VW T Roc Body Repairs Exterior Eng

Service
Workshop Manual
T-Roc 2018 ➤
General body repairs, exterior
Edition 06.2020
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
50 - Body - front
55 - Bonnet, rear lid
57 - Front doors, door components, central locking
58 - Rear doors, door components
60 - Sunroof
63 - Bumpers
64 - Glazing
66 - Exterior equipment
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.
T-Roc 2018 ➤
General body repairs, exterior - Edition 06.2020
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures when working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when using testers and measuring instruments during a road test . . . . 1
1.3 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Bonding surfaces for self-adhesive components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.4 Secured threaded connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Assembly overview – lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Removing and installing lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Moving to and back from service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Assembly overview - wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Removing and installing wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Assembly overview - plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Assembly overview - plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Removing and installing bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Removing and installing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1 Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.1 Assembly overview - bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2 Assembly overview - Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3 Removing and installing bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.4 Adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.5 Removing and installing rear lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.6 Removing and installing bonnet release lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.7 Removing and installing striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.8 Removing and installing hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.9 Removing and installing insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.10 Removing and installing support rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.11 Removing and installing Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2 Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.1 Assembly overview - rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.2 Removing and installing rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.3 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.4 Removing and installing rear lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.5 Removing and installing operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.6 Removing and installing hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.8 Removing and installing rear lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.9 Removing and installing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.10 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.11 Removing and installing drive unit for rear lid VX69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.12 Removing and installing rear lid control unit J605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3 Tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Contents i
T-Roc 2018 ➤
3.1 Assembly overview - tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

3.2 Removing and installing tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.3 Removing and installing fuel tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.1 Assembly overview - door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.2 Removing and installing inner door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.3 Removing and installing outer door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.4 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.5 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.6 Adjusting striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.7 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2 Door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.1 Assembly overview - door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.2 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.3 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.4 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.5 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.6 Removing and installing inner door cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.8 Removing and installing cap on door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2.9 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.10 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.11 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.12 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.13 Removing and installing window channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.14 Removing and installing window slot outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2.15 Removing and installing window slot inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3 Central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.1 Overview of fitting locations - central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.2 Removing and installing driver door control unit J386 and front passenger door control unit
J387 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.3 Removing and installing tank filler flap locking motor V155 . . . . . . . . . . . . . . . . . . . . . . . . 174
3.4 Removing and installing ignition key battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.5 Removing and installing cap on ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.1 Assembly overview - door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.2 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.3 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.4 Adjusting striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.5 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.6 Removing and installing inner door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
1.7 Removing and installing outer door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2 Door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.1 Assembly overview - door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.2 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.3 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.4 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.5 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.6 Removing and installing inner door cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.8 Removing and installing cap on door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.9 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
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T-Roc 2018 ➤
2.10 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

2.11 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.12 Removing and installing window channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
2.13 Removing and installing window slot outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.14 Removing and installing window slot inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1 Sliding sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.1 Assembly overview - sliding sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.2 Assembly overview - sliding sunroof seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1.3 Removing and installing sunroof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1.4 Removing and installing rear sunroof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
1.5 Adjusting sunroof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.6 Removing and installing sliding sunroof seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
1.7 Removing and installing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
1.8 Removing and installing sunroof motor V1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1.9 Removing and installing sunroof roller blind motor V260 . . . . . . . . . . . . . . . . . . . . . . . . . . 252
1.10 Removing and installing sunroof roller blind control unit J394 . . . . . . . . . . . . . . . . . . . . . . 254
1.11 Removing and installing sliding sunroof adjustment control unit J245 . . . . . . . . . . . . . . . . 255
1.12 Removing and installing sunroof roller blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1.13 Removing and installing sliding sunroof frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
1.14 Operating without current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
2 Water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
2.1 Assembly overview - water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
2.2 Removing and installing water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
2.3 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
1 Bumper, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
1.1 Assembly overview - bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
1.2 Assembly overview - impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
1.3 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
1.4 Removing and installing add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
1.5 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
2 Bumper, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2.1 Assembly overview - bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2.2 Assembly overview - impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
2.3 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
2.4 Removing and installing impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
2.5 Removing and installing add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
2.6 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
1 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
1.1 Minimum curing periods for bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
1.2 Window repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
1.3 Installation instructions for bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
1.4 Preparing old undamaged windows for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
1.5 Preparing new windows for installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
1.6 Preparing body flange for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
1.7 Cleaning off excess adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
2 Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
2.1 Assembly overview - windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
2.2 Removing and installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
3 Rear windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Contents iii
T-Roc 2018 ➤
3.1 Assembly overview - rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

3.2 Removing and installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
4 Door windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
4.1 Assembly overview - front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
4.2 Assembly overview - rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
4.3 Removing and installing front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
4.4 Removing and installing rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
4.5 Removing and installing fixed rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

1 Radiator grille and front trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
1.1 Assembly overview – radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
1.2 Removing and installing radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
2 Spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
2.1 Assembly overview - spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
2.2 Removing and installing spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
3 Mouldings, trims, extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
3.1 Assembly overview - trim strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
3.2 Assembly overview - wheel arch covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
3.3 Assembly overview – wheel arch covers, R model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
3.4 Assembly overview - side member trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
3.5 Removing and installing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
3.6 Removing and installing rear trim cover for door, R model . . . . . . . . . . . . . . . . . . . . . . . . 376
3.7 Removing and installing B-pillar trim on door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
3.8 Removing and installing trim strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
3.9 Removing and installing entry moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
3.10 Removing and installing wheel arch covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
3.11 Removing and installing side member trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
4 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
4.1 Assembly overview - noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
5 Underbody cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
5.1 Overview of fitting locations - underbody cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
5.2 Assembly overview - bracing on underbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
5.3 Removing and installing underbody cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
5.4 Removing and installing tunnel cross-piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
6 Roof moulding and roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
6.1 Assembly overview - roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
6.2 Removing and installing roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
7 Trim film and protective film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
7.1 Renewing decorative film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
8 Exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
8.1 Assembly overview - exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
8.2 Removing and installing exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
8.3 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
8.4 Removing and installing mirror adjustment unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
8.5 Removing and installing mirror cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
8.6 Removing and installing mirror trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
8.7 Removing and installing turn signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
8.8 Removing and installing entry light in exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
9 Wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
9.1 Assembly overview - front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
9.2 Assembly overview – front wheel housing liner, R model . . . . . . . . . . . . . . . . . . . . . . . . . . 438
9.3 Assembly overview - rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
9.4 Removing and installing front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
iv Contents
T-Roc 2018 ➤
9.5 Removing and installing front wheel housing liner, R model . . . . . . . . . . . . . . . . . . . . . . . . 441
9.6 Removing and installing rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
10 Lettering and emblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
10.1 Assembly notes – bonded lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
10.2 Dimensions - lettering and emblems on rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
10.3 Dimensions - lettering and emblems on sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
10.4 Removing and installing badges at front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
10.5 Renewing lettering and badges at rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
11 Towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
11.1 Assembly overview - towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
11.2 Removing and installing towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
12 Heat shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
12.1 Overview of fitting locations - heat shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
12.2 Removing and installing underbody heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
Contents v
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vi Contents
T-Roc 2018 ➤
00 – Technical data
1 Safety information
(VRL014347; Edition 06.2020)
⇒ m1.1 easures when working on vehicles with start/stop sys‐
tem”, page 1
⇒ p1.2 recautions when using testers and measuring instru‐
ments during a road test”, page 1
⇒ p1.3 recautions when working on cooling system”, page 1
1.1 Safety measures when working on vehicles with start/stop system

