo
by lksw
⇒ “3.8 Hood Striker Pin”, page 56 .
cted agen
Prote AG.
– Loosen the left and right nuts -5- on the hinge -6- and then
align the hood between the fenders. Do not remove the nuts.
– Make sure that the gap dimensions are the same. Refer to
⇒ Body Repair; Rep. Gr. 00 ; Specifications .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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pt
an
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hole
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es, in part or in w
t to the co
rrectness of i
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a
com
the hood.
r
te o
thi
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cum
fo
en
ng
t.
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Prote AG.
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
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ole,
spec
urposes, in part or in wh
t to the co
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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en
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t.
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Cop py
t. rig
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pyri by
Vo
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cted agen
Prote AG.
Note
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
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u or
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nl
pt
du
an
itte
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erm
ab
ility
ot p
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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
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t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Adjust the rear lid -1- on the striker pin -5-. Refer to
⇒ “1.14 Rear Lid Striker Pin, Adjusting”, page 39 .
Note
Note
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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pr
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fo
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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.
– Loosen the clamping screw -4- far enough until it is visible in‐
side the rubber buffer.
– Now pull notched slider -3- out of the adjusting buffer -1-.
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
– Open rear lid again.
urposes, in part or in wh
t to the co
– Screw in clamping screw -1- for adjusting buffer to a depth of
dimension -a- = 20 mm.
rrectne
– Check the adjustment.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1 - Gas Strut
❑ Removing and instal‐
ling, refer to
⇒ “3.11 Rear Lid Gas
Strut”, page 60 .
❑ Venting gas, refer to
⇒ “1.11 Rear Lid Gas
Strut, Venting”,
page 38 .
2 - Clips
3 - Bolt
❑ 10 Nm
❑ Quantity: 2
4 - Angle Bracket
5 - Ball Head Pin
❑ 20 Nm and 90°
n AG. Volkswagen AG do
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un
pt
an
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itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
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fo
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t.
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Cop py
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Prote AG.
WARNING
AG. Volkswagen AG d
agen oes
lksw n
Only clamp the gas strut in area d by V-x-. Otherwise, an accident ot gu
o
ara
may occur. oris
e nte
eo
th
au ra
ss c
ce
e
– Saw into the cylindrical part of strut in the first third of the total
nl
pt
du
an
cylinder length, determined starting from the edge of the cover
itte
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on the side with the piston rod.
erm
ab
ility
ot p
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Note
hole
spec
es, in part or in w
t to the co
♦ Cover the area of the saw cut with a clean rag.
♦ Dispose of the oil and rag properly.
rrectness of i
l purpos
nf
ercia
orm
m
atio
1 - Hinge
om
n in
c
❑ Removing, refer to
or
thi
e
sd
iva
page 62 .
o
r
rp
cu
o
❑ Adjusting, refer to
f
en
ng
t.
yi
⇒ “1.8 Rear Lid Adjust‐
Co
op py
ing”, page 34 . t. C rig
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pyri by
2 - Bolt
co Vo
by lksw
cted agen
Prote
❑ Tightening specifica‐
AG.
tion: 10 Nm
❑ 2 for each hinge
3 - Washer
4 - Nut
❑ Tightening specifica‐
tion: 24 Nm
❑ Quantity: 2
5 - Rear Lid
1 - Rear Lid
❑ Removing and instal‐
ling, refer to
⇒ “3.9 Rear Lid”,
page 56 .
❑ Adjusting, refer to
⇒ “1.8 Rear Lid Adjust‐
ing”, page 34 .
2 - Rear Lid Lock
❑ Removing and instal‐
ling, refer to
⇒ “3.13 Rear Lid Lock”,
page 64 .
. Volkswagen AG
a gen AG does
3 - Release Element Vol
ksw not
gu
by ara
❑ Removing ris and instal‐
ed
nte
ling, urefer
tho to eo
ra
⇒ s“3.14
sa Rear Lid Re‐ c
lease Element”,
ce
e
nl
pt
page 65 .
du
an
itte
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erm
4 - Gas Strut
ab
ility
ot p
ling, refer to h re
⇒ “3.11 Rear Lid Gas
hole
spec
Strut”, page 60 .
es, in part or in w
t to the co
page 38 .
l purpos
5 - Hinges
❑ Removing and instal‐
ling, refer to
nform
ercia
page 62 .
at
om
ion
c
6 - Adjusting Buffer
in t
or
his
te
do
priv
en
ng
t.
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7 - Seal
Co
Cop py
t. rig
❑ Removing and installing, refer to ⇒ “3.15 Rear Lid Seal”, page 67 .
gh ht
pyri by
Vo
o
by c lksw
8 - Striker Pin Prote
cted AG.
agen
❑ Removing and installing, refer to ⇒ “3.16 Rear Lid Striker Pin”, page 70 .
❑ Adjusting, refer to ⇒ “1.14 Rear Lid Striker Pin, Adjusting”, page 39 .
Note
♦ Loosen the bolts -1- and slide the rear lid catch -2- in the over‐
sized holes -arrows a and b-.
♦ Adjust the striker pin -2- so that the rear lid lock recess with
the rotary latch engages with the center of the striker pin -2-.
Note
♦ If tank flap does not open, it can be opened by hand via the actuator -6-.
♦ The actuator -6- and inside the side panel and is accessible after removing the luggage compartment trim
panel.
pt
3 - Bolt
du
an
itte
y li
❑ Tightening specifica‐
erm
ab
tion: 1.5 Nm
ility
ot p
wit
, is n
t to the co
6 - Actuator
❑ Removing and instal‐
ling, refer to
nform
ercia
at
Actuator”, page 75 .
om
ion
c
❑ Emergency release:
in t
or
-arrow-.
um
for
en
ng
t.
yi
7 - Electrical Connection
Co
Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
2 Specifications
Tightening Specifications
Component Tightening Specifications
Hood nuts 22 Nm
Hood hinge bolts 22 Nm
Hood latch bolts 12 Nm
Hood striker pin bolts 10 Nm
Rear lid hinge bolts 10 Nm
Rear lid hinge nuts 24 Nm
AG. Volkswagen AG d
agen
Rear lid lock bolts 23 Nm Volksw oes
not
gu
by ara
Rear lid release element bolts 4 Nmris ed
nte
ho eo
Rear lid striker pin bolts 18aut Nm ra
ss c
Rear lid unlocking element with 4 Nm
ce
e
nl
pt
du
an
itte
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Fuel filler door bolt 1.5 Nm
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.
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Cop py
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by c lksw
cted agen
Prote AG.
2. Specifications 41
Golf 2009 ➤
Body Exterior - Edition 06.2011
ce
le
un
pt
an
⇒ “3.8 Hood Striker Pin”, page 56
d
itte
y li
erm
ab
⇒ “3.9 Rear Lid”, page 56
ility
ot p
wit
⇒ “3.10 Rear Lid Adjusting Buffer”, page 60
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
⇒ “3.13 Rear Lid Lock”, page 64
rrectne
⇒ “3.14 Rear Lid Release Element”, page 65
⇒ “3.15 Rear Lid Seal”, page 67
ss o
⇒ “3.16 Rear Lid Striker Pin”, page 70
cial p
f inform
⇒ “3.17 Rear Lid Unlocking Element with Rearview Camera”,
mer
atio
page 70
om
n
c
i
⇒ “3.18 Fuel Filler Door Unit”, page 72
or
n thi
te
sd
va
o
pr
cum
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fo
3.1 Hood
en
ng
t.
yi Co
Cop py
.
Removing
ht rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
Note
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
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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
cu
o
en
ng
t.
yi Co
op
– Unclip the washer fluid hose -6- from the hood -1-. C py
t. rig
gh ht
yri
– Remove the washer fluid hose -6- from the hood -1-.
p by
co Vo
by lksw
cted agen
– Remove the caps -5- from the nuts.
Prote AG.
– Loosen the left and right nuts -4- from the hinge -4- (do not
remove the nuts).
A second technician is required for the rest of the removal pro‐
cedure.
– Remove the gas-filled strut -7-, refer to
⇒ “3.2 Hood Gas Strut”, page 45 .
– Remove the nuts -4- and lift the hood -1- out of the hinges
-3-.
Installation
Note
n AG. Volkswagen AG do
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o ot g
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u or
a ac
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erm
ab
ility
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wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Install the hood -1- in reverse order of removal.
Prote AG.
Note
Route the hose -6- in a bow as illustrated. Be sure not to twist the hose.
n AG. Volkswagen AG do
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o ot g
byV ua
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tho
u or
a ac
ss
ce
e
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pt
du
an
itte
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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
nform
ercia
at
om
io
in t
or
his
e
do
priv
en
ng
t.
yi
– Remove the clips -3- completely out from the mount -2-.
Co
Cop py
t. rig
gh
– Remove the gas-filled strut -1- from the mount -arrow c-.
ht
pyri by
Vo
co lksw
by
Removing Lower Mount
cted agen
Prote AG.
WARNING
ce
e
nl
pt
du
Check the mount for damage and replace if necessary. Refer to
an
itte
y li
⇒ “3.3 Hood Gas-Filled Strut Mount”, page 47 .
erm
ab
ility
ot p
wit
Installing Lower Mount
, is n
h re
hole
spec
es, in part or in w
t to the co
– Push the gas-filled strut into the mount.
rrectness of i
– Push the clip all the way into the mount.
l purpos
Venting
– Clamp area x of the gas strut in the vise, area x = 50 mm.
nf
ercia
orm
m
atio
WARNING
om
n in
or c
thi
te
sd
a
may occur.
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
– Saw into the cylindrical part of strut in the first third of the total C py
t. rig
cylinder length, determined starting from the edge of the cover gh ht
yri by
on the side with the piston rod. cop Vo
by lksw
cted agen
Prote AG.
Note
ce
e
nl
Two small screwdrivers can be used as an alternative to using wire -3-.
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
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cu
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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.
– Slide a wire -3- into both of the lower openings -arrow a- of the
mount -1-.
– This releases both hooks -2- and the mount can be removed
from the hood -arrow b-.
Note
ce
le
un
pt
an
d
Note itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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iva
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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Vo
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by
cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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pt
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rm
ab
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ility
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hole
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es, in part or in w
t to the co
rrectness of i
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thi
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Tightening Specifications
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Component Tightening Specifications
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Hood hinge bolts 22 Nm
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Prote AG.
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– Pry the retaining clips -3- out of the hood -2-. Use -80-200- ,
urposes, in part or in wh
t to the co
f inform
mer
atio
om
n
c
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n thi
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spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
– Slide insulation -1- with mounting tabs into the elongated
om
holes.
c
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t.
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nl
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du
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ility
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es, in part or in w
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rrectness of i
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nf
ercia
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m
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– Disconnect the connector for the hood contact switch -6-.
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Note
c by lksw
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Prote AG.
– Remove the screws -4 and 5- on the lock carrier -6- and re‐
move the hood latch -1- -arrow a-.
– To unclip the mount -3- press the retaining strap on the mount
together -arrows b-.
– The retainer will then be loosened and the release cable -2-
can then be removed from the hood latch -1-.
Note
Removing and installing front hood switch on hood lock, refer to ⇒ Electrical Equipment; Rep. Gr. 96 ; Removal
and Installation .
Installation
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
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au ra
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ce
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nl
pt
du
an
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ab
ility
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hole
spec
es, in part or in w
t to the co
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nf
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n in
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t.
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t. rig
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co lksw
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Prote AG.
AG. Volkswagen AG d
agen oes
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d by ara
ise nte
or eo
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nl
pt
du
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erm
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ility
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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
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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t. rig
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pyri by
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by c lksw
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Prote AG.
– Pull the hood release lever -2- and release the hood.
– Insert a small screwdriver into gap between operating lever
-2- and clip -3-.
– Pry the clip -3- out of the lever -2- -arrow- and then remove the
lever from the bracket -1-.
Remove the lower trim on the A-pillar to work on the bracket.
Installation
AG. Volkswagen AG d
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pe
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ot
wit
, is n
h re
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
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en
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t.
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ht. rig
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Prote AG.
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pt
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ility
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is n
spec
t to the co
f inform
atio
om
Removing
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
AG. Volkswagen AG d
agen oes
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V gu
d by ara
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or eo
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un
pt
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d
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pe
ility
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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
– Remove the rear lid trim panel. Refer to ⇒ Body Interior; Rep.
Gr. 70 ; Removal and Installation .
nform
ercia
nents.
a
com
tion in
– Loosen but do not remove the bolts -3- at the left and right
r
te o
thi
hinges.
s
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cedure.
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– Remove the gas-filled strut -2-, refer to t. C rig
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⇒ “3.11 Rear Lid Gas Strut”, page 60 . yri
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– Remove the bolts -3- and the rear lid -1-.
agen
Prote AG.
Note
The central connectors -4- are on the left and right sides of the C-pillar.
Installation
Note
♦ If a new rear lid is installed then new adhesive tape must also be reapplied.
♦ If no adhesive tape is applied, rainwater from the rear lid will drip into the luggage compartment.
1 - Rear Lid
2 - Adhesive Tape
– Apply the left and right
adhesive tape
-1K6.827.972- in the in‐
dicated positions.
3 - Rear Window
AG. Volkswagen AG d
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d by ara
ise nte
or eo
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pt
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d
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is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
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Prote AG.
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an
d
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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
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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Vo
co lksw
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Prote AG.
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
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nl
pt
du
an
itte
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erm
ab
ility
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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
nf
ercia
orm
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n in
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te
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t.
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t. rig
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pyri by
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co lksw
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Prote AG.
Removing
– Turn the adjustment bumper -3- 90° to the left -arrow a- and
remove it from the side panel -2-.
Installation
– Check that the stops are in the correct positions -1- in the rear
lid -4-.
– Insert the adjusting buffer -3- into the side panel -arrow c- at
a right angle and turn it 90° to the right -arrow b-.
– Adjust the adjusting buffer -3-. Refer to
⇒ “1.9 Rear Lid Adjustment Buffer, Adjusting”, page 35 .
Note
If one gas-filled strut is removed, then the rear lid must be supported. One gas-filled strut cannot hold the rear
lid open.
WARNING
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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
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en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
Gas Strut
– Open and support rear lid.
– Insert a small screwdriver -3- under the spring clips -2-.
– Lift the spring clips -2- just far enough so it is possible to slide
them over the ball sockets.
– Remove the gas-filled strut -1- from the ball stud -4-.
Slide the spring clips -2- back on immediately after removing the
gas-filled strut.
WARNING
Note
AG. Volkswagen AG d
agen oes
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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
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
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t.
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t. rig
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pyri by
Vo
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by c lksw
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Prote AG.
– Remove the roof end strip. Refer to ⇒ Body Interior; Rep. Gr.
70 ; Removal and Installation
– Remove rear lid -5-. Refer to ⇒ “3.9 Rear Lid”, page 56 .
– Remove the nuts -4- and remove the hinge -1- and wash‐
er-3-.
Installation
AG. Volkswagen AG d
agen oes
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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
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om
n in
or c
thi
te
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t.
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t. rig
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Vo
co lksw
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Prote AG.
Note
If the rear lid does not open, use the emergency release inside
the rear lid trim panel and open it manually.
Removing
AG. Volkswagen AG d
agen oes
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ara
ed
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un
pt
an
d
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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
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove the rear lid trim panel. Refer to ⇒ Body Interior; Rep.
Gr. 70 ; Removal and Installation .
– Disconnect connector -3- from lid lock -1-.
– Remove the screws -2- and remove rear lid latch -1- from rear
lid.
Installation
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
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ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
– Position the rear lid lock -1- on the rear lid and install the
screws -2-.
– Screw -2- tightening specification: 23 Nm.
– Connect harness connector -3- to lid lock -1-.
Further installation is in reverse order of removal.
Tightening Specifications
Component Tightening Specifications
Rear lid lock bolts 23 Nm
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
co Vo
by lksw
cted agen
Prote AG.
– Remove the rear lid trim panel. Refer to ⇒ Body Interior; Rep.
Gr. 70 ; Removal and Installation .
– Disconnect harness connector -4- from unlocking element
-1-.
– Remove the bolts -3-.
– Remove the unlocking element -1- from the rear lid -2-.
Installation
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
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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
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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iva
do
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t.
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Screw -3- tightening specification: 4 Nm. t. Cop py
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Tightening Specifications pyri by
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Component Tightening Specifications
Prote AG.
Note
A n AG d G. Volkswage
agen
♦ When the seal is removed, the sealant
olkis
swspread on the inner oes
not
side of the seal and the sides areedbent
V
by up slightly. If the seal gu
ara
is being installed again, the sealing
ho
ris performance and proper nte
eo
seating are no longer guaranteed.
sa
ut ra
c
s
♦ For this reason, every completely removed seal must be re‐
ce
le
un
pt
placed with a so-called “hammer-stroke seal”.
an
d
itte
y li
rm
ab
♦ For partially removed seals, seal flanks must be pressed to‐
pe
ility
gether before installation.
ot
wit
, is n
h re
hole
Removing
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
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.