Risk of injury from engine starting unexpectedly
If the vehicle's start/stop system is activated, the engine can
start unexpectedly. A message in the dash panel insert indi‐
cates whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
1.2 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring in‐
struments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
– Have a second person operate the test and measuring
equipment on the rear seat.
1.3 Safety precautions when working on cooling system

Risk of scalding from hot coolant
On a warm motor, the cooling system is under high pressure.
Hot steam/hot coolant can escape - risk of scalding.
– Wear protective gloves!
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
1. Safety information 1
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2 Repair notes
⇒ a2.1 nd attachment of lines”, page 2
⇒ c2.2 orrosion”, page 2
⇒ s2.3 urfaces for self-adhesive components ”, page 2
⇒ t2.4 hreaded connections”, page 2
2.1 Routing and attachment of lines

If hydraulic, pneumatic or electrical lines are disconnected or re‐
moved and installed, make corresponding drawings or photos.
This guarantees reinstallation in the original position.
2.2 Contact corrosion

Contact corrosion can occur if unsuitable fastening elements
(screws, bolts, nuts, washers) are used.
For this reason, only connecting elements with a special surface
coating have been fitted.
In addition, rubber, plastic and adhesives are made of non-con‐
ductive materials.
In case of doubt about the reusability of parts, use new parts as
listed in the Electronic parts catalogue.
Observe the following:
♦ We recommend the use of genuine parts only, since only
genuine parts are approved and aluminium compatible.
♦ We recommend the use of Volkswagen Genuine Accesso‐
ries.
♦ Damage resulting from contact corrosion is not covered by
the warranty.
2.3 Bonding surfaces for self-adhesive

components
♦ Before self-adhesive covers, door seals and similar compo‐
nents with self-adhesive strips are installed, vehicle must be
at room temperature.
♦ Bonding surfaces on vehicle body must be free of dust and
grease.
♦ Clean adhesive surfaces with cleaning solution and allow to
dry.
♦ After installation of self-adhesive covers, press them on firm‐
ly with a roller.
♦ After installation, check components for proper seating by
pulling them by hand.
2.4 Secured threaded connections

»Micro-encapsulated« bolts must be renewed after each remov‐
al, and threaded holes must be cleaned using a suitable thread
chaser.
2 Rep. gr.00 - Technical data

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50 – Body - front
1 Lock carrier
⇒ o1.1 verview – lock carrier”, page 3
⇒ a1.2 nd installing lock carrier”, page 4
⇒ t1.3 o and back from service position”, page 6
1.1 Assembly overview – lock carrier
Note
Different versions depending on model version; for allocation refer to ⇒ Electronic parts catalogue ETKA
1 - Lock carrier with add-on

parts
❑ Removing and instal‐
ling ⇒ page 4
❑ Moving to and back
from service position ⇒
page 6
2 - Bolt
❑ Qty. 3 on each side
❑ 8.0 Nm
3 - Carrier for headlight
❑ Left and right
4 - Air guide, left
5 - Centre air duct
6 - Bolt
❑ 8.0 Nm
7 - Bolt
❑ Qty. 4
❑ 8.0 Nm
8 - Bumper carrier
9 - Bolt
❑ 55 Nm
10 - Foam element
11 - Pop rivet
❑ Qty. 2
12 - Pedestrian protection
strut
❑ Not installed in all markets
13 - Centre guide profile
14 - Air guide, right
1. Lock carrier 3
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1.2 Removing and installing lock carrier

Special tools and workshop equipment required
♦ Guide pins -T10093-
♦ Torque wrench -V.A.G 1331-
♦ Engine and gearbox jack -VAS 6931-
4 Rep. gr.50 - Body - front

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Note
♦ The lock carrier is a safety-relevant component. The lock carrier must not be repaired for this reason.
♦ In the event of damage, renew lock carrier.
♦ For vehicles with adaptive cruise control unit -J428-, the adaptive cruise control unit -J428- must be
adjusted anew whenever the lock carrier has been removed, installed or replaced.
♦ General information and work instructions for the adaptive cruise control unit -J428- can be found in
⇒ Electrical system; Rep. gr. 27; Adaptive cruise control
Removing
– Always use guide pins -T10093- to move lock carrier to serv‐
ice position ⇒ page 6 .
– Remove guide pins -T10093- from left and right longitudinal
members with the aid of a second mechanic. Put down lock
carrier -1- with attachments. For example on engine and
gearbox jack -VAS 6931-.
– Remove bumper carrier and support arm ⇒ page 277 .
1. Lock carrier 5
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– Detach radiator module from lock carrier -arrow a-, but do

not remove it ⇒ Rep. gr. 19; Radiator, radiator fan; Remov‐
ing and installing radiator module.
– Lift condenser -3- off radiator module -2- -arrow b-, swing it
slightly out of lock carrier -arrow c-, but do not remove it.
– Pull out lock carrier -1- upwards between radiator module
and condenser -arrows d-.
Note
♦ Do not hang condenser and hydraulic oil cooler from lines.

♦ Do not kink lines for condenser and hydraulic systems.
Installing
Install in the reverse order of removal, observing the following:
Note
♦ Always fit lock carrier on the bolting points at the foremost

position in the elongated hole. Only then can the lock carrier
move in a crash situation.
♦ On vehicles equipped with adaptive cruise control unit -
J428-, the adaptive cruise control unit -J428- must be read‐
justed whenever the lock carrier has been removed, installed
or renewed.
♦ General information and work instructions for the adaptive
cruise control unit -J428- can be found in ⇒ Electrical sys‐
tem; Rep. gr. 27; Adaptive cruise control
Specified torques
♦ Lock carrier ⇒ o1.1 verview – lock carrier”, page 3 .
1.3 Moving to and back from service posi‐

tion
♦ Guide pins -T10093-

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♦ Adapter -T10467-
Moving to service position
Note
♦ The lock carrier is a safety-relevant component. The lock carrier must not be repaired for this reason.
♦ In the event of damage, renew lock carrier.
♦ For vehicles with adaptive cruise control unit -J428-, the adaptive cruise control unit -J428- must be
adjusted anew whenever the lock carrier has been removed, installed or replaced.
1. Lock carrier 7
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– Remove front bumper cover ⇒ page 279 .