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.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
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d ran
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u or
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ss
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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
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
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.
Removing
– Remove the lock carrier cover. Refer to ⇒ Body Interior; Rep.
Gr. 70 ; Removal and Installation .
– Remove the bolts -1- and remove the catch -1-.
Installation
– Install the rear lid catch -2-.
– Striker pin, adjusting, refer to
⇒ “1.14 Rear Lid Striker Pin, Adjusting”, page 39 .
Tightening Specifications
Component Tightening Specifications
Rear lid striker pin bolts 18 Nm
n AG. Volkswagen AG do
lkswage es n
o ot g
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tho
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a ac
ss
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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
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove the rear lid trim panel. Refer to ⇒ Body Interior; Rep.
Gr. 70 ; Removal and Installation .
– Refer to ⇒ Electrical Equipment; Rep. Gr. 94 ; Removal and
Installation for the work procedures for the unlocking element
with a rearview camera.
– Disconnect the connectors -4- from unlocking element -1-.
– Remove the bolts -3-.
– Remove the unlocking element -1- from the rear lid -2-.
Installation
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au 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
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
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en
ng
t.
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Installation of unlocking element -1- is the same in reverse order.
co Vo
by lksw
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Prote AG.
Screw -3- tightening specification: 4 Nm.
– Refer to ⇒ Electrical Equipment; Rep. Gr. 94 ; Removal and
Installation for the work procedures for the unlocking element
with a rearview camera.
Tightening Specifications
Component Tightening Specifications
Rear lid unlocking element with 4 Nm
rearview camera bolts
Note
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au ra
ss c
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
nf
ercia
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om
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te
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– Remove the tank cap.
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– Remove the bolt -3-.
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Prote AG.
– Fold back the rubber grommet -2- from the tank filler neck, and
also from the filling connection for the gas system, if neces‐
sary.
– Pull the fuel tank insert -1- and water drain hose -4-
-arrow a- out of the retainers and then pivot the fuel tank insert
-1- out of the side panel -arrow b-.
Installation
AG. Volkswagen AG d
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ara
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ris nte
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aut ra
ss c
ce
e
nl
pt
du
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ility
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– Insert drain hose -4- through opening in tank flap unit and pull
h re
hole
– Guide the water drain hose -4- into the side panel.
t to the co
– Slide the tank flap unit -1- with hinge side first into side panel
-arrow a-.
rrectness of i
– Pivot the fuel tank insert all the way into the side panel
l purpos
-arrow b-. Make sure the hook engages correctly inside the
side panel.
nform
ercia
– Pull the rubber grommet -2- over the tank filler neck -3- and
tighten the screw.
m
at
om
io
in t
or
his
e
Tightening Specifications
at
do
priv
cum
or
en
ng
t.
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Fuel filler door bolt 1.5 Nm
ht. Cop py
rig
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Prote AG.
Note
♦ If actuator does not open, then the rod on the actuator can be pushed upward -arrow c- after removing the
luggage compartment trim panel.
♦ The screw -3- has a left-hand thread.
AG. Volkswagen AG d
agen oes
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ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
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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
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t.
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Cop py
ht. rig
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Prote AG.
Installation wage
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To install, perform the steps used d for removal in reverse order.
by ua
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– Make sure the grommet au and the connector fit correctly.
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ss
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pt
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es, in part or in w
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4 Special Tools
Special tools and workshop equipment required
♦ Torque Wrench -V.A.G 1331-
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♦ Pry Lever -80-200-
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4. Special Tools 77
Golf 2009 ➤
Body Exterior - Edition 06.2011
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1.1 Central Locking Component Overview
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hole
1 - Coupling Station
spec
es, in part or in w
t to the co
A-pillar.
❑ Loosen the boot on the
pillar to disconnect the
rrectness of i
connector.
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ercia
at
om
i
the driver side.
on
c
in t
or
❑ Removing, refer to ⇒
his
te
Electrical Equipment;
a
do
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cum
or
and Installation .
f
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3 - Front Passenger Door Con‐
C py
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trol Module -J387-
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❑ Integrated in window Prote
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regulator motor.
AG.
❑ Removing, refer to
⇒ “4.3 Front Door Win‐
dow Regulator Motor”,
page 259 .
4 - Right Front Door Lock
❑ The door lock is attach‐
ed to the inner door pan‐
el.
❑ Electrical central locking
system is integrated in
door lock.
❑ Removing, refer to
⇒ “3.5 Door Lock”, page
103 .
ce
le
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6 - Driver Door Control Module -J386-
pt
an
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❑ Integrated in window regulator motor.
erm
ab
❑ Removing, refer to ⇒ “4.6 Rear Door Window Regulator Motor”, page 266 .
ility
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ole,
spec
urposes, in part or in wh
t to the co
❑ Removing, refer to ⇒ “3.4 Door Lock”, page 144 .
8 - Right Rear Lid Connector Station
rrectne
❑ Installed location: behind the trim on the C-pillar
s
❑ Removing and installing, refer to ⇒ Body Interior; Rep. Gr. 70 ; Removal and Installation .
s o
cial p
f i
9 - Unlocking Element with Button
nform
mer
atio
m
n
c
i
or
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10 - Rear Lid Lock
te
sd
iva
o
❑ Installed location: attached to the rear lid.
pr
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11 - Left Rear Lid Connector Station t. C rig
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❑ Installed location: behind the trim on the C-pillar cop Vo
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❑ Removing and installing, refer to ⇒ Body Interior; Rep. Gr. 70 ; Removal and Installation . Prote AG.
19 - Coupling Station
❑ Installed location: left A-pillar
❑ Loosen the boot on the pillar to disconnect the connector.
20 - Alarm Horn -H12-
❑ In the right front wheel housing.
❑ Removing, refer to ⇒ Electrical Equipment; Rep. Gr. 96 ; Removal and Installation .
21 - Engine Hood Contact Switch -F266-
❑ Anti-theft warning system contact switch.
❑ Installed location: on the latch.
❑ Removing, refer to ⇒ Electrical Equipment; Rep. Gr. 96 ; Removal and Installation .
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erm
ab
Note
ility
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gap dimension when closed, it is not too far inward or outward
hole
spec
and contours align.
es, in part or in w
t to the co
♦ Vehicle must stand on its wheels while they are on the ground
in order to be able to perform the adjustment.
rrectness of i
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ab
ility
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spec
urposes, in part or in wh
t to the co
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cial p
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mer
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n
c
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or
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te
sd
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pr
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t.
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AG. Volkswagen AG d
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ab
ility
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c
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Prote AG.
Note
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rm
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Prote AG.
Note
1 - Door Lock
❑ Door lock can only be
removed in conjunction
with subframe
❑ Removing and instal‐
ling, refer to
⇒ “3.5 Door Lock”, page
103 .
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2 - Bolt olks
wa not
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❑ Tightening rspecifica‐
ise
d ara
nte
tion: 4 Nm tho eo
au ra
❑ For lock ss cylinder c
ce
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un
3 - Mounting Bracket pt
an
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❑ Removing and instal‐
erm
ab
ling, refer to
ility
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⇒ “3.10 Mounting
wit
is n
spec
4 - Lock Cylinder
urposes, in part or in wh
t to the co
page 109 .
❑ Only the driver door has
s
a lock cylinder.
s o
cial p
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5 - Backing
nform
mer
6 - Cover
atio
om
i
or
sd
stalling, refer to
iva
o
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t.
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❑ Passenger side without Cop py
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lock cylinder, removing py
rig by
ht
and installing, refer to co Vo
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⇒ “3.1 Cap without Lock Cylinder”, page 95 .
cted agen
Prote AG.
7 - Door Handle
❑ Removing and installing, refer to ⇒ “3.4 Door Handle”, page 101 .
8 - Bolt
❑ Tightening specification: 1 Nm
❑ Mounting bracket is disengaged from door by loosening this bolt.
9 - Cable
❑ From the door lock to the mounting bracket.
10 - Cable
❑ For unlocking the lock by the interior door mechanism.
❑ With grommet as pass-through on subframe.
11 - Bolt
❑ Tightening specification: 20 Nm
❑ Quantity: 2
AG. Volkswagen AG d
12 - Cover agen oes
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1.4 Door Hinge Overview s a c
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Note
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ility
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♦ The illustration shows a right door hinge. The left door hinge is identical.
h re
hole
spec
es, in part or in w
t to the co
♦ Hinges are no longer manufactured as separated parts.
♦ Lubricate the new door hinge if the old one was replaced.
rrectness of i
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1 - Door
❑ Removing and instal‐
nform
ercia
ling, refer to
⇒ “3.3 Door”,
m
at
om
page 99 .
ion
c
in t
❑ Adjusting, refer to
or
his
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do
riv
page 80 .
p
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for
en
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2 - Guide Bolt
n
t.
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❑ Tightening specifica‐
C py
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tion: 10 Nm
rig ht
py by
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3 - Door Hinge with Door Ar‐
agen
Prote AG.
rester
❑ Lubricate if the hinge is
replaced, refer to
⇒ “1.9 New Door Hing‐
es, Lubricating”,
page 92 .
4 - Socket Head Bolt
❑ Tightening specifica‐
tion: 38 Nm
❑ Always replace bolts af‐
ter loosening them.
5 - Cover
6 - Socket Head Bolt
❑ Tightening specifica‐
tion: 50 Nm
❑ Installed from the inside
of the vehicle.
❑ Remove the lower A-pil‐
lar trim. Refer to ⇒ Body
Interior; Rep. Gr. 70 ;
Removal and Installa‐
tion .
❑ Always replace bolts after loosening them.
7 - Socket Head Bolt
❑ Tightening specification: 38 Nm
❑ Always replace bolts after loosening them.
8 - Cover
9 - Socket Head Bolt
❑ Tightening specification: 50 Nm
❑ Always replace bolts after loosening them.
10 - Lower Spacer Plate
11 - Adjustment Ring
❑ Provides the eccentric pin adjustment range.
12 - Bolt agen
AG. Volkswagen AG d
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❑ Tightening specification: 28 by VNm
o gu
ara
ed
❑ For the eccentric bolts
horis nte
e t or
au a
13 - Door Hinge ss c
ce
e
nl
pt
du
an
itte
❑ Lubricate if the hinge is replaced, refer to ⇒ “1.9 New Door Hinges, Lubricating”, page 92 .
y li
erm
ab
ility
14 - Socket Head Bolt
ot p
wit
, is n
❑ Tightening specification: 50 Nm
h re
hole
spec
es, in part or in w
t to the co
❑ Tightening specification: 50 Nm
❑ Always replace bolts after loosening them.
rrectness of i
16 - Cover
l purpos
nf
ercia
❑ Tightening specification: 38 Nm
orm
❑ Always replace bolts after loosening them.
m
atio
om
n in
18 - Eccentric Bolts
or c
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e
sd
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20 - Guide Bolt
Co
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❑ Tightening specification: 10 Nm
ht ht
rig by
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3 - LED
rm
ab
pe
ility
❑ This LED must blink
ot
wit
when remote control is
, is n
h re
operated.
hole
spec
❑ If LED does not blink es, in part or in w
when remote control is
t to the co
operated, the battery is
completely discharged
and must be replaced:
rrectness of i
4 - Battery
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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do
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
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Prote AG.
1 - Door
❑ Removing and instal‐ n AG. Volkswagen AG do
ling, refer to lkswage es n
o ot g
⇒ “3.3 Door”, d byV ua
ran
page 99 . ir se tee
tho
u or
❑ Adjusting, refer to ss
a ac
⇒ “1.2 Door, Adjusting”,
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e
nl
page 80 .
pt
du
an
itte
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2 - Window Guide
erm
ab
ility
ot p
❑ Removing and instal‐
wit
, is n
ling, refer to
h re
⇒ “4.4 Front Door Win‐
hole
spec
dow Guide”, page 262 .
es, in part or in w
t to the co
3 - Door Window
❑ Removing and instal‐
ling, refer to
rrectness of i
⇒ “4.2 Front Door Win‐
dow”, page 255 .
l purpos
4 - Trim
nf
ercia
orm
ling, refer to
m
atio
m
⇒ “3.16 Trim”,
o
n in
c
page 121 .
or
thi
te
sd
a
o
r
rp
cu
❑ Removing and instal‐
o
m
f
en
ng
ling, refer to
t.
yi Co
op
⇒ “3.11 Outer Window C py
t. rig
Recess Seal”,
gh ht
yri by
page 112 . cop Vo
by lksw
cted agen
Prote AG.
6 - Inner Window Recess Seal
❑ Removing and instal‐
ling, refer to
⇒ “3.7 Inner Window
Shaft Strip”, page 107 .
7 - Cover
❑ Only on the 2-door model
❑ Removing and installing, refer to ⇒ “3.2 Cover, 2-Door Vehicle”, page 97 .
8 - Door Lock
❑ Door lock can only be removed in conjunction with subframe
❑ Removing and installing, refer to ⇒ “3.5 Door Lock”, page 103 .
9 - Bolt
❑ Tightening specification: 20 Nm
❑ Quantity: 2
10 - Outer Door Seal
❑ Removing and installing on a 2-door model, refer to
⇒ “3.12 Outer Door Seal, 2-Door Vehicle”, page 113 .
❑ Removing and installing on a 4-door model, refer to
⇒ “3.13 Outer Door Seal, 4-Door Vehicle”, page 114 .
11 - Buffer
12 - Cover
13 - Subframe
❑ Removing and installing, refer to ⇒ “3.15 Subframe”, page 116 .
❑ With window regulator.
14 - Clips
❑ For mounting the subframe
15 - Bolt
❑ For the hinge mount, there are different tightening specifications.
16 - Bottom Door Hinge
❑ With a door arrester
❑ The hinge is not separated.
17 - Bolt
❑ Tightening specification: 8 Nm
❑ For mounting the window regulator inside the door.
18 - Upper Door Hinge
❑ The hinge is not separated.
AG. Volkswagen AG d
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ce
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nl
pt
du
an
itte
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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
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
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cted agen
Prote AG.
1 - Insulation
❑ Self-adhesive
❑ Installing:
– Cut if necessary and
mount it over the side
impact protection.
2 - Foam Piece
n AG. Volkswagen AG do
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itte
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erm
ab
ility
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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
nf
ercia
orm
m
atio
om
n in
or c
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te
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t.
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Cop py
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pyri by
Vo
co lksw
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cted agen
Prote AG.
1 - Insulation
❑ Self-adhesive
❑ Installing:
– Cut if necessary and po‐
sition it as illustrated.
2 - Foam Piece
AG. Volkswagen AG d
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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
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rig ht
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co Vo
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cted agen
Prote AG.
Note
n AG. Volkswagen AG do
lkswage es n
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pt
du
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itte
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erm
ab
ility
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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
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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by
– Lubricate the upper door hinge -1- with Grease -G 000 150- cted agen
Prote AG.
all the way around -arrows a- on the pin and hole.
– Lubricate the lower door hinge -3- with Grease -G 000 150- all
the way around -arrows a- on the pin and hole.
– Lubricate the door check torsion spring -2- on the lower hinge
with Grease -G 000 150- -arrows c-.
♦ Body
AG. Volkswagen AG d
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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
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nform
mercia
a
com
tion in
r
te o
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s
iva
do
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en
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Cop py
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Prote AG.
2 Specifications
Tightening Specifications
Component Tightening Specifications
Hinge bolts 38 Nm
Door lock bolts 20 Nm
Lock cylinder bolts 4 Nm
Mounting bracket bolt 1 Nm
Outer door trim bolts 2 Nm
AG. Volkswagen AG d
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ility
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ole,
spec
urposes, in part or in wh
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
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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le
un
pt
⇒ “3.4 Door Handle”, page 101
an
d
itte
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⇒ “3.5 Door Lock”, page 103
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
⇒ “3.9 Lock Cylinder”, page 109
⇒ “3.10 Mounting Bracket”, page 112
rrectne
⇒ “3.11 Outer Window Recess Seal”, page 112
ss
⇒ “3.12 Outer Door Seal, 2-Door Vehicle”, page 113
o
cial p
f inform
⇒ “3.13 Outer Door Seal, 4-Door Vehicle”, page 114
mer
atio
⇒ “3.14 Remote Foldable Vehicle Key Battery”, page 115
om
n
c
i
or
n
⇒ “3.15 Subframe”, page 116
thi
te
sd
va
o
pr
cum
r
fo
en
ng
Removing
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ab
ility
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is n
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ole,
spec
urposes, in part or in wh
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
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d b ara
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nl
pt
du
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itte
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erm
ab
ility
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wit
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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
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te
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en
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t.
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AG. Volkswagen AG d
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ility
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hole
spec
es, in part or in w
t to the co
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nform
ercia
ion
c
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ate
cum
for
Installation
en
ng
t.
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ab
ility
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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rig ht
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Prote AG.
3.3 Door
Special tools and workshop equipment required
♦ Door Adjusting Wrench -3320-
♦ Box Wrench -3320/3-
Note
The following describes removing and installing the right door on‐
ly. Removing and installing the left door is identical.