– Remove headlights ⇒ Electrical system; Rep. gr. 94; Head‐
lights; Removing and installing headlights.
– Remove cable on mounting bracket of electrically operated
lid ⇒ page 56 .
– Unhook filler neck for washer fluid reservoir on carrier -2-
⇒ Electrical system; Rep. gr. 92; Window washer system;
Removing and installing washer fluid reservoir.
– Only remove one bolt -3- on left and right side of each longi‐
tudinal member.
– Screw in special tool guide pins -T10093- to left and right
longitudinal members where the bolts were previously loca‐
ted.
– Remove remaining bolts -3- on left and right side of longitu‐
dinal members.
– The lock carrier with add-on parts -1- can be pulled forwards
about 10 cm on the special tool guide pins -T 10093-. When
doing this, be careful with the electrical wires/cables leading
to lock carrier and, if necessary, detach connectors.
– Install special tool adapter -10467- (2 on each side) on left
and right between bumper carrier and longitudinal member.

T-Roc 2018 ➤
Moving from service position
– Remove special tool adapter -T10467- on left and right from

between bumper carrier and longitudinal member.
– Push lock carrier together with add-on parts -1- on the guide
pins -T10093- and onto the longitudinal member.
– Place bolts -3- on left and right.
– Unscrew guide pins -T10093- on left and right.
– Align lock carrier together with add-on parts -1- to longitu‐
dinal members and between wings ⇒ Body Repairs; Rep.
gr. 00; Body gaps/shut lines; Body - front.
1. Lock carrier 9
T-Roc 2018 ➤
Note
♦ Always fit lock carrier on the bolting points at the foremost position in the elongated hole. Only then can
the lock carrier move in a crash situation.
♦ On vehicles equipped with adaptive cruise control unit -J428-, the adaptive cruise control unit -J428- must
be readjusted whenever the lock carrier has been removed, installed or renewed.
Further installation is carried out in reverse order of removal.

When proceeding, observe the following:
Note
Do not permit hoses and lines to be pinched.
– Adjust headlights ⇒ Electrical system; Rep. gr. 94; Head‐

lights; Adjusting headlights.
Specified torques
♦ Lock carrier ⇒ o1.1 verview – lock carrier”, page 3 .

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2 Wings
⇒ o2.1 verview - wing”, page 11
⇒ a2.2 nd installing wing”, page 11
2.1 Assembly overview - wing
Note
The illustrations show the left-hand side. The right side is similar.
1 - Wings
ling ⇒ page 11
2 - End plate
❑ Attached to wing
ling ⇒ page 14
3 - Bolt
❑ Qty. 7 for wing
❑ 6.0 Nm
4 - Centre hex stud
❑ Qty. 2, wing bracket
❑ 6.0 Nm
5 - Dampers
Inserted between wing and
top of longitudinal member
6 - Bolt
❑ Qty. 2
❑ 8.0 Nm
7 - Wing bracket
8 - Top longitudinal member
insulation
❑ Inserted in top of longi‐
tudinal member.
9 - Front deformable element
10 - Bolt
❑ Qty. 1
❑ 8.0 Nm
11 - Bolt
❑ Qty. 1
❑ 8.0 Nm
12 - Rear deformable element
2.2 Removing and installing wing

2. Wings 11
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Removing
Note
Removal and installation are described only for the left wing. Removal and installation of the right wing are
similar.
– Remove front wheel housing liner ⇒ page 439 .

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– Removing plenum chamber cover ⇒ page 20 .
– Unscrew hexagon nuts -4- and remove guide bracket -5-.
– Pull out wing insulation -3-.
– Unscrew centre hex studs -6-.
– Unscrew bolts -2-.
– Carefully remove wing -1- along with end plate.
Note
The zinc intermediate piece -AKL 381 035 50- -7- (if there is one) will be damaged during removal.
Installing
Note
Install wing -1- without subjecting it to tensile stress.
2. Wings 13
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– Wax threaded connection of side member ⇒ page 15 .
• Wing end plate is installed ⇒ page 14 .
– The wing is aligned free of tension with wing bracket loos‐
ened.
– Always insert zinc intermediate piece -AKL 381 035 50- -7-
between wing and side member.
– Ensure joints are parallel and shut lines are equal ⇒ Body
Repairs; Rep. gr. 00; Body gaps; Body, front.
Specified torques
♦ Wing ⇒ o2.1 verview - wing”, page 11 .
Removing and installing end plate
Note
♦ Should it be necessary to install the end plate individually, first remove the door ⇒ page 120 .
♦ When the wing is removed, the end plate is removed with it.

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Removing
– Press together locking device -2- -arrows a-.
– Remove end plate -1- from wing -3- -arrows b-.
Installing
– Mount end plate -1- on wing -3-.
– Guide end plate -1- into joint in wheel arch cover -4- -arrow-
thoroughly.
– Press on end plate -1- until retaining hooks -2- engage
-arrows a-.
Applying wax
2. Wings 15
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– Thoroughly wax area -1- of wing where end plate -2- is in‐
stalled.
– End plate -2- must not be installed until wax has dried.
– Install wheel housing liner ⇒ page 439 .

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3 Plenum chamber bulkhead

⇒ o3.1 verview - plenum chamber bulkhead”, page 17
⇒ o3.2 verview - plenum chamber cover”, page 17
⇒ a3.3 nd installing bulkhead”, page 18
⇒ a3.4 nd installing plenum chamber cover”, page 20
3.1 Assembly overview - plenum chamber bulkhead
1 - Plenum chamber bulkhead

ling ⇒ page 18
2 - Lock nut
❑ Qty. 2
❑ 8.0 Nm
3 - Seal
4 - Dampers
5 - Clamping washers
❑ Qty. 4
3.2 Assembly overview - plenum chamber cover
3. Plenum chamber bulkhead 17

T-Roc 2018 ➤
1 - Plenum chamber cover

❑ Right side
ling, left-hand drive ve‐
hicles ⇒ page 20
ling, right-hand drive
vehicles ⇒ page 23
❑ Left side
ling, left-hand drive ve‐
hicles ⇒ page 20
ling, right-hand drive
vehicles ⇒ page 23
3 - Clip
❑ Qty. 3
4 - Seal
5 - Foam element
❑ Left and right
6 - Windscreen seal
❑ Part of windscreen
7 - Windscreen
8 - Wings
9 - Pull-off tab
10 - Adhesive tape
3.3 Removing and installing bulkhead


T-Roc 2018 ➤
Removing
– Undo and remove hexagon nuts -5-.
– Press off insulation -4- from bulkhead -1-.
– Remove bulkhead -2-.
Installing
– Check seal -3- for damage and renew if necessary.
Specified torques
Hexagon nuts ⇒ page 17

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3.4 Removing and installing plenum cham‐

ber cover
⇒ a3.4.1 nd installing plenum chamber cover, left-hand drive
vehicles”, page 20
⇒ a3.4.2 nd installing plenum chamber cover, right-hand drive
vehicles”, page 23
3.4.1 Removing and installing plenum cham‐

ber cover, left-hand drive vehicles
♦ Adhesive strip remover -VAS 6349-
♦ Hot-air blower -V.A.G 1416-
Fitting instructions
♦ If a plenum chamber cover is installed for the first time on
a new vehicle or a newly painted surface, the procedure
described in the ⇒ Paintwork manual ⇒ Paintwork repairs ⇒
Paint finish ⇒ Mouldings & film should be observed.
♦ If a plenum chamber cover is removed and reinstalled, only
use adhesive remover to remove the adhesive remains in
installation area.
♦ Remove existing adhesive residue of adhesive tape using
adhesive strip remover -VAS 6349-.
♦ Ensure that the adhesive surfaces are free of dust and
grease.
♦ The plenum chamber cover must be bonded in place imme‐
diately following cleaning.
♦ Remove protective film immediately before installation.
♦ Working temperature is approx. 21°C.

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Removing
Note
The procedures for removing and installing the plenum chamber covers may have to be modified slightly
depending on model variants.
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92; Wind‐

screen wiper system; Removing and installing wiper arms.
– Pull off seal -4- along entire length of plenum chamber cov‐
ers.
– Loosen clips -3- (qty. 3) at bottom.
– First pull plenum chamber covers -2- by hand, starting from
middle, upwards from windscreen seal -5-.
– Lift plenum chamber covers -2- over wiper arm shafts -7-.
– Remove plenum chamber covers -2-.
– Then pull out plenum chamber covers -1- by hand, starting
from middle, upwards from windscreen seal.

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– Heat up plenum chamber cover in area of adhesive strips

-10- using hot air blower -V.A.G 1416-.
– Pull off plenum chamber covers -1 and 2- from wing -8-.
– Remove plenum chamber covers -1 and 2-.
Installing
Note
♦ An insert is fitted in windscreen seal of new windscreens. Remove this insert before installing plenum
chamber cover.
♦ Push the plenum chamber cover into the windscreen seal by hand using only slight force. Never force it in
by hitting or using tools.
♦ Striking or banging the plenum chamber cover into the windscreen seal may crack the windscreen.
– Observe fitting instructions for adhesive surfaces ⇒ page

20 .

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– Spray windscreen seal -5- with a soapy solution so that ple‐

num chamber covers -1- and -2- are easier to press in.
– First push in plenum chamber covers -1-.
– Place plenum chamber covers -1- on windscreen seal -5-.
Starting from the outside, press into beading -5- by applying
light pressure.
– Then push in plenum chamber covers -2- over wiper arm
shafts.
Starting from outside, press into windscreen seal by applying
light pressure.
– Attach clips -3- (qty. 3) at bottom.
– Fit seal -4- on plenum chamber covers -1- and -2-.
– Using removal aids, pull protective film -9- off adhesive tape
-10-.
– Press on plenum chamber cover -1- forcefully in area of
adhesive tape sections -10-.
– Install wiper arms ⇒ Electrical system; Rep. gr. 92; Wind‐
3.4.2 Removing and installing plenum cham‐

ber cover, right-hand drive vehicles
Removing
Note
The procedures for removing and installing the plenum chamber covers may have to be modified slightly
depending on model variants.

T-Roc 2018 ➤
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92; Wind‐

– Pull off seal -4- along entire length of plenum chamber cov‐
ers.
– Loosen clips -3- (qty. 3) at bottom.
– First, starting from middle, pull plenum chamber covers -2-
by hand upwards out of windscreen seal -6-.
– Then, starting from middle, pull plenum chamber covers -1-
by hand upwards out of windscreen seal -6-.
– Heat up plenum chamber cover in area of adhesive strips
-10- using hot air blower -V.A.G 1416-.
– Pull off plenum chamber covers -1 and 2- from wing -8-.
– Remove plenum chamber covers -1 and 2-.
Installing

T-Roc 2018 ➤
Note
♦ An insert is fitted in windscreen seal of new windscreens. Remove this insert before installing plenum
chamber cover.
♦ Push the plenum chamber cover into the windscreen seal by hand using only slight force. Never force it in
by hitting or using tools.
♦ Striking or banging the plenum chamber cover into the windscreen seal may crack the windscreen.
– Observe fitting instructions for adhesive surfaces ⇒ page

20 .
– Spray windscreen seal -5- with a soapy solution so that ple‐
num chamber covers -1- and -2- are easier to press in.
– First push in plenum chamber covers -1-.
Starting from the outside, press into beading -5- by applying
light pressure.
– Then push in plenum chamber covers -2- over wiper arm
shafts.

T-Roc 2018 ➤

Starting from outside, press into windscreen seal by applying
light pressure.
– Attach clips -3- (qty. 3) at bottom.
– Fit seal -4- on plenum chamber covers -1- and -2-.
– Using removal aids, pull protective film -9- off adhesive tape
-10-.
– Press on plenum chamber cover -1- forcefully in area of
adhesive tape sections -10-.
– Install wiper arms ⇒ Electrical system; Rep. gr. 92; Wind‐