Removing
ce
e
nl
pt
du
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itte
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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
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nf
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Prote AG.
– Press on the catch -arrow a- and remove the boot -6- from the
A-pillar.
– Move the locking lever -5- downward -arrow b- and disconnect
the connector from coupling station.
– Remove the caps -3- from the bolts.
– Remove bolts-2, 7 and 8- using -3320- and -3320/3- from
hinge.
– These screws -4 and 9- are actually guide screws and remain
on the hinge.
– Pull the door -1- off the guide screws -4 and 9- in
-direction of arrow c-
Installation
AG. Volkswagen AG d
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Tightening Specifications Cop py
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Component Tightening Specifications
cop Vo
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Hinge bolts -2, 7 and 8- (always 38 Nm
Prote AG.
replace)
Note
Removing
– Remove the lock cylinder housing, refer to
n AG. Volkswagen AG do
⇒ “3.9 Lock Cylinder”, page 109
olks
w.age es n
o
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b a
– Pull door handle -1- slightly
ris
ed toward rear -arrow a- out of mount ran
tee
of mounting bracket.ut
ho
or
a ac
ss
– Swivel door handle around in -direction of arrow b-.
ce
le
un
pt
an
– Remove the door handle at right angle -arrow a- from the
d
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bracket -2-.
rm
ab
pe
ility
Installation
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– Install the door handle -1- into the bracket at right angle
-arrow a-.
– Swing door handle -1- into door -arrow b-.
– Slide the door handle toward front -arrow c- into the mount
inside the bracket.
Install the lock cylinder housing.
ce
e
pt
du
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♦ It is not necessary to remove the subframe on a 2-door vehicle.
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Removing
spec
es, in part or in w
t to the co
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2-door Vehicles
– On a 2-door vehicle, remove just the cover. Refer to
⇒ “3.2 Cover, 2-Door Vehicle”, page 97 .
4-door Vehicles
– On a 4-door vehicle, remove the subframe. Refer to
⇒ “3.15 Subframe”, page 116 .
All Vehicles
– Remove the lock cylinder.
– Remove the bolts -4-.
– Loosen the cable -3- on the door lock bracket.
– Remove the lock -1- from the door -2-.
Installation AG. Volkswagen AG d
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urposes, in part or in wh
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Prote AG.
Note
Make sure to install the cover before installing the door lock.
– Push the cover -1- onto the guide -2- -arrow a-.
– Lock the cover -1- into the center of the door lock -2-
-arrow b-.
Install in reverse order of removal.
Tightening Specifications
Component Tightening Specifications
Door lock bolts 20 Nm
• Then a function test must be performed because the lock will
not open if the release cable is not adjusted and secured cor‐
rectly.
Note
pt
an
d
itte
ab
door seal only. Removing and installing the left inner door seal
pe
ility
is identical.
ot
wit
, is n
h re
hole
Removing
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
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tion in
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Cop py
ht. rig
rig ht
py by
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by lksw
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Prote AG.
AG. Volkswagen AG d
agen oes
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d b ara
rise nte
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au ra
ss c
ce
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nl
pt
du
an
itte
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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
nform
mercia
at
om
ion
c
in t
or
his
e
– Remove the pillar trim in order to remove the inner door seal.
at
do
riv
cum
or
lation
f
en
ng
t.
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– Remove sill panel strip. Refer to ⇒ Body Interior; Rep. Gr. Cop py
68 ; Removal and Installation
t. rig
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pyri by
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co
– Pull off inner door seal -1- from body flange.
by lksw
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Prote AG.
Installation
AG. Volkswagen AG d
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nl
pt
du
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es, in part or in w
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nf
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n in
or c
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– Align the inner door seal -1- with the vulcanized point
rp
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op
– Start installation of inner door seal in upper radius of door cut‐ C py
ht. rig
out. rig ht
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3.7 Inner Window Shaft Strip
cted agen
Prote AG.
Note
n AG. Volkswagen AG do
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spec
urposes, in part or in wh
t to the co
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Prote AG.
Removing
– Remove front door trim. Refer to ⇒ Body Interior; Rep. Gr.
70 ; Removal and Installation .
– Pull the seal -1- -arrows- evenly off the flange -2-.
Installation
Press the seal -1- evenly onto the flange -2-.
Note
♦ Do not turn the screwdriver to pry off the lock cylinder cap.
♦ The lock cylinder and cap are on the driver side only.
– Place the lock cylinder cap -2- gently at an angle from above
-arrow a- on the lock cylinder.
– Press the lock cylinder cap -2- on to door -arrow b- until cover
cap engages with lock cylinder.
AG. Volkswagen AG d
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Note
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AG. Volkswagen AG d
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– Remove the bolt -5-.
ole,
spec
urposes, in part or in wh
– Turn the screw -7- until it stop and press the screw in t to the co
-arrow a-, so that the bracket -8- releases the lock cylinder.
– Remove the lock cylinder housing -1- from the bracket -3- at
rrectne
f inform
mer
atio
om
n
c
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AG. Volkswagen AG d
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urposes, in part or in wh
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mer
atio
– Insert the lock cylinder housing -1- into the bracket -3- at a right
om
n
angle.
c
i
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Note
Co
Cop py
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During installation, lock cylinder housing must be pressed onto the outer door panel.
p by
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Prote AG.
Further installation is in reverse order of removal.
Tightening Specifications
Component Tightening Specifications
Lock cylinder bolts 4 Nm
pt
du
an
itte
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ab
ility
ot p
h re
Tightening Specifications
hole
spec
t to the co
Note
at
om
ion
c
in t
r
♦ The seal contains a metal insert. Once this metal insert is bent,
o
his
te
do
priv
cum
or
♦ This why the seal must be removed evenly without bending it.
f
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t.
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Cop py
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AG. Volkswagen AG d
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un
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tion in
r
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Removing
AG.
Note
AG. Volkswagen AG d
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nl
pt
du
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es, in part or in w
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rrectness of i
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Removing
nform
ercia
– Remove the outer door seal -1- together with the clips -2- from
m
at
ion
c
in t
Installation
or
his
ate
– Press the seal -1- together the clips -2- onto the door.
do
priv
cum
for
– Peel off the protective film -3- and press the seal onto the door.
en
ng
t.
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op
3.13 Outer Door Seal, 4-Door Vehicle
C py
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Note
AG. Volkswagen AG d
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spec
urposes, in part or in wh
t to the co
Removing
rrectne
– Remove the outer door seal -1- together with the clips -2- from
s
f i
Installation
nform
mer
– Press the seal -1- together the clips -2- onto the door.
atio
om
n
c
n thi
te
sd
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Removing
i
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-1- and key -2-. . Cop py
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rig
– Rotate screwdriver in -direction of arrow- and detach radio py by
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frequency unit from key.
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Prote AG.
– Press radio frequency unit -1- apart with key bit on key -2-.
AG. Volkswagen AG d
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– Use a screwdriver to unclip battery -1- out of holders -2- inaut ra
s c
-direction of arrow-. s
ce
le
un
pt
Installation
an
d
itte
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rm
ab
pe
ility
ot
Note
wit
, is n
h re
hole
spec
es, in part or in w
ed.
t to the co
♦ The radio remote container is reset and only recognize a new
battery.
rrectness of i
l purpos
Keep the correct polarity and position when installing the batter‐
ies.
nform
ercia
a
com
tion in
– Press the battery lightly to secure it in the radio frequency unit.
r
te o
thi
– Install the cover on the radio frequency unit without damaging
s
iva
do
the seal.
r
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cum
fo
en
g
t.
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Cop py
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rig ht
py by
co Vo
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Prote AG.
3.15 Subframe
Note
ce
le
un
pt
If electrical malfunction is present, repair this malfunction first.
an
d
itte
y li
erm
ab
If there is an electrical malfunction due to window regulator motor,
ility
ot p
wit
by hand into the necessary work position.
is n
h re
ole,
Removing
spec
urposes, in part or in wh
t to the co
Note
rrectne
The bolts -3- have a left-hand thread.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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fo
en
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t.
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Cop py
t. rig
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by
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Prote AG.
ce
le
un
pt
an
d
itte
– Lower the door window -2- until the screws -3- are accessible.
y li
rm
ab
pe
– Loosen the screws -3- (left-hand thread) but do not remove
ility
ot
and press the clamping brackets apart.
wit
, is n
h re
hole
– Lift the door window -1- and secure it, for example, with ad‐
spec
hesive tape. es, in part or in w
t to the co
Note
rrectness of i
♦ On one series of vehicles, up to 3 clips have been replaced by rivets.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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en
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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.
– Open the catches -arrow a- and pull off the protective sleeve
-3-.
– Open the locking mechanism on the connector by pivoting it
downward -arrow b- and disconnect the connector.
– Disconnect the connectors on the door lock and the speaker
-5-.
– Remove the caps -6- and remove the screws -7-.
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
atio
om
thi
e
– When pulling out subframe -1-, guide out wiring harness -2-
t
sd
iva
accordingly.
o
r
rp
cu
o
m
f
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ng
Installation
t.
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Cop py
t. rig
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Vo
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Prote AG.
ce
e
nl
pt
du
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itte
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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
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om
n in
or c
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Cop py
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rig ht
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by lksw
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Prote AG.
Note
♦ Press the subframe firmly against the door when installing the clips.
♦ Gently push in the pins on the clips so that the subframe seal fits correctly.
♦ It will be difficult to install the clips with the subframe is not pressed firmly against the door.
♦ The clips will get caught and the seal will not fit properly. This means the door will not be sealed.
♦ On one series of vehicles, up to 3 clips have been replaced by rivets.
♦ These rivets are being replaced by clips again at installation.
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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aut ra
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ce
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un
pt
an
d
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– Press the subframe firmly -1- against the door.
ss
– Mount the clips -arrows- and press the pins in.
o
cial p
f in
– Tighten the bolts -7-.
form
mer
atio
i
or
n thi
e
sd
iva
o
pr
en
ng
order.
t.
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op py
Tightening Specifications
t. C rig
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Component Tightening Specifications
lksw
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Prote AG.
Bolt -7- 8 Nm
3.16 Trim
Removing
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
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
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.
AG. Volkswagen AG d
agen oes
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ara
ed
ris nte
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aut ra
ss c
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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
o
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f
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Check the spring nuts -2- for damage and replace them if nec‐
essary.
– Slide the trim -1- onto the door -arrow b- and then
upward-arrow a-.
– Tighten bolts -3-.
– Slide the window guide -4- into the door.
Tightening Specifications
Component Tightening Specifications
Trim bolts 2 Nm
4 Special Tools
Special tools and workshop equipment required
♦ Door Adjusting Wrench -3320-
♦ Joint -3320/1-
♦ Box Wrench -3320/2-
♦ Box Wrench -3320/3-
♦ Roller -3356-
♦ Torque Wrench -V.A.G 1331-
♦ Adjusting Gauge -3371-
♦ Socket -3410-
♦ Trim Removal Wedge -3409-
AG. Volkswagen AG d
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y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
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
thi
te
sd
a
♦ Socket -3410-
iv
o
r
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cu
o
m
f
t.
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op
♦ Hot Air Gun -V.A.G 1416-
C py
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AG. Volkswagen AG d
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or eo
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ss c
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un
pt
an
d
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erm
ab
ility
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wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
n thi
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t.
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Cop py
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Prote AG.
58 – Rear Doors
1 Description and Operation
⇒ “1.1 Door Adjusting”, page 126
⇒ “1.2 Door Handle and Door Lock Overview”, page 130
⇒ “1.3 Door Hinge Overview”, page 131
⇒ “1.4 Insulation Overview”, page 133
⇒ “1.5 New Door Hinge, Lubricating”, page 134
⇒ “1.6 Rear Door Overview”, page 135
Note
n AG. Volkswagen AG do
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tho
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nl
pt
du
an
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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
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om
n in
or c
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Cop py
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126
Prote AG.
Rep. Gr.58 - Rear Doors
Golf 2009 ➤
Body Exterior - Edition 06.2011
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Adjusting the Gap Dimensions Prote
cted AG.
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Door adjusting wrench -3320- with -3320/3- must be used for this.
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Note
♦ The following describes adjusting the right front door only. Ad‐
justing the left front door is identical.
♦ When closing, the front door must latch completely without
having to press it and it must not have any play.
♦ The door must not be pushed up or down when adjusting the
striker pin.
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The illustration shows a right door hinge. The left door hinge is identical.
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1 - Door Lock
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ling, refer to
⇒ “3.4 Door Lock”, page
144 .
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2 - Cable
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⇒ “3.7 Mounting Brack‐
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♦ The illustration shows a right door hinge. The left door hinge is identical.
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♦ Hinges are no longer manufactured as ris separated parts.
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♦ Lubricate the new door hinge if the
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1 - Door
erm
ab
ility
❑ Removing and instal‐
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⇒ “3.2 Door”,
hole
spec
page 140 .
es, in part or in w
❑ Adjusting, refer to
t to the co
⇒ “1.1 Door Adjusting”,
page 126 .
rrectness of i
2 - Guide Bolt
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❑ Tightening specifica‐
tion: 10 Nm
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i
❑ lubricate if the hinge is
on
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❑ Tightening specifica‐
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ter loosening them.
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5 - Cover
6 - Socket Head Bolt
❑ Tightening specifica‐
tion: 50 Nm
❑ Installed from the inside
of the vehicle.
❑ Removing the lower B-
pillar trim, refer to ⇒
Body Interior; Rep. Gr.
70 ; Removal and Instal‐
lation .
❑ Always replace bolts af‐
ter loosening them
7 - Socket Head Bolt
❑ Tightening specification: 38 Nm
❑ Always replace bolts after loosening them.
8 - Socket Head Bolt
❑ Tightening specification: 50 Nm
❑ Always replace bolts after loosening them.
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11 - Adjustment Ring itte
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❑ Provides the eccentric pin adjustment range.
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12 - Bolt
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❑ Tightening specification: 28 Nm
spec
es, in part or in w
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13 - Door Hinge
❑ The door hinge is not separated.
rrectness of i
❑ lubricate if the hinge is replaced, refer to ⇒ “1.5 New Door Hinge, Lubricating”, page 134 .
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15 - Socket Head Bolt
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❑ Tightening specification: 50 Nm
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❑ Always replace bolts after loosening them.
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❑ Tightening specification: 38 Nm C py
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17 - Eccentric Bolts
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1.4 Insulation Overview
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❑ Self-adhesive
spec
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❑ installing:
t to the co
– Cut if necessary and
mount it over the side
impact protection.
rrectne
– Heat using a Heat Gun -
s
V.A.G 1416- and press
s o
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el.
form
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2 - Rear Door
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– Lubricate the upper door hinge -1- with Grease -G 000 150-
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all the way around -arrows a- on the pin and hole. C py
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– Lubricate the lower door hinge -3- with Grease -G 000 150- all cop Vo
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the way around -arrows b- on the pin and hole. cted agen
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– Lubricate the door check torsion spring -2- on the lower hinge
with Grease -G 000 150- -arrows c-.
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⇒ “3.2 Door”,
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page 140 .
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❑ Adjusting, refer to
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⇒ “1.1 Door Adjusting”,
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page 126 .
hole
spec
2 - Trim
es, in part or in w
t to the co
❑ Removing and instal‐
ling, refer to
⇒ “3.11 Trim”,
rrectness of i
page 158 .
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3 - Window Guide
❑ Removing and instal‐
nf
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ling, refer to
or
⇒ “4.8 Rear Door Win‐
m
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atio
dow Guide”, page 269 .
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4 - Door Window
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2 Specifications
Tightening Specifications
Component Tightening Specifications
Door hinge bolt (always re‐ 38 Nm
place)
Mounting bracket bolt 1 Nm
Door trim bolt 2 Nm
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2. Specifications 137
Golf 2009 ➤
Body Exterior - Edition 06.2011
3.1 Cover
Special tools and workshop equipment required
♦ Assembly Tool -T10389-
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– Remove the plug -5-.
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– Insert a screwdriver -4- on the hooks -3-.
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– Push the screwdriver -arrow- until the hook engages. cted agen
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3.2 Door
Special tools and workshop equipment required
♦ Door Adjusting Wrench -3320-
Note
The following describes removing and installing the right door on‐
ly. Removing and installing the left door is identical.
Removing
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– Press on the catch -arrow a- and remove the boot -6- from the
B-pillar.
– Move the locking lever -5- downward -arrow b- and disconnect
the connector from coupling station.
– Remove the caps -3- from the bolts.
– Remove bolts-2, 7 and 8- using -3320- and -3320/3- from
hinge.
– These bolts -4 and 9- are actually guide screws and remain
on the hinge.
– Pull the door -1- off the guide screws -4 and 9- in
-direction of arrow c-
Installation
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To install, perform the steps used for removal in reverse order.
– Make sure the front door gap dimension is correct. rrectne
Tightening Specifications
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Removing and installing the right door handle is described here.
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– Install the door handle -1- into the bracket at right angle
-arrow a-.