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55 – Bonnet, rear lid

1 Bonnet
⇒ o1.1 verview - bonnet”, page 27
⇒ o1.2 verview - Bowden cable”, page 28
⇒ a1.3 nd installing bonnet”, page 29
⇒ b1.4 onnet”, page 31
⇒ a1.5 nd installing rear lid lock”, page 38
⇒ a1.6 nd installing bonnet release lever”, page 45
⇒ a1.7 nd installing striker pin”, page 48
⇒ a1.8 nd installing hinges”, page 50
⇒ a1.9 nd installing insulation”, page 52
⇒ a1.10 nd installing support rod”, page 54
⇒ a1.11 nd installing Bowden cable”, page 56
1.1 Assembly overview - bonnet
1. Bonnet 27
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1 - Bonnet
ling ⇒ page 29
❑ Adjusting ⇒ page 31
2 - Seal in centre
3 - Striker
❑ Left and right
ling ⇒ page 48
4 - Adjusting buffer
5 - Lock nut
❑ Qty. 2 on each striker
❑ 12 Nm
6 - Clip
❑ Qty. 10
7 - Dampers
ling ⇒ page 52
8 - Hinge
ling ⇒ page 50
9 - Lock nut
❑ For securing bonnet
❑ 22 Nm
10 - Bolt
❑ For securing hinge
❑ 22 Nm Volkswagen Technical Site: http://vwts.ru http://vwts.info
11 - Bolt
❑ Self-locking; must be renewed after each time it has been loosened
❑ Qty. 2
❑ 12 Nm
12 - Lid lock
❑ Removing and installing ⇒ page 38
13 - Release lever
14 - Support rod
15 - Bracket
1.2 Assembly overview - Bowden cable
28 Rep. gr.55 - Bonnet, rear lid

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1 - Mounting bracket
2 - Bowden cable
❑ From mounting bracket
-1- to coupling -15-
3 - A-pillar trim
ling ⇒ General body
repairs, interior; Rep.
gr. 70; Trims, interior;
Removing and instal‐
ling A-pillar trim
4 - Operating lever
ling ⇒ page 45
5 - Bolt
❑ Qty. 1
❑ 1.5 Nm
6 - Expanding nut
❑ Qty. 1
7 - Foam element
8 - Bonnet lock, left
ling ⇒ page 38
9 - Connector
10 - Bowden cable
❑ From clutch -15- to left
bonnet lock -8-
11 - Adjuster screw
❑ For establishing syn‐
chronous operation of
bonnet locks
12 - Bowden cable
❑ From clutch -15- to right bonnet lock -13-
13 - Bonnet lock, right
14 - Cap
15 - Bowden cable coupling
16 - Release lever
17 - Bowden cable
❑ From release mechanism -16- to left bonnet lock -8-
18 - Bowden cable
❑ From release mechanism -16- to right bonnet lock -13-
1.3 Removing and installing bonnet

1. Bonnet 29
T-Roc 2018 ➤
Removing
– Remove spray jets -4- ⇒ Electrical system; Rep. gr. 92; Win‐
dow washer system; Removing and installing spray jets.
– Pull line -5- out of opening in bonnet -1-.
– If fitted, pull off caps -3-.
– Loosen hexagon nuts -2- in left and right hinges -6- (do not
remove).

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Further dismantling requires the assistance of a second me‐

chanic.
– Now, and only now, unscrew and remove hexagon nuts -2-
and lift bonnet -1- out of hinges -6-.
Installing
Installation of bonnet -1- is carried out accordingly in reverse

order of removal.
Note
Install the line -5- in a curve. If line is installed twisted it will kink.
– Adjusting bonnet -1- ⇒ page 31 .

Specified torques
♦ Hexagon nuts ⇒ o1.1 verview - bonnet”, page 27
1.4 Adjusting bonnet

1. Bonnet 31
T-Roc 2018 ➤
Note
♦ Vehicle must be standing on its wheels to enable bonnet to be adjusted.

♦ The adjusting buffers -2- on the left and right sides cannot be used to adjust the rear lid. They have the
function of stabilising and damping the bonnet.
♦ The bonnet is correctly adjusted when all shut lines are even when closed. The bonnet must not protrude
too far inwards or outwards. The contours must also be flush with each other.
♦ The bonnet must engage into the lid lock without excessive force.

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– Remove striker on left and right -1- ⇒ page 48 .

– The gaps/shut lines are adjusted via the hinges -3- ⇒ page
33 .
– Adjustment buffers -2- can be used to adjust height of front
part of bonnet relative to wings ⇒ page 34 .
– After bonnet has been adjusted, striker pins -1- can be rein‐
stalled and adjusted ⇒ page 35 .
Specified torques
♦ Lid lock ⇒ o1.2 verview - Bowden cable”, page 28
Adjusting hinges
Note
Do not unscrew bolts -3- and hexagon nuts -2- completely, just loosen them.
1. Bonnet 33
T-Roc 2018 ➤

– By loosening bolts -3- on left and right lid hinges -1-, bonnet
can be adjusted in height -arrow a- in relation to wings.
– By loosening hexagon nuts -2- on left and right bonnet
hinges -1-, bonnet can be centred in longitudinal direction
-arrow b- and aligned between wings -arrow c-.
– Ensure that gaps are uniform: ⇒ Body Repairs; Rep. gr. 00;
Body panel gaps/shut lines; Body - front.
– After adjusting, carry out corrosion protection measures on
bonnet hinges -1-, hexagon nuts -2- and bolts -3-.
– If necessary, readjust adjustment buffers.
Specified torques
♦ Hinges ⇒ o1.1 verview - bonnet”, page 27
Adjusting buffer adjustment

T-Roc 2018 ➤
– Turn adjustment buffer -1- to adjust -arrows-.
Note
The threads of the adjusting buffers and the key hole must be sprayed with preservative wax before screwing
in and adjusting.
– After bonnet -2- has been adjusted, the striker pin can be
reinstalled and adjusted ⇒ page 35 .
Adjusting striker pin
1. Bonnet 35
T-Roc 2018 ➤
– Loosen hexagon nuts -2-.

– Striker pins -1 and 3- can now be adjusted on bonnet in
lateral direction via elongated holes.
Specified torques

T-Roc 2018 ➤
Adjusting lid lock

♦ Setting gauge -3371-
Note
Use new bolts when adjusting the lid lock.
1. Bonnet 37
T-Roc 2018 ➤

– Loosen bolts -2- to adjust bonnet lock -1- relative to bonnet
laterally -arrow b- and vertically -arrows a- ⇒ Body Repairs;
Rep. gr. 00; Body panel gaps/shut lines; Body - front.
Specified torques
1.5 Removing and installing rear lid lock

⇒ a1.5.1 nd installing left bonnet lock”, page 38
⇒ a1.5.2 nd installing right bonnet lock”, page 41
1.5.1 Removing and installing left bonnet

lock

T-Roc 2018 ➤
Removing
Note
♦ Bolt -3- is self-locking and must be renewed after each time

it has been loosened.
♦ The microswitch cannot be renewed individually.
1. Bonnet 39
T-Roc 2018 ➤

– Disconnect connector for bonnet contact switch -3-.
– Remove bolts -2- from lock carrier and remove lid lock -1-
upwards -arrow a-.
– Unclip Bowden cables -3 and 6- from bonnet lock -arrow b-.

– Detach Bowden cables -3 and 6- from bonnet lock -1-
-arrow c-.
– Remove bonnet lock -1- completely from lock carrier
-arrow a-.
Note
♦ If the Bowden cable -3- is not long enough to remove the bonnet catch -1-, release the Bowden cable -3-
from the actuating lever -7- -arrows d and e-.
from the coupling -5-.

T-Roc 2018 ➤
Installing
– Attach Bowden cables -3 and 6- -arrow b-.

– Insert lid lock -1- in lock carrier -arrow a-.
– Screw in new bolts -2-.
– Connect connector for bonnet contact switch -4-.
– Adjust bonnet locks via adjusting threads -5- to ensure syn‐
chronous operation -arrow g-.
– Before closing bonnet, check function of release lever and
cable.
– Adjust lid lock ⇒ page 31 .
Specified torques
1.5.2 Removing and installing right bonnet

lock
1. Bonnet 41
T-Roc 2018 ➤
Note
♦ Bolt -3- is self-locking and must be renewed after each time

it has been loosened.
♦ The microswitch cannot be renewed individually.

T-Roc 2018 ➤

– Disconnect connector for bonnet contact switch -3-.
– Remove bolts -2- from lock carrier and remove lid lock -1-
upwards -arrow a-.
– Unclip Bowden cables -3 and 4- from bonnet lock -arrow b-.

– Detach Bowden cables -3 and 4- from bonnet lock -1-
-arrow c-.
– Remove bonnet lock -1- completely from lock carrier
-arrow a-.
Note
from the actuating lever -7- -arrows d and e-.
from the coupling -5-.
Installing
1. Bonnet 43
T-Roc 2018 ➤
– Attach Bowden cables -3 and 4- -arrow b-.

– Connect connector for bonnet contact switch -7-.
chronous operation -arrow g-.
cable.
– Adjust lid lock ⇒ page 31 .
Specified torques

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1.6 Removing and installing bonnet re‐

lease lever
⇒ a1.6.1 nd installing bonnet release lever”, page 45
⇒ a1.6.2 nd installing release lever on lock carrier”, page 46
1.6.1 Removing and installing bonnet re‐

lease lever
Removing
– Pull operating lever -1- slightly and unlock bonnet.

– Insert -arrow a- a small screwdriver in gap between release
lever -1- and retaining clip -2-.
– Lever retaining clip -2- out of release lever -1- -arrow b- and
pull release lever off mounting bracket -3- -arrow c-.
For further work on mounting bracket -4- , remove lower A-pillar
trim -3- ⇒ General body repairs, interior; Rep. gr. 70; Trims,
interior; Removing and installing A-pillar trim.
Installing
1. Bonnet 45
T-Roc 2018 ➤
• Lower A-pillar trim -3- is installed.

– Push retaining clip -2- into release lever -1-.
– Press release lever -1- onto mounting bracket -4-.
cable.
1.6.2 Removing and installing release lever

on lock carrier
Removing

T-Roc 2018 ➤
– Remove radiator grille ⇒ page 358 .

– Pull out locking clip -5- from release lever -1- as far as stop
-arrow c- using pliers.
– Unclip Bowden cables -4- -arrow a- and detach from release
lever -1- -arrows b-.
– Carefully detach spring clip -2- -arrow-.
– Pull out release lever -1- from lock carrier -arrow c-.
Note
If the retaining hooks -6- are damaged, renew the release lever -1-.
Installing
1. Bonnet 47
T-Roc 2018 ➤
– Place release lever -1- in lock carrier -arrow a- and press

down locking clip -6- -arrow b-.
– Engage spring clip -3- in lock carrier -arrow e-.
– Hook Bowden cables -5- into release lever -1- -arrows c-
and clip into place -arrows d-.
– Before closing the bonnet, perform functional test.
1.7 Removing and installing striker pin


T-Roc 2018 ➤
Removing

– Detach striker pin -1 or 3- from bonnet.
1. Bonnet 49
T-Roc 2018 ➤
Installing
Note
Always use new hexagon nuts after the hexagon nuts have been loosened.
Installation of striker pin -1 or 3- is carried out in reverse order

of removal.
– Adjust striker pin ⇒ page 31 .
Specified torques
♦ Striker pin ⇒ o1.1 verview - bonnet”, page 27
1.8 Removing and installing hinges

♦ Supplement tool set -T10395/8-/10-

Removing

T-Roc 2018 ➤
– Remove bonnet -3- ⇒ page 29 .

– Pull off hinge -1-.
Installing
1. Bonnet 51
T-Roc 2018 ➤
Installation of the hinge -1- is carried out in the reverse order of

removal.
– Install bonnet ⇒ page 29 .
Specified torques
1.9 Removing and installing insulation

♦ Removal lever -80-200-

T-Roc 2018 ➤
Removing
– Lever out retaining clips -2- from bonnet -1- using removal
lever -80-200-.
– Pull insulation -1- out of elongated holes -arrows a-.
Installing
1. Bonnet 53
T-Roc 2018 ➤
• When installing insulation -1-, ensure that retaining clips -2-

are fitted with wide side outwards.
– Slide insulation -1- with fitting lugs -arrows b- in longitudinal
holes.
– Insert all retaining clips -2- into bonnet until they engage.
1.10 Removing and installing support rod

T-Roc 2018 ➤
Removing
– Support bonnet with suitable workshop equipment.
– Swing support rod -1- forwards and pull it out of rubber
grommet -2-.
Installing
– Slide support rod -1- into rubber grommet -2- -arrow a-.
Swing support rod round to lock carrier -arrow b-.
– Check bracket -3- for damage, renew if necessary.
1. Bonnet 55
T-Roc 2018 ➤
1.11 Removing and installing Bowden cable

⇒ a1.11.1 nd installing Bowden cable to mounting bracket”,
page 56
⇒ a1.11.2 nd installing Bowden cable from right bonnet lock to
release lever”, page 58
⇒ a1.11.3 nd installing Bowden cable from left bonnet lock to
release lever”, page 59
⇒ a1.11.4 nd installing Bowden cable coupling with Bowden
cables”, page 62
1.11.1 Removing and installing Bowden cable

to mounting bracket
Note
♦ The illustrations show a left-hand drive vehicle.

♦ At the Bowden cable coupling -7-, the Bowden cable -2-
from mounting bracket -1- is installed from the left -arrow e-.
♦ For right-hand drive vehicles, the same procedures apply
accordingly.
♦ Only at the Bowden cable coupling -7-, the Bowden cable -2-
from mounting bracket -1- is installed from the right -arrow f-.