Note
Removing
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– Remove rear door trim. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Prote
cted AG.
agen
Removal and Installation .
– Remove subframe. Refer to ⇒ “3.10 Subframe”, page 152 .
– Remove the bolts -5-.
– Remove the lock -1- from the door -2-.
– Loosen the cable -7- on the door lock bracket.
Installation
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Note
urposes, in part or in wh
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Make sure to install the cover before installing the door lock.
rrectne
– Push the cover -1- onto the guide -2- -arrow a-.
– Lock the cover -1- into the center of the door lock -2-
ss
-arrow b-.
o
cial p
f inform
atio
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c
i
or
not open if the release cable is not adjusted and secured cor‐
sd
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rectly.
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Note
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is identical.
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Removing
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– Remove the pillar trim in order to remove the inner door seal.
Refer to ⇒ Body Interior; Rep. Gr. 70 ; Removal and Instal‐
lation .
– Remove sill panel strip. Refer to ⇒ Body Interior; Rep. Gr.
68 ; Removal and Installation .
– Remove the inner door seal -1- from the body flange -2-.
Installation
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– Align the inner door seal -1- with the vulcanized point
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– Start installation of inner door seal in upper radius of door cut‐
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Removing
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– Pull the seal -1- -arrows- evenly off the flange -2-.
mer
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Installation
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Removing
h re
hole
spec
– Remove the outer door seal -1- together with the clips -2- from
es, in part or in w
Installation
– Press the seal -1- together the clips -2- onto the door.
rrectness of i
The seal -1- must touch the seals on the window guide -4-
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Note
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♦ The seal contains a metal insert. Once this metal insert is bent,
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Removing
inform
mer
– Pull the seal -1- -arrows- evenly off the flange -2-.
atio
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Installation
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3.10 Subframe
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♦ Removing and installing the right subframe is described here.
Removing and installing the left subframe is identical.
♦ Bolts -3- have a left-hand thread.
♦ The subframe on a 2-door vehicle and 4-door vehicle is iden‐
tical. The door on a 2-door vehicle has an additional cover.
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Note
If the work step is not possible due to a malfunction via the electrical window regulator, then the window regulator
-7- can be disconnected -8-, in order to push the window down.
Note
When screwing the bolt into spreader plug, do not use excessive force on the plug otherwise it may fall inside
into the door.
– Pull the spreader plug -4- out of the window guide -2- and out
of door window.
– Lift the door window -1- and secure it, for example, with ad‐
hesive tape.
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♦ On one series of vehicles, up to 3 clips have been replaced
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– Disconnect the connectors on the door lock -2-.
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– Remove the clips -arrows- with pliers -3- -arrow a-.
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– Open the catches -arrow a- and pull off the protective sleeve
-1-.
– Open the locking mechanism on the connector by pivoting it
downward -arrow b- and disconnect the connector.
– Remove the subframe -4- from the door -arrow c-.
– Pull the cable -2- out of the subframe.
– Remove the subframe -4- -arrow d- from the door -3-.
– Remove the wiring harness -1- from the mount -5-.
– When pulling out subframe -1-, guide out wiring harness -1-
accordingly.
Installation
Note
If the door window was not removed, then install the spreader plug and the expanding pin into the door window
before installing the subframe.
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– Insert subframe upward -arrow a- at an angle into door.
AG.
– Pull the connector -6- through the door -4- and secure the wire
holder -5-.
– Pull the cable -2- through the subframe. Make sure the grom‐
met fits correctly.
– Push the subframe -1- on the bottom of the door -arrow b-.
– Connect the connectors -3-.
Note
♦ Press the subframe firmly against the door when installing the clips.
♦ Gently push in the pins on the clips so that the subframe seal fits correctly.
♦ It will be difficult to install the clips with the subframe is not pressed firmly against the door.
♦ Also, the clips will get caught and seal will not fit correctly.
♦ On one series of vehicles, up to 3 clips have been replaced by rivets.
♦ These rivets are being replaced by clips again at installation.
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3.11 Trim
Removing
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– Remove the window guide -4- from the door -3- -arrow a-. spec
urposes, in part or in wh
t to the co
– Remove the seal from the flange -arrow b-.
– Remove the bolts -2-.
rrectne
– Slide the trim -1- downward -arrow c- and remove it from the
door -arrows d-.
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Installation
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– Check the spring nuts -5- for damage and replace them if nec‐
nform
ercia
essary.
m
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com
– Slide the trim -1- onto the door -arrow a- and then
tion in
upward-arrow b-.
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– Slide the window guide -4- into the door -3- -arrow c-.
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– Press the seal onto the flange -arrow d-. C py
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Tightening Specifications
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Component Tightening Specifications
AG.
Trim bolt 2 Nm
4 Special Tools
Special tools and workshop equipment required
♦ Torque Wrench -V.A.G 1331-
♦ Socket -3410-
♦ Application Roller -3356-
♦ Trim Removal Wedge -3409-
♦ Hot Air Gun -V.A.G 1416-
♦ Adhesive Remover -VAS 6349-
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60 – Sunroof
1 Description and Operation
⇒ “1.1 Installation Unit Overview ”, page 163
Volkswagen AG
⇒ “1.2 Operating without Electricity”,swpage
agen 164
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⇒ “1.3 Panel Seal, Adjusting”, by
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⇒ “1.4 Parallel Movement,
au Checking”, page
t 165 ra
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⇒ “1.5 Parallel Movement, Adjusting”, page 165
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165
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⇒ “1.10 Water Drain Hoses, Cleaning”, page 169
⇒ “1.11 Wind Deflector, Adjusting”, page 171
rrectness of i
1.1 Installation Unit Overview
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1 - Installation Unit
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❑ Removing and instal‐
com
tio
ling, refer to
n in
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page 176 .
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2 - Bolt
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3 - Connector cted agen
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page 181 .
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1.5 Parallel Movement, Adjusting
rrectness of i
Note
l purpos
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mercia
a
– Remove drive motor for sunroof glass panel, refer to
com
tion in
⇒ “3.8 Sunroof Glass Panel Drive”, page 181 .
r
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Marking -arrow- on upper part of rear guide -1- must be located
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rail -2-.
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Link guide -2- must be engaged in guide rail (cannot be moved C py
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by hand).
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– Slide upper part of guide -1- at left and right centered between cted agen
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the markings.
– Install drive motor (zero position) in this position.
• Then check the zero position.
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position.
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For the emergency close function, the closing force limit is deac‐
hole
spec
tivated.
es, in part or in w
t to the co
The drive motor for sunroof with glass panel is protected against
overheating via a running time limit. The locking mechanism ac‐
tivates after an uninterrupted operation of approximately. two
rrectness of i
minutes.
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moving and installing,
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refer to
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⇒ “3.6 Sunroof Glass
ab
ility
Panel”, page 180 .
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❑ Sunroof glass panel, ad‐
h re
justing, refer to hole
spec
⇒ “1.9 Sunroof Glass
es, in part or in w
t to the co
ing”, page 168 .
2 - Panel Seal
rrectness of i
❑ Adjusting panel seal, re‐
l purpos
fer to
⇒ “1.3 Panel Seal, Ad‐
justing”, page 164 .
nf
ercia
o
❑ Seal joint at center in
rm
m
rear area.
atio
om
n in
❑ Panel Seal, Replacing,
or c
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refer to
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3 - Sun Shade
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page 181 .
4 - Bolt
❑ 1.8 Nm
❑ Screws are microen‐
capsulated and must al‐
ways be replaced after
removing.
❑ Quantity: 4
5 - Spring Glider
❑ Attached to the sun visor.
❑ Quantity: 4
❑ can be replaced separately.
6 - Bellows
❑ For covering slotted guide rail.
7 - Water Channel
8 - Guide Locking Hook
❑ removed together with slotted rail.
9 - End Piece, Upper Part
❑ Clipped to lower part of end piece.
10 - End Piece, Lower Part
❑ Can be replaced separately.
❑ Use a -AKL 450 005 05- for sealing.
11 - Installation Unit
❑ Removing and installing installation unit. Refer to ⇒ “3.2 Installation Unit”, page 176 .
ce
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❑ Removing, refer to ⇒ “3.8 Sunroof Glass Panel Drive”, page 181 .
ility
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❑ Drive Motor, Neutral Position, Adjusting, refer to
is n
h re
⇒ “1.6 Sunroof Glass Panel Drive Zero Position, Adjusting”, page 165 .
ole,
spec
urposes, in part or in wh
15 - Spring
t to the co
❑ Quantity: 2
❑ To open wind deflector.
rrectne
❑ Clipped inside the wind deflector and cannot be replaced individually.
❑ Removing, refer to ⇒ “3.10 Wind Deflector”, page 182 .
ss
16 - Wind Deflector
o
cial p
f in
❑ Removing, refer to ⇒ “3.10 Wind Deflector”, page 182 .
form
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❑ Quantity: 2
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❑ Clipped inside the wind deflector and cannot be replaced individually.
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❑ Removing, refer to ⇒ “3.10 Wind Deflector”, page 182 .
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18 - Front Guide
AG.
Note
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♦ Glass panel must not be higher than roof at any point at front
pe
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– Install bellows.
spec
es, in part or in w
t to the co
a
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tion in
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AG. Volkswagen AG d
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The front water drain hoses run through the A-pillars and end at
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the bulkhead crossmember. Cleaning is performed at cut out for
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Rear Water Drain Hoses
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The rear water drain hoses run through the C-pillars and end in
the rear wheel housings. Cleaning is performed in the wheel
housing, but the wheel housing liner must be removed.
Note
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Wind deflector bearing must engage in guide rails audibly.d by ua
ran
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2 Specifications
Tightening Specifications
Component Tightening Specifications
Installation unit bolts 8 Nm
Mounting bolt 4.5 Nm
Sunroof drive motor bolt 3.5 Nm
AG. Volkswagen AG d
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2. Specifications 173
Golf 2009 ➤
Body Exterior - Edition 06.2011
ce
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⇒ “3.10 Wind Deflector”, page 182
ility
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3.1 Bellows
, is n
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hole
spec
Removing
es, in part or in w
t to the co
rrectness of i
l purpos
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c
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Only remove and install drive motor for sunroof glass panel
pt
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when roof is closed (zero position).
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Requirements for removing and installing the drive: the engine
ility
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and the ignition must be off, remove the key and open the door.
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spec
es, in part or in w
Removing
t to the co
rrectness of i
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at
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ion
c
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ate
do
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for
en
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t.
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AG. Volkswagen AG d
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cutout.
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– Firmly bolt (8 Nm) installation unit -1- of drive motor for sunroof
-5- beginning at left and right toward rear.
nform
ercia
at
om
ion
c
do
riv
cum
for
t.
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Tightening Specifications
C py
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Component Tightening Specifications
o
by c lksw
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Prote AG.
Installation unit bolts 8 Nm
ce
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un
pt
– Removing sunroof glass panel, refer to
an
d
itte
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⇒ “3.6 Sunroof Glass Panel”, page 180 .
erm
ab
ility
ot p
– Pull off seal -1- from glass panel for sunroof -2-.
wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
– Pull new seal -1- at rear panel edge in center, beginning from
n
c
i
or
n
bottom to top, onto glass panel for sunroof -2-.
thi
te
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Note
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♦ Coat the edge of the panel with soapy water to make it easier
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to install the seal.
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Prote AG.
♦ If the seal is not correctly installed, the seal surface is wavy.
♦ Panel seal must be shortened corresponding to the panel cir‐
cumference.
Note
Removing
– Removing sunroof glass panel, refer to
⇒ “3.6 Sunroof Glass Panel”, page 180 .
– Removing installation unit, refer to
⇒ “3.2 Installation Unit”, page 176 .
– Remove drive motor for sunroof glass panel, refer to
⇒ “3.8 Sunroof Glass Panel Drive”, page 181 .
– Remove slotted guide rail. Refer to
⇒ “3.5 Slotted Guide Rail”, page 179 .
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– Slide lower part of rear guide -1- in -direction
auth of arrow- in guide eo
ra
rail -3- until the lock mechanism of guide
ss catch -2- is released. c
ce
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nl
pt
– Pull lower part of rear guide -1- and guide catch -2- together
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Installation
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orm
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-1- and guide retaining hook.
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spec
– Slide front guide -2- toward front and pull out slotted guide rail
es, in part or in w
t to the co
-1- in -direction of arrow- from front guide -2-.
Installation
rrectness of i
To install, perform the steps used for removal in reverse order.
l purpos
nform
mercia
a
com
tion in
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fo
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t.
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op py
Removing t. C rig
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– Remove bellows.
co Vo
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Prote AG.
– Remove mounting bolts -1- on left and right sides.
– Remove glass panel for sunroof -2- upward.
WARNING
Slotted guide rail must not be driven into “opened” position with
sunroof glass panel removed because the rain channel is no
longer pressed down by the glass panel and may be wedged
in roof.
Installing
• The panel must be installed in the neutral position (panel
closed).
Neutral Position:
– Insert glass panel for sunroof -2- from above and screw in
mounting bolts -1-.
– Tighten mounting bolts -1- lightly.
– Adjusting glass panel for sunroof (height adjustment). Refer to
⇒ “1.9 Sunroof Glass Panel Height, Adjusting”, page 168 .
Note
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♦ Tighten bolts after panel height adjustment (4.5 Nm).
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♦ Install bellows after panel height adjustment.
tho
ris tee
or
au ac
ss
Tightening Specifications
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nl
pt
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itte
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erm
ab
Mounting bolt 4.5 Nm
ility
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, is n
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3.7 Sun Shade
hole
spec
es, in part or in w
t to the co
Removing
– Remove the glass panel. Refer to
⇒ “3.6 Sunroof Glass Panel”, page 180 .
rrectness of i
– Slide sun shade slightly toward rear.
l purpos
– Remove the front screw -arrow- on the left and right side. Slide
the spring glider forward over the stop -1-.
nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
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t.
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Cop py
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– Slide sun shade forward and lift sun shade slightly over the
Prote AG.
ce
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un
pt
an
d
♦ If this is not the case, it may lead to the drive motor incorrectly
itte
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detecting the preset switch and the selected position is not
rm
ab
pe
ility
reached. If this happens, it must be realized that glass panel
ot
will remain stationary at a closed switch position approximate‐
wit
, is n
h re
ly 10 cm (4 inches) short of the actual closing position.
hole
spec
es, in part or in w
t to the co
WARNING
Only remove and install drive motor for sunroof glass panel
rrectness of i
when roof is closed (zero position).
l purpos
nform
mercia
a
com
t
– Switch off engine and ignition, remove key and open door.
ion in
r
te o
thi
s
iva
motor.
do
r
rp
cum
fo
– Remove bolts -arrows- and pull off drive motor for sunroof.
en
ng
t.
yi Co
op
– Disconnect harness connector for drive motor of sunroof. C py
t. rig
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Installation cop Vo
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Prote
• The bolts for the sunroof drive motor are microencapsulated
AG.
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tor bearing -arrow-.
nl
pt
du
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– Pull wind deflector bearing out of side locking mechanism of erm
ab
left and right guide rails using special tool -3370- in
ility
ot p
-direction of arrow-.
wit
, is n
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– Remove wind deflector upward from guide rail.
hole
spec
Installation
es, in part or in w
t to the co
– Insert wind deflector into guide rail and slide wind deflector
with height stop under front roof opening at left and right sides.
rrectness of i
– Using light pressure, press wind deflector bearing into guide
rails.
l purpos
nf
ercia
Note
orm
m
atio
m
n in
or c
thi
te
sd
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f
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t.
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Cop py
t. rig
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Prote AG.
4 Special Tools
Special tools and workshop equipment required
♦ Roller -3356-
♦ Special Hook -3370-
♦ Torque Wrench -V.A.G 1783-
♦ Trim Removal Wedge -3409-
♦ Cleaning and Pulling Tool -VAS 6620-
n AG. Volkswagen AG do
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nl
pt
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erm
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mercia
at
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ion
c
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or
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ate
do
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cum
for
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Cop py
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Prote AG.
63 – Bumpers
1 General Information
⇒ “1.1 Front Bumper Cover”, page 185
⇒ “1.2 Rear Bumper Cover”, page 185
Note
Note
Note
pt
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ility
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spec
es, in part or in w
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nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
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Prote AG.
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⇒ “2.1 Front Bumper Overviews”, page 186
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⇒ “2.2 Front Bumper Overviews, GTI”, page 189
ility
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spec
⇒ “2.4 Front Bumper Carrier Overview”, page 194
urposes, in part or in wh
t to the co
⇒ “2.5 Side Guide Overview”, page 195
⇒ “2.6 Rear Bumper Cover”, page 196
rrectne
⇒ “2.7 Rear Bumper Overviews, GTI”, page 198
⇒ “2.8 Rear Bumper Overviews, Golf R”, page 200
ss o
cial p
f
⇒ “2.9 Rear Bumper Cover Substructure Overview”, page 202
inform
mer
atio
m
n
c
i
or
n thi
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pr
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fo
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ng
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⇒ “2.1.2 Front Bumper Cover Attachments”, page 188 C py
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2.1.1 Front Bumper Cover Overview
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Prote AG.