T-Roc 2018 ➤
Removing
– Remove release lever ⇒ page 45 .
– Lift cap -8- off Bowden cable coupling -7-.
– Unclip Bowden cable -2- from mounting bracket -1-
-arrow c-, and detach it -arrow d-.
– Pull out Bowden cable towards front using a piece of wire or
cord -arrow b-.
– Detach Bowden cable -2- from Bowden cable coupling -7-.
Installing
– Attach Bowden cable -2- to Bowden cable coupling -7-.
– Using a piece of wire or cord, pull the Bowden cable towards
inside.
– Attach Bowden cable -2- to mounting bracket -1-, and en‐
gage clips.
1. Bonnet 57
T-Roc 2018 ➤

from right bonnet lock to release lever
Removing

– Unscrew bolts -2- on lock carrier, and remove bonnet lock
-1- pulling it upwards slightly -arrow a-.
– Unclip Bowden cable -3- from bonnet lock -arrow b-, and
detach it -arrow c-.
– Unclip Bowden cable -3- from release lever -arrow e- and
detach -arrow d-.
Installing

T-Roc 2018 ➤
• The microswitch is installed on the bonnet lock.

– Engage Bowden cable -3- in release lever -arrow d- and
secure -arrow e-.
– Hook Bowden cable -3- into lid lock -1- -arrow c- and engage
-arrow b-.
chronous operation -arrow f-.
Specified torques
♦ Lid lock ⇒ o1.2 verview - Bowden cable”, page 28 .

from left bonnet lock to release lever
Removing
1. Bonnet 59
T-Roc 2018 ➤

– Unscrew bolts -2- on lock carrier, and remove bonnet lock
-1- pulling it upwards slightly -arrow a-.
– Unclip Bowden cable -3- from bonnet lock -arrow b-, and
detach it -arrow c-.
– Unclip Bowden cable -3- from release lever -5- -arrow d- and
detach -arrow e-.
Installing

T-Roc 2018 ➤
– Hook Bowden cable -3- into release lever -7- -arrow e- and
clip into place -arrow d-.
– Hook Bowden cable -3- into lid lock -1- -arrow c- and clip
into place -arrow b-.
chronous operation -arrow f-.
Specified torques
1. Bonnet 61
T-Roc 2018 ➤

coupling with Bowden cables
Note
♦ The Bowden cable coupling -1- and the Bowden cables

-2 and 3- leading to the bonnet locks are genuine replace‐
ment parts (form one genuine replacement part?).
♦ Bolts -6 and 7- remain screwed in.
Removing
– Unscrew bolts on lock carrier, and pull bonnet locks
-5 and 8- slightly upwards to remove.
– Unclip Bowden cables -2 and 3- from bonnet locks -arrow c-
and detach.

T-Roc 2018 ➤
– Release Bowden cable coupling -1- -arrow a- and remove

from lock carrier -arrow b-.
– Unclip Bowden cable -4- from Bowden cable coupling -1-
and detach.
Installing
– Engage Bowden cable -4- from Bowden cable coupling and
clip into place.
– Engage Bowden cable coupling -1- in lock carrier.
– Hook in Bowden cables -2 and 3- on bonnet locks -5 and 8-
and clip into place.
– Guide bonnet locks -5 and 8- into lock carrier -arrows c-.
– Screw in new bolts.
chronous operation -arrow d-.
Specified torques
1. Bonnet 63
T-Roc 2018 ➤
2 Tailgate
⇒ o2.1 verview - rear lid”, page 64
⇒ a2.2 nd installing rear lid”, page 67
⇒ r2.3 ear lid”, page 70
⇒ a2.4 nd installing rear lid lock”, page 77
⇒ a2.5 nd installing operating mechanism”, page 89
⇒ a2.6 nd installing hinges”, page 94
⇒ a2.8 nd installing rear lid seal”, page 98
⇒ a2.9 nd installing gas strut”, page 99
⇒ g2.10 as from gas strut”, page 101
⇒ a2.11 nd installing drive unit for rear lidVX69”, page 104
⇒ a2.12 nd installing rear lid control unitJ605”, page 106
2.1 Assembly overview - rear lid

⇒ o2.1.1 verview - rear lid”, page 64
⇒ o2.1.2 verview - rear lid with electric drive”, page 66
2.1.1 Assembly overview - rear lid

T-Roc 2018 ➤
1 - Tailgate
ling ⇒ page 67
2 - Lid lock
ling ⇒ page 77
3 - Hexagon nuts
❑ Qty. 2
❑ 20 Nm
4 - Adjusting buffer
❑ Left and right
5 - Ball-head pin
❑ Renew if loosened
❑ Left and right
❑ On rear lid
❑ 20 Nm + 45°
6 - Gas strut
ling ⇒ page 99
❑ Releasing gas ⇒ page
101
7 - Mounting bracket for ball-
head pin
❑ Left and right
❑ On side panel
8 - Bolts
❑ On side panel
❑ 10 Nm + 90°
9 - Lock nut
❑ Qty. 1 for each hinge
❑ 20 Nm + 90°
10 - Hinge
❑ Left and right
11 - Bolts
❑ 10 Nm
12 - Rubber grommet
13 - Support for buffer stop
❑ Qty. 2
2. Tailgate 65
T-Roc 2018 ➤
14 - Hexagon nuts
❑ Qty. 2
❑ 20 Nm
15 - Striker
16 - Rear lid seal
17 - Bolts
❑ Qty. 3
❑ 5 Nm
18 - Operating mechanism
2.1.2 Assembly overview - rear lid with electric drive
1 - Drive unit for rear lid -

VX69-
ling drive for rear lid ⇒
page 104
2 - Gas strut with cover
ling ⇒ page 99
❑ Releasing gas from gas
strut with cover ⇒ page
102
3 - Rear lid power opening
control unit -J938-
ling ⇒ page 106
4 - Connector
5 - Rear lid warning buzzer
-H32-
6 - Power latching motor for
rear lid -V382-
ling ⇒ page 85
7 - Button to close rear lid in
luggage compartment -E406-
ling ⇒ Electrical sys‐
tem; Rep. gr. 96; Con‐
trols; Removing and in‐
stalling button to close
rear lid in luggage com‐
partment -E406-

T-Roc 2018 ➤
2.2 Removing and installing rear lid

Removing
– Remove upper rear lid trim ⇒ General body repairs, interior;

Rep. gr. 70; Luggage compartment trims; Removing and
installing rear lid trim.
2. Tailgate 67
T-Roc 2018 ➤
– Remove lower rear lid trim ⇒ General body repairs, interior;

Rep. gr. 70; Luggage compartment trims; Removing and
installing lower rear lid trim.
– Remove roof spoiler ⇒ page 361 .
– Separate wiring connectors -arrows- of installed electrical
components.
– Thread wires together with rubber grommet out of rear lid.
– Loosen bolts -3- of left and right hinges but do not remove
completely yet.
Further removal requires the help of a second mechanic.
– Detach gas strut -2- from rear lid ⇒ page 99 .
– Alternatively, detach drive from rear lid ⇒ page 104 .
– Now, remove bolts -3- completely and then remove rear lid
-1-.
Installing

T-Roc 2018 ➤
Installation of rear lid -1- is carried out in reverse order of re‐

moval.
• Install gas struts -2- ⇒ page 99 or install drive ⇒ page 104 .
• Before closing rear lid -1-, check function of lid release com‐
ponents.
– Adjusting rear lid ⇒ page 70 .
2. Tailgate 69
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– Guide wires -2- into rear lid and attach rubber grommet.
– Connect connectors of all installed electrical components.
2.3 Adjusting rear lid


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Note
♦ Vehicle must be standing on its wheels to enable rear lid to be adjusted.