Note
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4 - Bolt
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❑ 4 pieces per side
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ility
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❑ Tightening specifica‐
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tion: 2 Nm
hole
spec
❑ Attached to the wheel
es, in part or in w
housing liner.
t to the co
5 - Side Marker Lamps
❑ Left and right
rrectness of i
❑ Not for all countries
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❑ Removing, refer to ⇒
Electrical Equipment;
nform
ercia
a
com
tio
6 - Bolt
n in
r
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thi
❑ Tightening specifica‐
s
iva
do
tion: 2 Nm
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rp
cum
fo
t.
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❑ Attached to the wheel Cop py
housing liner.
t. rig
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Vo
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7 - Bolt
c by lksw
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Prote AG.
❑ Tightening specification: 1.5 Nm
❑ Quantity: 4
❑ Attached to the lock carrier.
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pt
❑ Left
an
d
itte
catch. ab
ility
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catch.
8 - Decorative Ring
rrectne
❑ Left
❑ Depending on the ver‐
ss
f in
atio
n
c
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11 - Clips C py
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12 - Decorative Ring
agen
Prote AG.
❑ Right
❑ Depending on the version of the fog lamp.
13 - Side Air Grille
❑ Right for the fog lamp.
❑ Pull forward out of the catch.
14 - Side Air Grille
❑ Right
❑ Pull forward out of the catch.
pt
an
d
❑ Pointing upward
itte
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ab
4 - Bolt
ility
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❑ Tightening specifica‐
is n
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tion: 2 Nm
ole,
spec
t to the co
❑ Removing, refer to ⇒
inform
Electrical Equipment;
mer
and Installation .
o
n
c
i
or
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6 - Bolt
te
sd
iva
❑ Tightening specifica‐
pr
cum
r
fo
tion: 2 Nm
en
ng
t.
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❑ 3 pieces per side t. Cop py
rig
❑ Attached to the wheel housing liner.
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7 - Bolt cted agen
Prote AG.
❑ Tightening specification: 1.5 Nm
❑ Quantity: 4
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2.2.2 Bumper Cover Attachments
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ility
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1 - Front Bumper Cover
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❑ PP/EPDM material
hole
spec
❑ Removing and instal‐
es, in part or in w
ling, refer to
t to the co
⇒ “4.2.1 Front Bumper
Cover”, page 213 .
rrectness of i
2 - Support Piece
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ercia
a
com
t
❑ Remove only when
ion in
bumper cover -1- has
r
te o
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been removed.
s
iva
do
❑ Removing and instal‐
r
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ling, refer to
en
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⇒ “4.2.2 Inner Assembly
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Components”,
C py
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page 216 .
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3 - Assembly Piece
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Prote AG.
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❑ Locked inside the front bumper cover -1-.
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❑ Remove only when bumper cover -1- has been removed
erm
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❑ Removing and Installing, refer to ⇒ “4.2.2 Inner Assembly Components”, page 216
wit
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16 - Support Piece
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spec
❑ Right for the headlamp washer system
urposes, in part or in wh
t to the co
❑ Locked inside the front bumper cover -1-.
❑ Remove only when bumper cover -1- has been removed
❑ Removing and Installing, refer to ⇒ “4.2.2 Inner Assembly Components”, page 216
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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t.
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Cop py
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Prote AG.
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3 - Bolt
nl
pt
du
an
❑ Tightening specifica‐
itte
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erm
tion: 2 Nm
ab
ility
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wit
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❑ Pointing upward
hole
spec
4 - Bolt
es, in part or in w
t to the co
❑ Tightening specifica‐
tion: 2 Nm
❑ 4 on each side
rrectness of i
housing liner.
5 - Bolt
nform
ercia
❑ Tightening specifica‐
m
tion: 2 Nm
at
om
ion
❑ 3 on each side
c
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or
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or
derneath.
f
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t.
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6 - Bolt ht. Cop py
rig
❑ Tightening specification: 2 Nm rig ht
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❑ Quantity: 4
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Prote AG.
❑ With the lock carrier installed from underneath.
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Cover”, page 220 .
pt
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❑ Installing, refer to
erm
ab
⇒ page 221 .
ility
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wit
2 - Support Piece
, is n
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hole
spec
washer system.
es, in part or in w
t to the co
❑ Removing and instal‐
ling, refer to
⇒ “4.3.2 Support”,
rrectness of i
page 222 .
l purpos
3 - Cover
❑ For the headlamp wash‐
er system.
nf
ercia
orm
m
4 - Spoiler Bracket
atio
om
n in
or c
thi
te
sd
a
been removed.
iv
o
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rp
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5 - Spoiler
f
en
ng
t.
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❑ Remove only when Cop py
bumper cover -1- has ht. rig
rig ht
been removed.
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6 - Parking Aid Sensor
Prote AG.
❑ Left
❑ Not applicable to the
NAR market.
7 - End Plate
❑ Left
❑ Remove only when
bumper cover -1- has been removed.
8 - Vent Grille
❑ Left
❑ Remove only when bumper cover -1- has been removed.
9 - License Plate Holder
❑ There are different sizes for different markets
❑ Installing, refer to ⇒ “4.2.4 License Plate Holder”, page 219 .
10 - Clips
❑ Quantity: 4
11 - Vent Grille
❑ Right
❑ Remove only when bumper cover -1- has been removed.
12 - End Plate
❑ Right
❑ Remove only when bumper cover -1- has been removed.
13 - Parking Aid Sensor
❑ Right
pt
an
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
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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
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pyri by
Vo
co lksw
by
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Prote AG.
Note
1 - Side Guide
❑ Left and right
2 - Bolt
❑ Tightening specifica‐
tion: 2 Nm
❑ Quantity: 2
3 - Bolt
❑ Tightening specifica‐
tion: 5 Nm
❑ Quantity: 2
4 - Expanding Nut
❑ Quantity: 2
n AG. Volkswagen AG do
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urposes, in part or in wh
t to the co
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mer
atio
om
n
c
i
or
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te
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pr
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ng
t.
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Cop py
t. rig
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Vo
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195
Prote AG.
2. Description and Operation
Golf 2009 ➤
Body Exterior - Edition 06.2011
ce
le
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pt
an
❑ Left and right
d
itte
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rm
ab
❑ Attached to the wheel
pe
ility
housing liner.
ot
wit
, is n
h re
3 - Bolt
hole
spec
❑ Tightening specifica‐
es, in part or in w
tion: 2 Nm
t to the co
❑ Quantity: 2
❑ Attached to the back
rrectness of i
panel.
l purpos
4 - Bolt
❑ Tightening specifica‐
nform
ercia
tion: 2 Nm
❑ 3 pieces per side
m
a
com
tio
housing liner.
te o
thi
s
iva
do
5 - Bolt
r
rp
cum
fo
❑ Tightening specifica‐
en
ng
t.
yi
tion: 2 Nm
Co
Cop py
t. rig
❑ Left and right opyri
gh by
Vo
ht
❑ Pointing upward
c by lksw
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Prote AG.
❑ Attached to the side
panel.
9 - Clips
un
pt
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rm
ab
pe
wit
❑ Quantity: 2
, is n
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hole
nform
mercia
a
com
tion in
r
te o
thi
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iva
do
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cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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197
Prote AG.
2. Description and Operation
Golf 2009 ➤
Body Exterior - Edition 06.2011
ce
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nl
pt
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an
itte
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erm
ab
❑ Attached to the wheel
ility
ot p
housing liner.
wit
, is n
h re
3 - Bolt
hole
spec
❑ Tightening specifica‐
es, in part or in w
t to the co
tion: 2 Nm
❑ Quantity: 2
❑ Attached to the back
rrectness of i
panel.
l purpos
4 - Bolt
❑ Tightening specifica‐
nf
ercia
tion: 2 Nm orm
m
atio
❑ 3 pieces per side
om
n in
c
thi
e
housing liner.
t
sd
iva
o
r
rp
cu
5 - Bolt
o
m
f
en
ng
❑ Tightening specifica‐
t.
yi Co
op
tion: 2 Nm C py
t. rig
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❑ Left and right p by
co Vo
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❑ Pointing upward
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Prote AG.
❑ Attached to the side
panel.
ce
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nl
❑ Right
pt
du
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itte
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❑ Attaches the wheel
erm
ab
housing liner to the
ility
ot p
bumper cover.
wit
, is n
h re
3 - Bolt
hole
spec
❑ Tightening specifica‐
es, in part or in w
tion: 2 Nm
t to the co
❑ 2 pieces per side
4 - Right Rear Reflector
rrectness of i
❑ Attached inside the rear
l purpos
bumper cover.
❑ To be removed only with
nform
ercia
at
om
io
5 - License Plate Lighting
n
c
in t
or
his
e
❑ Quantity: 2
at
do
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❑ Removing ⇒ Electrical
p
cum
or
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t.
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94 ; Removal and Instal‐
Co
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6 - Towing Eyelet Cap
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Prote
❑ Secured to spoiler.
AG.
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housing liner.
erm
ab
ility
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5 - Bolt
wit
, is n
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❑ Tightening specifica‐
hole
tion: 2 Nm
spec
es, in part or in w
❑ Pointing upward
❑ Attached to the side
rrectness of i
panel.
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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Prote AG.
ce
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nl
3 - Bracket
pt
du
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itte
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❑ Right
erm
ab
ility
❑ Connects the spoiler
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with the back plate.
, is n
h re
hole
spec
es, in part or in w
❑ Left
t to the co
❑ Removing ⇒ Electrical
Equipment; Rep. Gr.
94 ; Removal and Instal‐
rrectness of i
lation .
l purpos
nform
ercia
bumper cover.
m
at
om
io
rear bumper cover re‐
n
c
in t
r
moved.
o
his
ate
do
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cum
or
❑ 2 minimum
f
en
ng
t.
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op
7 - Spoiler
C py
t. rig
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yri
❑ Material PC/ABS p by
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by c lksw
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❑ Attached inside the rear
agen
Prote AG.
bumper cover.
❑ To be removed only with rear bumper cover removed.
8 - Towing Eyelet Cap
❑ Attached in the spoiler -5-.
9 - Heat Shield
❑ For the rear bumper cover.
❑ Attached in the rear spoiler with metal clips.
10 - Clips
❑ Different quantity is possible.
11 - License Plate Holder
❑ Installing, refer to ⇒ “4.8 Rear Bumper License Plate Holder”, page 231 .
12 - Left Rear Reflector
❑ Attached inside the rear bumper cover.
❑ To be removed only with rear bumper cover removed.
13 - License Plate Lamp
❑ Right
1 - Center Guide
2 - Guide Trim
❑ Right and left tail lamp
assembly
❑ Position with the tail AG. Volkswagen AG d
lamp assembly agen oes
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3 - Expanding Nut rised
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❑ Gas-tight s aut ra
c
s
❑ Right and left
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pt
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DANGER!
erm
ab
ility
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wit
, is n
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and replace if necessary.
hole
spec
es, in part or in w
t to the co
off the passenger com‐
partment from exhaust
gas and must always be
rrectness of i
replaced if they are dam‐
l purpos
aged.
nform
ercia
4 - Guide Trim
m
ion
c
5 - Nut
in t
or
his
te
❑ Tightening specifica‐
a
do
riv
tion: 2 Nm
p
cum
for
en
g
t.
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right and left sides t. Cop py
rig
gh ht
yri
6 - Nut p by
o Vo
by c lksw
❑ Tightening specifica‐
cted agen
Prote AG.
tion: 2 Nm
❑ Right and left
7 - Screws
❑ Tightening specification: 2 Nm
❑ Right and left
8 - Nut
❑ Tightening specification: 2 Nm
❑ Quantity: 4
AG. Volkswagen AG d
agen oes
olksw not
V gu
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or eo
h
aut ra
ss c
ce
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pt
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erm
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ility
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, is n
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hole
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es, in part or in w
t to the co
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mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
203
by c lksw
cted
2. Description and Operation
agen
Prote AG.
Golf 2009 ➤
Body Exterior - Edition 06.2011
Note
♦ Due to model variations, small deviations must be considered during removal and installation.
♦ The tightening specifications only apply to factory-installed trailer hitches.
♦ If a different trailer hitch is installed, ask the manufacturer for the tightening specifications.
1 - Trailer Hitch
❑ Trailer hitch with remov‐
able ball head.
2 - Ball Head
❑ The removable ball
head is located in the left
luggage compartment
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❑ 20 Nm thor eo
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4 - Bolt
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2.12.1 Tools
Special tools and workshop equipment required
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2.12.2 Materials
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♦ 2K-Plastic-Adhesive -D 180 3) 1 4) 2
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♦ Primer applicator
Note
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The 4 markings for the mount -1- are found on the inside of the
bumper cover.
rrectness of i
– Drill the holes from inside outward with a tool set and supplied
drill -3-.
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– Position the stamping holes with the bolt head -1-, washer
ion in
thi
-5-.
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– Push the iron punch -4- on the bumper cover.
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– Tighten the hole stamper -1-.
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Note
The iron punch -4- cannot rotate on the bumper cover paint.
Note
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– Lightly grind the inside of the bumper cover -6- and thoroughly
clean it.
– Thinly apply the bonding agent for the plastic to the bumper
rrectne
– Slide the mount -8- onto the centering drift -1- and push
s o
f inform
nut -5-.
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– Remove the clamping clip -3- and position the knurled nut
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3 Specifications
Tightening Specifications
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Front bumper cover bolts
oris 2 Nm tee
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Front lower bumper
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⇒ “4.7 Rear Bumper Cover, Golf R”, page 228
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⇒ “4.8 Rear Bumper License Plate Holder”, page 231
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– Install the front bumper cover -1- parallel -arrows a- onto the
lock carrier.
– Press the front bumper cover -1- onto the guides until it latches
-arrows b-.
Note
When installing front bumper cover, make sure it is guided on parallel on fender.
ce
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⇒ “4.2.4 License Plate Holder”, page 219
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4.2.1 Front Bumper Cover
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– Remove radiator grille. utho
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– Remove the bolts -4-.
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– Pull the front bumper cover -1- out of the guides on the left and
right sides of the fender -arrows a-.
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Rep. Gr.63 - Bumpers cted agen
Prote AG.
Golf 2009 ➤
Body Exterior - Edition 06.2011
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– Install the front bumper cover -1- parallel -arrows a- onto the
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lock carrier.
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– Press the front bumper cover -1- onto the guides until it latches
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-arrows b-.
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Note
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When installing front bumper cover, make sure it is guided on parallel on fender.
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Tightening Specifications
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Removing Support
– Remove the lift cylinder for the headlamp washer system. Re‐
fer to ⇒ Electrical Equipment; Rep. Gr. 92 ; Removal and
Installation .
– Remove the bolts -3-.
– Loosen the catches -arrows- from the support.
Installing Support Piece
– Press the support -2- into the catches -arrows- in the bumper
cover -1-.
– Tighten the screws, tightening specification: 2 Nm.
Removing Assembly Part
– Remove the fog lamp. Refer to ⇒ Electrical Equipment; Rep.
Gr. 95 ; Removal and Installation
– Remove the bolts -3-.
– Loosen the catches on the assembly part.
Installation
– Press the assembly part -4- securely into the catches inside
the bumper cover -1-.
– Tighten the screws, tightening specification: 2 Nm.
Tightening Specifications
Component Tightening Specifications
Inner assembly bolt 2 Nm
Note
The front spoiler consists of several parts. The following describes removing the entire front spoiler. This is not
always necessary.
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Removing
– Remove the bolts -6-.
– Remove the spoiler upper section -5- and the support -4-.
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– Remove the spoiler lower section -2- from the catches
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-arrows- inside the front bumper cover -1-.
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– Check the spring nuts -3- inside the spoiler lower section and
h re
replace them if necessary.
hole
spec
es, in part or in w
– Press the spoiler lower section -2- securely into the catches
t to the co
inside the bumper cover -1-.
– Mount the spoiler upper section -5- and the support -4-.
rrectness of i
– Tighten bolts -6-, tightening specification: 2 Nm.
l purpos
Tightening Specifications
Component Tightening Specifications
nf
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Front spoiler bolt 2 Nm
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♦ The license plate holder can have different sizes depending on the market.
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hole
♦ The contour of the bumper cover determines the height of the license plate holder.
spec
es, in part or in w
♦ Drill 12 mm holes.
t to the co
rrectness of i
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With Holes
– Place the license plate holder -2- on the front bumper cover
-3- and press the clips in -1-.
Without Holes
– Center the license plate holder -2- to the emblem -4- on the
front bumper cover -1-.
– Set the drill stop depth to 12 mm and drill the holes.
– Place the license plate holder -2- on the front bumper cover
-3- and press the clips in -1-.
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– Install the front bumper cover -1- parallel -arrows a- onto the
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– Press the front bumper cover -1- onto the left and right guide
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on the fender until they lock onto each other -arrows b-. Prote
cted AG.
agen
Note
When installing front bumper cover, make sure it is guided on parallel on fender.
– Install the bolts -2, 3, 4, 5, and 6- and tighten them to the tight‐
ening specification. Refer to
⇒ “2.3.1 Bumper Cover Overview, Golf R ”, page 192 .
– Install the radiator grille. Refer to
⇒ “4.7 Radiator Grille”, page 316 .
Tightening Specifications
Component Tightening Specifications
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Note
♦ The license plate holder can have different sizes depending on the market.
AG. Volkswagen
♦ The contour of the bumper cover determines
lksw the height of the license
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With Holes
– Place the license plate holder -2- on the front bumper cover
-3- and press the clips in -1-.
Without Holes
– Center the license plate holder -2- to the emblem -4- on the
front bumper cover -1-.
– Set the drill stop depth to 12 mm and drill the holes.
– Place the license plate holder -2- on the front bumper cover
-3- and press the clips in -1-.
Note
Removing
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Note
Be sure to hold the rear bumper cover parallel when inserting it into the left and right guides.
– Press the rear bumper cover -1- onto the center guide
-arrows a- and onto the left and right guides -arrows b- until it
audibly engages.
– Check the parallel alignment and the gap dimensions.
– Install the screws -2, 3, 4 and 5- and tighten them to the tight‐
ening specification. Refer to
⇒ “2.6.1 Rear Bumper Cover Overview”, page 196
Tightening Specifications
Component Tightening Specifications
Bolts 2 Nm
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Prote AG.
Rep. Gr.63 - Bumpers
Golf 2009 ➤
Body Exterior - Edition 06.2011
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– Mount the rear bumper cover -1-. A second technician is nee‐
ded for this.
Note
Be sure to hold the rear bumper cover parallel when inserting it into the left and right guides.
– Press the rear bumper cover -1- onto the center guide
-arrows a- and onto the left and right guides -arrows b- until it
audibly engages.
– Check the parallel alignment and the gap dimensions.
– Install the screws -2, 3, 4 and 5- and tighten them to the tight‐
ening specification. Refer to
⇒ “2.6.1 Rear Bumper Cover Overview”, page 196 .
Tightening Specifications
Component Tightening Specifications
Bolt 2 Nm
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Note
Be sure to hold the rear bumper cover parallel when inserting it into the left and right guides.
– Press the rear bumper cover -1- onto the center guide
-arrows a- and onto the left and right guides -arrows b- until it
audibly engages.
– Check the parallel alignment and the gap dimensions. Refer
to ⇒ Body Repair; Rep. Gr. 00 ; Specifications .
– Install the screws -2, 3, 4 and 5- and tighten them to the tight‐
ening specification. Refer to
⇒ “2.8.1 Bumper Cover Overview”, page 200 .
Tightening Specifications
Component Tightening Specifications
Bolts 2 Nm
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a ac
ss
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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
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cum
fo
en
ng
t.
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Cop py
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pyri by
Vo
co lksw
by
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Prote AG.
Note
♦ The license plate holder is not installed on all models for all markets.
♦ The license plate holder can have different sizes depending on the market.
♦ The contour of the bumper cover determines the height of the license plate holder.
♦ Drill 12 mm holes.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
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tho
u or
a ac
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nl
pt
du
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ab
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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
With Holes
nform
ercia
– Position the license plate holder -5- on the rear bumper cover
m
at
om
in t
or
do
riv
Without Holes
p
cum
for
en
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– Align the license plate holder -5- on the rear bumper cover
n
t.
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op
-1- with the rear lid striker pin -2-. C py
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– Set the drill stop depth to 12 mm and drill the holes.
p by
co Vo
by lksw
cted agen
Prote AG.
– Position the license plate holder -2- on the rear bumper cover
and press the clips -4- in.
– Tighten the pop rivet nuts -3-.
4.9.1 Tools
Special tools and workshop equipment required
♦ Assembly tool for PDC-mount -VAS 6614-
n AG. Volkswagen AG do
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nl
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spec
4.9.2 Materials
es, in part or in w
t to the co
♦ 2K-Plastic-Adhesive -D 180 5) 1 6) 2
K2 A1-
rrectness of i
at
om
ion
♦ Primer applicator
c
in t
or
his
ate
do
riv
cum
for
en
g
t.
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⇒ “4.9.4 Minimum Curing Time”, page 236 . t. Cop py
rig
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by
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Note
nl
pt
du
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After the bumper cover is painted, install the mount.
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
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
The 4 markings for the mount -1- are found on the inside of the
bumper cover.
– Determine the central point -2-, if not already present.
– Drill the holes from inside outward with a tool set and supplied
drill -3-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
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or eo
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aut ra
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ce
le
un
pt
an
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erm
ab
ility
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wit
is n
h re
ole,
spec
urposes, in part or in wh
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
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Position the stamping holes with the bolt head -1-, washer
-2- and counterholder-3- on the inside of the bumper cover
-5-.
– Remove the iron punch -4- up to the bumper cover.
– Push the iron punch -4- on the bumper cover.
– Tighten the hole stamper -1-.
Note
The iron punch -4- cannot rotate on the bumper cover paint.
Note
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
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le
un
pt
an
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rm
ab
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ility
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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
ercia
– Lightly grind the inside of the bumper cover -6- and thoroughly
m
a
com
clean it.
ion in
r
te o
– Thinly apply the bonding agent for the plastic to the bumper
thi
s
iva
cum
fo
– Slide the mount -8- onto the centering drift -1- and push
en
ng
t.
through the bumper cover -6-.
yi Co
Cop py
t. rig
– Remove the counterholder -4- and lightly tighten the knurled
gh ht
pyri by
nut -5-.
co Vo
by lksw
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Prote AG.
– Remove the clamping clip -3- and position the knurled nut
-2-, do not tighten.
– All the mounts are prepared in this way.
Note
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le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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.
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness
♦ Hand pressure pistol -VAS 5155-
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
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
1.1 Materials
Note
For the correct part numbers, refer to the Electronic Parts Catalog
(ETKA).
ce
le
un
pt
♦ Glass primer/paint primer
an
1
d
7)
itte
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rm
ab
pe
ility
♦ Cleaning solution 7) 1
ot
wit
, is n
h re
♦ Primer applicator 7) 1
hole
spec
es, in part or in w
♦ Adhesive remover 7) 1
t to the co
♦ Cutting wire
rrectness of i
7) Follow the manufacturer instructions, supplied in the packaging.
l purpos
1939- .
a
com
tion in
10) Double Cartridge Gun -VAS 5237- must be used to process this material.
r
te o
thi
11) Small cartridge (180 ml) for sealing and/or when a 400 ml double cartridge is
s
iva
do
not enough.
r
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fo
t.
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Cop py
t.
Special tools and workshop equipment required
rig
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pyri by
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♦ Double Cartridge Gun -VAS 5237-
lksw
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Prote AG.
WARNING
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e
nl
pt
du
an
itte
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erm
The minimum curing time for 2K adhesive is 2 hours for all win‐
ab
ility
dows.
ot p
wit
, is n
Curing time means the time from when the window is bonded to
h re
hole
when the vehicle is put back into use. During this time, the vehicle
must stand on an even surface at room temperature (at least 15 spec
es, in part or in w
t to the co
°C) (59 °F).
WARNING
rrectness of i
l purpos
orm
m
atio
om
n in
or c
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te
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.
1 - Rear Window
❑ Removing rear window,
refer to
⇒ “4.1.6 Undamaged
n AG. Volkswagen AG do
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ing”, page 251 . d byV
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2 - PUR Adhesive Sealant utho
or
a ac
❑ Bead diameter: width = ss
ce
le
6.5 mm -dimension b-
un
pt
height = 10 mm
an
d
itte
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-dimension a- (including
rm
ab
pre-coating, residual
pe
ility
ot
material on window
wit
, is n
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hole
flange).
spec
es, in part or in w
t to the co
sive on the side edge of
the window glass.
❑ Minimum curing time, rrectness of i
refer to
l purpos
3 - Body Flange
m
4 - Spacer
a
com
tion in
thi
nector
s
iva
do
r
rp
6 - Antenna Connectors
um
fo
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.
1 - Side Window
❑ Remove side window,
refer to
⇒ “4.1.7 Undamaged
Side Window, Remov‐
ing”, page 252 .
❑ Installing side window,
refer to
⇒ “4.1.5 Side Window,
Installing”, page 250 .
2 - Seal
❑ Component part of side
window.
3 - PUR Adhesive Sealant
❑ Bead diameter: width =
6.5 mm -dimension a-
height = 10 mm
-dimension b- (including
pre-coating, residual
material on window
glass and window
flange). n AG. Volkswagen AG do
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❑ Minimum curing time, byV
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refer to ir se
d ran
tee
⇒ “1.3 Minimum Curing utho
or
Time”, page 239 . ss
a ac
ce
le
un
4 - Body Flange
pt
an
d
itte
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5 - Upper Gap Dimension
erm
ab
ility
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wit
same.
is n
h re
ole,
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 - Windshield
❑ Removing windshield,
refer to
⇒ “4.1.8 Windshield”,
page 253 .
2 - PUR Adhesive Sealant
❑ Bead diameter: width =
6.5 mm, height = 10 mm
(including pre-coating,
residual material on win‐
dow glass and window
flange).
❑ Minimum curing time,
refer to
⇒ “1.3 Minimum Curing
Time”, page 239 .
3 - Body Flange
4 - Drip Rail
❑ Removing and instal‐
ling, refer to
⇒ “4.2 Drip Rail”,
page 298 .
5 - Gap Dimension n AG. Volkswagen AG do
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❑ From window edge to d byV ua
ran
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tho
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❑ Set a constant dimen‐ ss
a ac
sion of 2.5 mm using ad‐
ce
le
un
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6 - Sealing Lip
erm
ab
ility
ot p
shield.
h re
ole,
windshield.
❑ Install a new sealing lip.
rrectne
❑ 443.845.631 A
o
cial p
f inform
9 - Retainer
mer
n
c
n thi
te
sd
o
pr
cum
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en
ng
t.
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❑ Apply the adhesive bead in this area.
Co
Cop py
t. rig
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Vo
co lksw
by
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Prote AG.
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un
pt
Note
an
d
itte
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erm
ab
♦ When using an undamaged window again, cut back remaining
ility
ot p
wit
is n
h re
ole,
spec
♦ The remaining material serves as a base for the new adhesive
urposes, in part or in wh
t to the co
WARNING
rrectne
Do not prime the adhesive surface or use a cleaning solution
ss
on it. Keep the adhesive surface free of dirt and grease.
o
cial p
f inform
mer
atio
Exception: If bonding is not performed immediately after cutting
om
n
c
i
or
n
D 181 801 A1.
thi
te
sd
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cum
r
fo
en
ng
t.
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Special tools and workshop equipment required . Cop py
rig
ht ht
♦ Gauge -T10391-
rig by
copy Vo
by lksw
cted agen
Prote AG.
Note
♦ The narrow seam on the windshield can damage the sealing lip when removing it.
♦ Install a new sealing lip if an undamaged window is going to be reinstalled.
♦ Make sure the adhesive surfaces are free of dust and grease.
♦ Only use adhesive remover -D 002 000 10- .
♦ Apply the sealing lip immediately after cleaning.
♦ Peel off the protective film just before installing.
♦ Temperature approximately. 21 °C (70 °F).
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
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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
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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
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by c lksw
cted agen
Prote AG.
Note
WARNING
AG. Volkswagen AG d
agen oes
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byV gu
ara
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ris nte
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s c
2.6 Window Flange, Preparing for Glazing
s
ce
e
nl
pt
du
an
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erm
ab
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.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
Note
WARNING
The activator must not come into contact with the paint or the
paint will be damaged.
ce
e
Note
nl
pt
du
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itte
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erm
It is possible that the laser weld seam does not lie in the area of
ab
ility
the adhesive bead. In this case, the open weld seam must be
ot p
wit
sealed with window adhesive before bonding the window.
, is n
h re
hole
spec
es, in part or in w
– If the laser weld seam -3- on the sheet metal flange -4- is not
t to the co
covered by the adhesive bead -1-, then coat the laser weld
seam -3- with glass/paint primer -3- and fill the weld seam with
window adhesive -1-.
rrectness of i
Rear Window Body Flange
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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te
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Note C py
t. rig
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♦ If the adhesive tape is damaged when removing the rear window, new adhesive tape must be reapplied. by c lksw
cted agen
Prote AG.
♦ If no adhesive tape is applied, rainwater from the rear lid will drip into the luggage compartment.
ce
e
nl
pt
1 - Rear Lid
du
an
itte
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erm
2 - Adhesive Tape
ab
ility
ot p
– Apply the left and right
wit
adhesive tape , is n
h re
hole
-1K6.827.972- in the in‐
spec
dicated positions.
es, in part or in w
t to the co
3 - Rear Window
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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Prote AG.
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an
d
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Component Tightening Specifications
y li
rm
ab
pe
ility
Front door window regulator 3.5 Nm
ot
motor bolts
wit
, is n
h re
Rear door window regulator 3.5 Nm
hole
spec
motor bolts
es, in part or in w
t to the co
Rear door fixed window bolts 8 Nm
rrectness of i
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
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en
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t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
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Prote AG.
pt
an
d
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ab
pe
ility
it.
ot
wit
, is n
h re
hole
WARNING
spec
es, in part or in w
t to the co
When cleaning from inside the vehicle, do not press out on the
window that was just installed.
rrectness of i
– Clean the plastic trim: let the adhesive sealant harden for ap‐
m
tion in
thi
s
iva
do
cum
en
ng
– Bond flange -2- all around with fabric reinforced adhesive tape.
– Cut through adhesive material (with glass residue) in window
opening using -V.A.G 1561 A- and knife -V.A.G 1561- .
WARNING
an
itte
page 244 ab
ility
ot p
h re
⇒ “2.6 Window Flange, Preparing for Glazing”, page 245
hole
spec
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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rp
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f
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
Note
If windshield is to sbe
wagused
en AGagain, make
. Volkswagen AGsure that electrical connections for windshield heating are not damaged.
does
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ris nte
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nl
pt
du
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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
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
Remove the rear lid trim panel and the window frame trim panel.
Refer to ⇒ Body Interior; Rep. Gr. 70 ; Removal and Installation
– Disconnect the right and left connectors for the heated rear
window and tape them to the window glass.
– Depending on the vehicle equipment level, disconnect the an‐
tenna connections and tape them to the window glass
– Secure end of cutting cord -3- with handle -1- -V.A.G 1351/1-
before pulling out.
– Lay cutting cord -3- around the window and also guide inside
the second cord end.
– Secure end of cutting cord to -V.A.G 1654 A- -2-.
– Mount the -V.A.G 1654 A- -2- as illustrated.
– Relocate -V.A.G 1654 A- -2- appropriately and cut window
free.
– While cutting free, press cutting cord -3- against window using
-V.A.G 1474/5- to have clearance to window flange.. Volkswag
AG en AG
agen does
olksw not
yV
4.1.7 Undamaged Side Window, Removing
gu
db ara
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c
ss
Note
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pt
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The following describes removing and installing the left side win‐
erm
ab
wit
is n
h re
spec
t to the co
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
– Insert the cutting cord -3- into the window flange behind the
iv
o
pr
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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4.1.8 Windshield
rm
ab
pe
ility
ot
Removing
wit
, is n
h re
– Remove the A-pillar trim. Refer to ⇒ Body Interior; Rep. Gr.
hole
spec
70 ; Removal and Installation .
es, in part or in w
t to the co
– Remove the sun visors. Refer to ⇒ Body Interior; Rep. Gr.
68 ; Removal and Installation .
rrectness of i
– Remove interior rearview mirror. Refer to ⇒ Body Interior;
Rep. Gr. 68 ; Removal and Installation .
l purpos
tion in
r
thi
do
r
rp
cum
en
ng
n AG. Volkswagen AG do
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– Secure cutting cord enduth on the inside against pulling out using
o
or
-V.A.G 1351/1- -3-.ss a ac
ce
le
– Insert cutting cord -2- into window flange by aid of small tube
un
pt
an
d
-1-.
itte
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erm
ab
– Lay cutting cord around window.
ility
ot p
wit
is n
– Make sure the cutting cord is inserted under the corners of the
h re
ole,
windshield.
spec
urposes, in part or in wh
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
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
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
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rp
cu
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
255
AG.
4. Removal and Installation
Golf 2009 ➤
Body Exterior - Edition 06.2011
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
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erm
ab
h re
ole,
– Lower the door window -2- until the clamping screws -3- are
t to the co
accessible.
– Loosen bolts -3- (do not remove. left-hand thread) and press
rrectne
Note
o
cial p
f inform
mer
If this cannot be done because of a power window malfunction, remove the window regulator motor and then
atio
n
c
i
or
n thi
te
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Tightening Specifications
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The exterior mirror, the window shaft strip and the trim have been
removed.
– Remove the window guide -1- out of the mounts -3 and 4-
-arrows a and b-.
– From the inside, fold back the sealing lip on the window guide
-1- from the window frame -arrow d-.
– Starting the rear, pull the window guide -1- evenly -arrows c-
off the door flange -2-.
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4.5 Rear Door Window
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The following describes removing and installing the right rear door
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Note
If the work step is not possible due to a malfunction via the electrical window regulator, window regulator motor
can be unscrewed -8- to be able to slide window down.
Note
When screwing the bolt into spreader plug, do not use excessive force on the plug otherwise it may fall inside
into the door.
– Pull the spreader plug -3- out of the window guide -1- and out
of door window.
– Remove the trim. Refer to ⇒ “3.11 Trim”, page 158
AG. Volkswagen AG d
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– Center the spreader plug -3- and insert spreader plug with
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– Using a light pressure from above -arrow a-, engage window cted agen
Prote AG.
-1- into window regulator -5-.
– Continue by performing the steps used in removal in reverse
order.
Note
Removing
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Installation
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– Install the window regulator motor -1- and pull door window up
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and down so that splines are located better between motor Prote
cted AG.
agen
and cable drum.
– Connect the connectors -3-.
Tightening specification for the bolts -2-: 3.5 Nm
– Code a new window regulator motor with -Vehicle diagnostic
tester- .
– After coding, let the window regulator work in the one-touch
up/one-touch down mode and pull the switch for 2 seconds.
This way the window regulator recognizes it upper stop.
– Continue by performing the steps used in removal in reverse
order.
Tightening Specifications
Component Tightening Specifications
Bolts 3.5 Nm
AG. Volkswagen AG d
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Installation
– Slide back the locking ring -2-.
– Install the window crank -1-.
Note
♦ The illustration shows a right door hinge. The left door hinge
is identical.
♦ Do not bend window guide when removing!
Removing
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– From the inside, fold back the seal on the window guide -1-
from the window frame -arrow d-.
– Remove the window guide -3- from the mounts -arrows b-.
– Remove both seal clips -4- -2- from the door.
– Remove the seal -2- evenly -arrows a- from the door flange.
– Remove the window guide evenly -arrows c- from the door
flange.
– Start with the fixed door window -6-.
Installation
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-arrows a-.
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♦ While installing window guide, make sure it is seated evenly (wind noise).
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♦ The window guide -2- must touch the outer door seal -5-.
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Prote AG.
– Remove door trim. Refer to ⇒ Body Interior; Rep. Gr. 70 ;
Removal and Installation
– Remove the window shaft strip. Refer to
⇒ “3.9 Outer Window Recess Seal”, page 151
– Remove the window guide. Refer to
⇒ “4.8 Rear Door Window Guide”, page 269
– Pry out cover caps -4-.
– Remove the bolts -5-.
– Fold back the seal -2- from the flange.
– Insert the -T10236- under both clips -7-.
– Push the door window -1- slightly out -arrow a- until the clips
-7- are pushed out of the door -3-.
– Remove the door window -1- and the bar -6- -arrow b- from
the door -3-.
Installation
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– Install the door window -1- into the door -arrow a-.
– Push the door window onto the door -5- until the clips -6- au‐
dibly latch -arrows b-.
– Tighten bolts -4-, tightening specification: 8 Nm.
– Fold back the seal -2- around the flange.
Tightening Specifications
Component Tightening Specifications
Bolts 8 Nm
5 Special Tools
Note
The following describes removing bonded windows using the -AG. Volkswagen A
V.A.G 1474 A- . It is also possible to use -VAS 6452- . lkswagen G do
es n
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Special tools and workshop equipment requiredho
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♦ Removal Kit for Bonded Windows -V.A.G ss 1474 A- or Removal c
ce
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Kit for Bonded Windows -VAS 6452- nl
pt
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♦ Cutting Tools for Glass -V.A.G 1351-
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♦ Cartridge Gun -V.A.G 1628-
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♦ Cartridge Heater -V.A.G 1939-
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♦ Gauge -T10391-
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66 – Exterior Equipment
1 General Information
⇒ “1.1 Roof Edge Spoiler”, page 276
⇒ “1.2 Name Plates and Emblems Installation Information”, page
278
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♦ 1K window adhesive -DH 009 100 03-
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♦ Cleaning solution -D 009 401 04-
rrectne
♦ Primer applicator -D 009 500 25-
s
♦ Adhesive remover -D 002 000 10-
s o
cial p
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♦ Cutting wire -357 853 999 A-
mer
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1.1.2 Preparing Roof Edge Spoiler Bodywork
AG.
for Adhesive
Note
WARNING
The activator must not come into contact with the paint or the
paint will be damaged.
Note
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– Saturate a cloth with -LSE 020 100 A3- .
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– Always wipe application area for adhesive bead twice using
ility
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– Now apply glass/primer uniformly in one stroke using -D 009
hole
spec
500 25- .
es, in part or in w
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♦ Drying time is approximately 10 minutes
– Adhesive material must be applied to the primed surfaces of
the component.
rrectness of i
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WARNING
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1.1.4 Roof Edge Spoiler Minimum Curing
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Time
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WARNING
– Clean the painted surface with a dry cloth. Clean off any dirt
with -D 002 000 10- .
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⇒ “2.4 Front Wheel Housing Liner Overview”, page 283
un
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⇒ “2.5 Rear Wheel Housing Liner Overview”, page 284
erm
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⇒ “2.6 Roof Edge Spoiler Overview”, page 285
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⇒ “2.7 Sill Panel Cover Overview”, page 286
ole,
spec
⇒ “2.8 Sill Panel Extension Overview, GTI”, page 287 urposes, in part or in wh
t to the co
⇒ “2.9 Sill Panel Extension Overview, Golf R”, page 287
⇒ “2.10 Special Component Overview, Golf R ”, page 289
rrectne
⇒ “2.11 Wheel Cover Trim Overview”, page 290
s
2.1 Anti-Rodent System Overview
s o
cial p
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♦ Adapting the anti-rodent system brushes.
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❑ 5 x 20
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3 - Upper Protection
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❑ The material is polypro‐
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brush.
spec
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t to the co
4 - Front Protection, Anti-Ro‐
dent System
❑ The material is polypro‐
rrectne
pylene shaped like a
brush.
s
❑ With 3 spring nuts
s o
cial p
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5 - Bolt
form
mer
❑ 2 Nm
atio
m
❑ Quantity: 3
o
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❑ 5 x 16
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6 - Noise Insulation
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❑ Material is polypropy‐
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❑ Assembly overview, re‐
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fer to
c by lksw
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⇒ “1.7 Noise Insulation Prote AG.
Overview”, page 8 .
Note
2.0L diesel vehicles with steel wheel rims have a balance weight
on the left driveshaft to reduce noise. The anti-rodent system
brushes are adapted for collision reasons!
AG. Volkswagen AG d
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2.2 Drip Rail Overview
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The illustration shows a right door hinge. The left door hinge is identical.
hole
spec
es, in part or in w
t to the co
1 - Drip Rail
❑ Removing and instal‐
rrectness of i
ling, refer to
⇒ “4.2 Drip Rail”,
l purpos
page 298 .
2 - Retaining Strip
nform
ercia
a
removed, removing and
com
tio
installing.
n in
r
te o
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3 - Pop Rivet
s
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❑ Quantity: 5
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Pliers -VAS 5072- C py
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4 - Grommet
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Note
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❑ 10 Nm
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4 - Connector
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5 - Assembly Piece
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spec
es, in part or in w
t to the co
ling, refer to
⇒ “4.4.5 Turn Signal and
Entry Lamp Inside Exte‐
rrectness of i
rior Mirror”, page 309 .
l purpos
ling, refer to
m
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Co
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8 - Bolt Prote AG.
❑ 1 Nm
❑ Quantity: 3
9 - Mirror Glass
❑ Removing and installing, refer to ⇒ “4.4.1 Mirror Glass”, page 302 .
10 - Bolt
❑ 1 Nm
❑ Quantity: 2
11 - Frame
❑ Removing and installing, refer to ⇒ “4.4.3 Frame”, page 305 .
12 - Mirror Housing
❑ Removing and installing, refer to ⇒ “4.4.4 Mirror Housing”, page 307 .
Note
Note
ce
e
nl
pt
du
an
2 - Bolt
itte
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erm
ab
❑ Tightening specifica‐
ility
ot p
tion: 2 Nm
wit
, is n
❑ Quantity: 7
h re
hole
spec
❑ Different quantity is pos‐
es, in part or in w
sible
t to the co
Note
rrectness of i
The upper bolt must not be in the
l purpos
orm
m
ing Liner
o
n in
or c
❑ Material - PP/EPDM
thi
te
sd
iva
cu
m
f
en
ng
Note
ce
le
un
pt
an
d
itte
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Note
rm
ab
pe
ility
ot
wit
, is n
h re
wheel housing liner. Removing and installing the right rear
hole
spec
es, in part or in w
t to the co
♦ Due to equipment variations, small deviations must be con‐
sidered during removal and installation.
rrectness of i
1 - Rear Wheel Housing Liner
l purpos
❑ Material - PP/EPDM
nform
❑ Removing and instal‐
ercia
ling, refer to
m
a
⇒ “4.6 Rear Wheel
com
tio
Housing Liner”,
n in
r
te o
page 313 .
thi
s
iva
do
2 - Bolt
r
rp
cum
fo
❑ Tightening specifica‐
en
ng
t.
yi
tion: 2 Nm
Co
Cop py
t. rig
❑ Quantity: 9
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pyri by
Vo
o
by c lksw
3 - Nut cted agen
Prote AG.
❑ Quantity: 3
4 - Nut
❑ Gas-tight
DANGER!
Check the gas-tight ex‐
panding nuts for damage
and replace if necessary.
The expanding nuts seal
off the passenger com‐
partment from exhaust
gas and must always be
replaced if they are dam‐
aged.
1 - Rear Lid
2 - Primer Surface
❑ For adhesive bead on
retaining strip.
❑ Position of primer sur‐
face should be transfer‐
red from adhesive bead
depression to retaining
strip.
3 - Primer Surface
❑ For adhesive bead on
roof edge spoiler.
❑ Position of primer sur‐
face is to be transferred
from roof edge spoiler. AG. Volkswagen AG d
agen oes
olksw not
4 - Retaining Strip d by
V gu
ara
ise nte
❑ With recess for adhe‐ hor eo
ut
sive bead, bead diame‐ ss a ra
c
ter: width = 6 mm, height
ce
e
nl
= 10 mm.
pt
du
an
itte
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❑ Installation Information,
erm
ab
refer to
ility
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wit
, is n
h re
formation”, page 277 .
hole
spec
es, in part or in w
5 - Adhesive Tape
t to the co
❑ Two strips for securing
sides of roof edge spoil‐
er.
rrectness of i
6 - Adhesive Surface
l purpos
nform
ercia
7 - Foam Band
m
at
om
i
❑ Self-adhesive
on
c
in t
or
❑ Foam band should be checked for damage and replaced if necessary before installing roof edge spoiler.
his
ate
do
riv
cum
for
❑ Material PC/PET
en
ng
t.
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op
❑ Installation Information, refer to ⇒ “1.1.3 Roof Edge Spoiler Installation Information”, page 277 . C py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
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rm
ab
1 - Sill Panel Cover pe
ility
ot
wit
❑ Removing and instal‐
, is n
h re
ling, refer to
hole
spec
⇒ “4.12 Sill Panel Cov‐
es, in part or in w
t to the co
2 - Bolt
❑ Tightening specifica‐
rrectness of i
tion: 2 Nm
l purpos
❑ Quantity: 4
3 - Nuts
nform
ercia
❑ Quantity: 2
m
a
com
4 - Nuts
tion in
❑ Gas-tight
r
te o
thi
s
iva
❑ Quantity: 2
do
r
rp
cum
fo
en
ng
t.
DANGER!
yi Co
Cop py
t.
Check the gas-tight ex‐
rig
gh ht
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panding nuts for damage
op Vo
by c lksw
and replace if necessary. cted agen
Prote AG.
Note
ce
le
un
pt
❑ For attaching the sill
an
d
itte
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panel extension
erm
ab
ility
❑ 2 each on the bracket
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
The following describe removing and installing the left sill panel
extension. Removing and installing the right sill panel extension
is identical.
ce
e
nl
❑ 1 on the sill panel cover.
pt
du
an
itte
y li
3 - Adhesive Tape
erm
ab
ility
ot p
4 - Retaining Strip
wit
, is n
❑ Installing, refer to
h re
hole
⇒ page 333 .
spec
es, in part or in w
5 - Bolt
t to the co
❑ 1.2 Nm
❑ Secures retaining strip
rrectness of i
to sill panel.
l purpos
❑ Quantity: 9
6 - Bracket
nform
ercia
❑ Quantity: 2
m
at
❑ Secured to underbody
om
io
with expanding clip.
n
c
in t
or
his
e
7 - Expanding Nut
at
do
priv
c
❑ Pressed onto the under‐
um
for
body.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
⇒ “4.3 Front Bumper,
an
d
itte
Golf R”, page 220 .
y li
erm
ab
ility
2 - Cover Strip
ot p
wit
is n
h re
ole,
ling, refer to
spec
⇒ “4.11 Sill Cover Strip”,
urposes, in part or in wh
page 323 .
t to the co
3 - Extended Sill Panel
❑ Removing and instal‐
rrectne
ling, refer to
⇒ “2.9 Sill Panel Exten‐
ss
sion Overview, Golf R”,
o
cial p
f
page 287 .
inform
mer
atio
m
n
c
ling, refer to
i
or
n thi
e
sd
va
o
pr
cum
r
page 228 .
fo
en
ng
t.
yi Co
5 - Rear Name Plate t. Cop py
rig
gh
❑ Rear name plate dimen‐
ht
pyri by
Vo
sions, refer to
o
by c lksw
cted agen
⇒ “3.1 Rear Name Plate Prote AG.
Dimensions”,
page 291 .
6 - Roof Edge Spoiler
❑ Removing and instal‐
ling, refer to
⇒ “4.8 Roof Edge Spoil‐
er”, page 318 .
7 - Emblem On the Radiator
Grille
❑ Removing and installing, refer to ⇒ “4.3 Emblem on Radiator Grille, Golf R”, page 301 .
ce
e
nl
– Warm the rear wheel
pt
du
an
cover trim with a -V.A.G
itte
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erm
1416- and carefully re‐
ab
ility
move it. ot p
wit
, is n
❑ Installing:
h re
hole
spec
– Install the rear wheel
es, in part or in w
t to the co
rear bumper cover sep‐
aration and side panel.
rrectness of i
– Remove the protective
l purpos
nform
ercia
at
om
ion
c
-2-.
in t
or
his
ate
do
riv
2 - Bolt
p
cum
or
❑ Tightening specifica‐
f
en
ng
t.
tion: 2 Nm
yi Co
Cop py
t. rig
3 - Front Wheel Cover Trim
gh ht
pyri by
Vo
o
❑ Self-adhesive
c by lksw
cted agen
Prote AG.
❑ removing:
– Warm the front wheel
cover trim with a Hot Air
Gun -V.A.G 1416- and
carefully remove it.
❑ Installing:
– Clean the adhesive surface with adhesive remover -D 002 000 10- .
– Install the front wheel cover trim flush with the front wheel cover separation and the fender.
– Remove the protective backing -4- and forcefully press on the wheel cover trim.
4 - Protective Film
❑ Must be removed before adhering.
3 Specifications
⇒ “3.1 Rear Name Plate Dimensions”, page 291
⇒ “3.2 Rear Name Plate, GTI”, page 292
⇒ “3.3 Rear Name Plate, Golf R”, page 293
⇒ “3.4 Emblem Adidas on B-Pillar”, page 294
⇒ “3.5 Emblem STYLE on B-Pillar”, page 295
⇒ “3.6 Tightening Specifications”, page 295
1 - Name Plate
❑ Depending on the mod‐
el designation
2 - Name Plate
❑ Engine designation
3 - Side Dimension
❑ 30 mm from the outer
edge of the rear lid to the
name plate. agen
AG. Volkswagen AG d
oes
olksw not
4 - Height Dimension d by V gu
ara
ise nte
❑ 25 mm from the lower uthor eo
edge of the rear lid to the ss a ra
c
name plate.
ce
le
un
pt
an
d
itte
y li
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
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Specifications 291
Golf 2009 ➤
Body Exterior - Edition 06.2011
Note
♦ The name plate GTI is attached to the left side of where the name plate Golf is located.
♦ The dimensions are identical to the dimensions for the Golf name plate.
1 - Name Plate
❑ GTI
2 - Height Dimension
❑ It is 25 mm from the low‐
er edge of the tail lamp
to the name plate. agen
AG. Volkswagen AG d
oes
olksw not
V
3 - Side Dimension d by gu
ara
rise nte
❑ 30 mm from the outer utho eo
ra
edge of the rear lid to the ss a c
name plate.
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
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 - Name Plate R
❑ Model designation
2 - Height Dimension
❑ It is 15 mm from the low‐
er edge of the tail lamp
to the name plate.
3 - Side Dimension
❑ 70 mm from the outer
edge of the rear lid to the
name plate.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
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
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Specifications 293
Golf 2009 ➤
Body Exterior - Edition 06.2011
1 - Emblem
❑ Attached on the B-pillar
trim.
❑ 2 and 4 door
2 - Height Dimension for 2 door AG. Volkswagen AG d
agen oes
❑ 32.5 mm from the em‐ olksw not
yV gu
blem to the window se d b ara
nte
shaft strip. thori
eo
au ra
c
3 - Side Dimension, 2 door
ss
ce
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un
pt
an
d
itte
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erm
ab
emblem.
ility
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wit
is n
h re
❑ 32.5 mm from the em‐
ole,
spec
blem to the window
urposes, in part or in wh
shaft strip.
t to the co
5 - Side Dimension, 4 door
❑ 20 mm from the front
rrectne
edge of the trim to the
emblem.
ss 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.
Note
1 - Emblem
❑ Attached on the B-pillar
trim
❑ 2 and 4 door
2 - Side Dimension a
❑ Dimension (a) for 2
door, 18.5 mm from the
front edge of the trim to
the emblem.
❑ Dimension (a) for 4
door, 11 mm from the
front edge of the trim to
the emblem.
3 - Side Dimension b
❑ Dimension (b) for 2
door, 18 mm from the
rear edge of the trim to
the emblem.
❑ Dimension (b) for 4
door, 11.5 mm from the
rear edge of the trim to
the emblem.
AG. Volkswagen AG d
agen
4 - Height Dimension c Volksw
oes
not
by gu
❑ Same dimension for 2 rised ara
nte
and 4 door vehicles. ut
ho eo
ra
a
❑ 15 mm from the emblem ss c ce
e
pt
du
strip.
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
Tightening Specifications
nf
ercia
n in
thi
e
sd
iva
o
r
rp
cu
m
f
en
ng
3. Specifications 295
Golf 2009 ➤
Body Exterior - Edition 06.2011
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
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
⇒ “4.5 Front Wheel Housing Liner”, page 311 itte
y li
erm
ab
⇒ “4.6 Rear Wheel Housing Liner”, page 313
ility
ot p
wit
, is n
h re
hole
spec
⇒ “4.8 Roof Edge Spoiler”, page 318
es, in part or in w
t to the co
⇒ “4.9 Roof Edge Spoiler Retaining Strip”, page 320
⇒ “4.10 Sill Cover Strip Installation Instructions”, page 322
rrectness of i
⇒ “4.11 Sill Cover Strip”, page 323
l purpos
nf
ercia
or
⇒ “4.14 Sill Panel Extension, Golf R”, page 330
m
m
atio
m
n in
or c
thi
e
sd
iva
o
r
rp
cu
4.1 Anti-Rodent System
o
m
f
en
ng
t.
yi Co
op
Removing C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
Note
agen
Prote AG.
The wheel and the suspension strut are not shown in the illustra‐
tion.
Note
Installation
– Install the front protection. Pay attention to the guide -arrow-.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
4.2 Drip Rail
ce
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nl
pt
du
an
itte
y li
Removing
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
es, in part or in w
The following describes removing and installing the right drip rail.
t to the co
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
298
co Vo
by lksw
Rep. Gr.66 - Exterior Equipment cted agen
Prote AG.
Golf 2009 ➤
Body Exterior - Edition 06.2011
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
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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.
– Pry drip rail -1- from retaining strip -2- starting from top.
– Remove the drip rail -1- from the grommet at the bottom of the
fender -3-.
Installation
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.
Note
♦ When the drip rail is installed, check the sealing lip on the fender. If necessary, smooth out the sealing lip
with light pressure.
♦ Check the position of the upper edge. The lip must be touching the upper edge and must not be above the
edge of the roof.
Note
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
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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
l purpos
nform
mercia
a
com
tion in
Removing
r
te o
thi
s
iva
en
ng
t.
yi
– Remove the bolt -2- from the inside of the radiator grille -3-.
Co
Cop py
t. rig
gh
– Remove the emblem R -1- toward the front and from the radi‐
ht
pyri by
Vo
o
ator grille -3-.
c by lksw
cted agen
Prote AG.
Installation
Install in reverse order of removal.
Tightening specification for bolt -2-: 2 Nm.
Tightening Specifications
Component Tightening Specifications
Bolts -2- 2 Nm
ce
e
nl
pt
du
an
Note
itte
y li
erm
ab
ility
The following describes removing and installing the left mirror
ot p
wit
glass only. Removing and installing the right mirror glass is iden‐
, is n
h re
tical.
hole
spec
es, in part or in w
Removing
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.
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
es, in part or in w
t to the co
rrectness of i
Note
l purpos
Protect the paintwork on the edge of the housing with fabric-reinforced adhesive tape.
nf
ercia
– Press the bottom of the mirror glass -1- into the mirror housing
orm
-3-.
m
atio
om
n in
– Remove the mirror glass -1- from the bracket -2- and housing
or c
thi
sd
iva
o
r
cu
o
nect the mirror heater connector -4- on the back of the mirror
f
en
ng
t.
yi
glass -1-.
Co
Cop py
t. rig
gh
Installation
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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
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.
n AG. Volkswagen AG do
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
at
– Move the adjusting unit and motor -1- to the side and discon‐
om
io
in t
or
his
e
Installation
at
do
priv
cum
en
ng
t.
yi
– Tightening specifications for bolts -1-: 2 Nm.
Co
Cop py
t. rig
gh ht
• Perform a function test before installing the mirror glass. yri
p by
co Vo
by lksw
cted
Tightening Specifications
agen
Prote AG.
4.4.3 Frame
Special tools and workshop equipment required
♦ Pry Lever -80-200-
Note
Removing
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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.
Installation
Note agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ar
Always check the catches is for damage and replace if necessary.ante
ed
or eo
th
s au ra
c
To install, perform the steps used for removal in reverse order. s
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Tightening Specifications
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Component Tightening Specifications
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Prote AG.
Note
Note
Removing
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– Remove the mirror housing..
Prote AG.
– Remove the bulb socket -4- from the entry lamp -3-.
Removing Turn Signals
– Disconnect the connector -2- from turn signal -1-.
Installation
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To install, perform the steps used for removal in reverse order.
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Note
t to the co
The following describes removing and installing the left exterior
mirror. Removing and installing the right exterior mirror is identi‐
rrectne
cal.
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Removing
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– Remove the exterior mirror -1- and guide the wire through
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Installation
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Tightening Specifications
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4.5 Front Wheel Housing Liner
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Check the expanding nuts -5- for damage and replace if necessary.
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Installing the front part of the wheel housing liner -3- and the back
Prote AG.
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Check the expanding nuts -3- for damage and replace if necessary.
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DANGER!
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Check the gas-tight expanding nuts -4- for damage and replace
es, in part or in w
t to the co
if necessary.
The expanding nuts seal off the passenger compartment from
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rrectness of i
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– Install the rear wheel housing liner -1- making sure it is not
bent.
nform
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Tightening Specifications
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4. Removal and Installation
agen
Prote AG.
Golf 2009 ➤
Body Exterior - Edition 06.2011
Note
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ab
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Prote AG.
Note
There are locking tabs that are located at the bottom of the radiator grille that may have to be released.
Installation
AG. Volkswagen AG d
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– Install the radiator grille -1- into the front bumper cover.
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– Using light pressure, engage the radiator -1- into the front form
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Tightening Specifications
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Prote AG.
Component Tightening Specifications
Bolts -2- 25 Nm
WARNING
Before beginning the work, clean and seal off all surrounding
part.
Never use cutting wire to remove the spoiler on the edge of the
roof.
AG. Volkswagen AG d
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es, in part or in w
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– Thread cutting wire -6- between the rear lid -1- and spoiler on
the edge of the roof -4-.
nform
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– With “sawing motion” of both pull handles -5-, cut through ad‐
m
at
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or
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318
AG.
Rep. Gr.66 - Exterior Equipment
Golf 2009 ➤
Body Exterior - Edition 06.2011
AG. Volkswagen AG d
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c
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-1- and spoiler on the edge of the roof -arrows a- until all the
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must be heard.
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Cop py
Remove the side hooks -dimension c- = 260 mm (10.25 inches)
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and -dimension d- = 400 mm (15.75 inches).
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– Reach between the spoiler on the edge of the roof and the rear
Prote AG.
lid, press the spoiler -3- on the rear lid and remove the it up‐
ward -arrows b- from the catches -4-.
Installation
Note
ce
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un
pt
an
d
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erm
ab
ility
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wit
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spec
urposes, in part or in wh
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Prote AG.
Note
AG. Volkswagen AG d
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– Cut through adhesive bead -2- with help of cutting wire and
hole
spec
pull handles.
es, in part or in w
t to the co
– Remove the retaining strip from the rear lid. When doing this,
any remaining adhesive -2- will come loose. The hooks -4- in
the brake lamp opening will likewise disengage.
rrectness of i
Installing
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nf
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Prote AG.
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nf
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– Press the retaining strip securely to the rear lid -1- until the
Co
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hooks -4- engage.
t. C rig
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Vo
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– Secure the retaining strip with tape.
c by lksw
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Prote AG.
Note
♦ Make sure the adhesive surfaces are free of dust and grease.
♦ If removing the cover strip, only use the adhesive remover -D
002 000 10- to remove the adhesive residue.
♦ Bond the cover strip immediately after cleaning the surface
that will be bonded.
AG. Volkswagen AG d
agen oes
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wit
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spec
es, in part or in w
t to the co
rrectness of i
Removing
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– Heat the cover strip -1- with a -V.A.G 1416- and remove the
cover strip from the sill panel.
nform
ercia
Installation
m
a
com
ti
thi
s
iva
– Remove the protective backing from the new cover strip -1-.
do
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fo
t.
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entry point.
Co
Cop py
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Dimension -a- = 35 mm
rig ht
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Distance from the cover strip -1- to the sill panel strip -2-.
cted agen
Prote AG.
Note
The following describes removing and installing the left sill panel
cover. Removing and installing the right sill panel cover is identi‐
cal.
AG. Volkswagen AG d
agen oes
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ara
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un
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an
d
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ab
pe
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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
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove the screw -4- and move the rear wheel housing liner
-3- to the side.
– Remove the bolts -2-.
– Remove the sill panel cover -1-.
Installation
AG. Volkswagen AG d
agen oes
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ara
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aut ra
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nl
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du
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spec
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nf
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n in
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Note
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Check the expanding nuts -3 and 4- for damage and replace if necessary.
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t.
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Cop py
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DANGER! rig ht
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Check the gas-tight expanding nuts -4- for damage and replace Prote AG.
if necessary.
The expanding nuts seal off the passenger compartment from
exhaust gas and must always be replaced if they are damaged.
– Install the sill panel cover -1- and tighten the screws -2-.
– Position the wheel housing liner -5- and tighten the screw
-6-.
ce
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un
pt
an
d
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erm
ab
ility
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wit
is n
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spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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sd
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pr
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
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Prote AG.
– Remove the screws -2- from both bracket -3- from underneath
and remove the sill panel cover.
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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ce
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nl
pt
du
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nf
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– Slide the sill panel trim -1- forward -arrows a- until it is possible
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Screw Dimensions Cop py
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Note
agen
Prote AG.
♦ The screws for the stone chip protective molding are protected against corrosion. It is not necessary to apply
corrosion protection again.
♦ If a screw was over-torqued, this must be replaced with a “black” oversize screw.
AG. Volkswagen AG d
agen oes
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rise nte
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d
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wit
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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
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
Note
♦ The measurement -a- includes the wheel housing liner -1-. The other measurements -b through i- are always
measured starting from the center hole.
♦ Measurement -k- is made only on a 4-door vehicle.
♦ If the vehicle is a 2-door vehicle, then the measurement -k- must be aligned in height according to the front
holes.
Dimensions table
Dimension -a- = 997 mm
Dimension -b- = 712 mm
Dimension -c- = 457 mm
Dimension -d- = 302 mm
Dimension -e- = 147 mm
Dimension -f- = 628 mm
Installation
AG. Volkswagen AG d
agen oes
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or eo
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nl
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du
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spec
es, in part or in w
t to the co
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at
ion
c
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his
te
torqued.
a
do
priv
cum
or
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ng
over the screws -2- until the rocker panel extension touches
t.
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the sill panels -3-. C py
t. rig
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Position the rocker panel extension with a second mechanic so
op Vo
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that all screws remain in the openings when molding is slid on. cted agen
Prote AG.
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du
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erm
ab
ility
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spec
– Install the bolts -2- in both brackets -3- and in the sill panel
es, in part or in w
Tightening Specifications
Component Tightening Specifications
rrectness of i
Bolts -2- 2 Nm
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Removing
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Prote AG.
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– Remove
ss bolts -2- (quantity: 4).
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pt
– Warm sill panel extension -1- in adhesive surface area -3- be‐
an
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-4- between the sill panel strip and the rocker panel extension
wit
is n
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-1-.
ole,
spec
urposes, in part or in wh
– As soon as the bonded joint loosens, lift out the rocker panel
t to the co
Note
the sill panel extension. The procedure is identical for the right
o
cial p
f i
♦ The bolts for the retaining strip are protected against corro‐
atio
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Screw Dimensions
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Cop py
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Dimension -a- = 855 mm
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331
Prote AG.
4. Removal and Installation
Golf 2009 ➤
Body Exterior - Edition 06.2011
Note
The measurement -a- includes the wheel housing liner. The other measurements -b through i- are always
measured starting from the center hole.
n AG. Volkswagen AG do
lkswage es n
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byV ua
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spec
urposes, in part or in wh
t to the co
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f inform
mer
atio
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n
c
i
or
n thi
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pr
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fo
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t.
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Cop py
t. rig
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Prote AG.
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-arrow b- to stop.
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Installation
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Assembly Information
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
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pyri by
Vo
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Prote AG.
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un
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tape on the sill panel extension -1-.
an
d
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ab
– First press the sill panel extension-1- evenly and forcefully
pe
ility
near the adhesive surfaces.
ot
wit
, is n
h re
4.15 Stone Chip Protective Molding
hole
spec
es, in part or in w
t to the co
♦ Cordless Drill -VAS 5036-
Removing
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ The screws for the stone chip protective molding are protected against corrosion. It is not necessary to apply
corrosion protection again.
♦ If a screw was over-torqued, this must be replaced with a “black” oversize screw.
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Note
♦ The measurement -a- includes the wheel housing liner -1-. The other measurements -b through i- are always
measured starting from the center hole.
♦ Measurement -k- is made only on a 4-door vehicle.
♦ If the vehicle is a 2-door vehicle, then the measurement -k- must be aligned in height according to the front
holes.
Dimensions Table
Dimension -a- = 855 mm
Dimension -b- = 822 mm
Dimension -c- = 617 mm
Dimension -d- = 411 mm
Dimension -e- = 205 mm
Dimension -f- = 822 mm
Dimension -g- = 617 mm
Dimension -h- = 411 mm
Dimension -i- = 205 mm
Dimension -k- = 35 mm
Installation
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Rep. Gr.66 - Exterior Equipment
Golf 2009 ➤
Body Exterior - Edition 06.2011
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– Tighten screw with lowest torque so that screw is not over-
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– Position stone chip protective molding -1- evenly -arrow a- with
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openings on rear side over all screws -2- until molding comes
in contact with side members -3-.
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5 Special Tools
Special tools and workshop equipment required
♦ Cutting Tool Kit -V.A.G 1474 A-
♦ Suction Lifter -V.A.G 1344-
♦ Cutting Tools For Glass -V.A.G 1351-
♦ Window Removing Kit -V.A.G 1755-
♦ Cartridge Gun -V.A.G 1628-
♦ Cartridge Heater -V.A.G 1939-
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WARNINGS and CAUTIONS before you will be allowed to view this information.
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•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
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suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
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you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
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•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
rrectne
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
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check with your authorized Volkswagen retailer parts department for the latest information.
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•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
atio
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
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•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
t
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a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
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vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
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•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
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battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
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become inoperable, even if the correct code is used in a later attempt. Prote
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•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the soily n AG. Volkswagen AG do and burn spontaneously.
wagerags, which can ignite es
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•= Use pneumatic and ris electric tools only to loosen threaded partsnte and fasteners. Never use these tools to tighten
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fasteners, especially on light alloy parts. Always use a torque wrenchra to tighten fasteners to the tightening torque
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•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
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ignited, it will ignite gas trapped in the cells and cause the battery to explode.
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•=
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Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
hole
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
spec
es, in part or in w
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
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trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
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•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
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negative terminal (ground strap) and the ABS control module connector.
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•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
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•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
f
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Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
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components is not separately fused, disconnect the control module connector(s). ht. rig
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•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
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automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
AG. Volkswagen AG d
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Cautions & Warnings th eo
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•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
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battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
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•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
h re
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Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
spec
must never be electrically tested while it is not installed in the vehicle.
es, in part or in w
t to the co
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
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area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
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•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
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vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
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Page 3 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0