♦ The rear lid lock -2- is bolted directly to the rear lid -1-. The rear lid lock cannot be adjusted.
♦ The adjusting buffers -4- on the left and right sides cannot be used to adjust the rear lid. They have the
function of stabilising and damping the rear lid.
♦ The rear lid is correctly adjusted when all shut lines are even when closed. it is not protruding too far
inwards or outwards, and when the contours are flush with each other.
♦ The rear lid must engage in the striker plate without excessive force being applied.
2. Tailgate 71
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Use the setting gauge -3371-⇒ Body Repairs; Rep. gr. 00;
Bodywork gaps/shut lines; Rear body to check or set the gap
dimensions.
– The rear lid lock -2- cannot be adjusted.
– Loosen striker pin -4-, and adjust it after adjustment of hinge
and adjustment buffer ⇒ page 75 .
– If bolts -6- are loosened on left and right, it is possible to ad‐
just rear lid -1- in the oversized holes of hinge -5- -arrows a-
and -arrows b-.
– After completing adjustments, perform corrosion protection
measures on hinge and bolts -6-.
– Readjust adjusting buffer -3-.
Specified torques
♦ Bolts ⇒ o2.1 verview - rear lid”, page 64
Adjusting buffer adjustment
Note
If necessary, renew adjusting buffer ⇒ page 74 .

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– Loosen clamping bolt -4- until it is visible in rubber buffer.

– Pull detent slide -3- out of adjusting buffer -1-.
– Adjust detent slide to dimension -a- = 12.5 mm.
– Close rear lid in preliminary detent position with slight pres‐
sure in the middle.
– Open rear lid again.
2. Tailgate 73
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– Screw in clamping screw -1- of adjustment buffer -2- to a

depth of -a- = 20 mm.
– Check the adjustment.
Renew adjustment buffer.

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Removing
– To remove bump stop, turn entire adjusting buffer -1- by 90°
-arrow a-.
– Remove buffer stop from rear lid -2-.
Installing
– Carefully check that stop -3- is correctly seated in side panel
-4-.
– To install, insert entire bump stop -1- at right-angle into rear
lid -2- -arrow c-.
– Turn bump stop -1- through 90° -arrow b-.
– Adjust adjustment buffer -1- ⇒ page 72 .
Adjusting striker pin
2. Tailgate 75
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Note
♦ If hexagon nuts are loosened -2-, it is possible to adjust striker pin -1- in the oversized holes of hinge
-arrow a- and -arrow b-.
♦ Adjust striker pin -1- so that the recess of the rear lid lock with rotary latch is centred relative to the striker
pin -1- when it engages.

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– Remove trim for rear lid lock ⇒ General body repairs, interi‐
or; Rep. gr. 70; Luggage compartment trims; Removing and
installing trim for rear lid lock.
– Loosen hexagon nuts -2-.
– Move striker pin -1- into upper position and tighten hexagon
nuts -2-.
– Close rear lid and make sure adjustment has been carried
out correctly.
Specified torques
♦ Hexagon nut ⇒ o2.1 verview - rear lid”, page 64
2.4 Removing and installing rear lid lock

⇒ a2.4.1 nd installing rear lid lock”, page 77
⇒ a2.4.2 nd installing lid lock with power latching system”, page
79
⇒ n2.4.3 ew lid lock with power latching system”, page 83
⇒ a2.4.4 nd installing power latching system”, page 85
⇒ n2.4.5 ew power latching system”, page 88
2.4.1 Removing and installing rear lid lock

Removing
2. Tailgate 77
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Note
If the rear lid does not open, it can be opened in an emergency by reaching through the rear lid trim and
actuating the emergency release -3- by hand ⇒ Operating Manual.
– Remove rear lid trim ⇒ General body repairs, interior; Rep.

gr. 70; Luggage compartment trims; Removing and installing
lower rear lid trim.
– Pull off lid lock cover -5-.
– Separate electrical connector -4- from lid lock -1-.
– Unscrew hexagon nuts -2- and pull off lid lock -1- from stud.
– This causes retaining hooks -6- to be released from rear lid.
Installing

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– Push lid lock -1- onto studs until hooks -6- engage in rear lid
-arrow c-.
– Tighten hexagon nuts -2-.
– Fit electrical connector -4- on lid lock -1-.
• Before closing rear lid, check function of lid release compo‐
nents.
Specified torques
♦ Hexagon nuts ⇒ o2.1 verview - rear lid”, page 64
2.4.2 Removing and installing lid lock with

power latching system
2. Tailgate 79
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Removing
Note
actuating the emergency release -3- by hand ⇒ Operating Manual.

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– Pull off lid lock cover -5-.
– Separate electrical connector -4- from lid lock -1-.
– Unscrew hexagon nuts -2- and pull off lid lock -1- from stud.
– This causes retaining hooks -6- to be released from rear lid.
– Lock latch -7- of lid lock -4-.

– Using a screwdriver -5-, push lever -6- to stop in
-direction of arrow c-, and hold it in this position.
– Detach Bowden cable -1- from retainer by turning it
-arrow b-.
– Guide Bowden cable -1- out of lever -2- -arrow c-.
Installing
2. Tailgate 81
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– Using a screwdriver -5-, push lever -6- to stop in

-direction of arrow c-, and hold it in this position.
– Guide Bowden cable -1- into lever -2- -arrow a-.
– Attach Bowden cable -3- to retainer by turning it -arrow b-.
– Release lever -6-, and operate release mechanism -7-
-arrow d-.

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-arrow c-.
nents.
Specified torques
2.4.3 Installing new lid lock with power latching system
2. Tailgate 83
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– Push clip -3- to stop in -direction of arrow c-, and hold it in

this position.
– Guide Bowden cable -1- into lever -7- -arrow a-.
– Attach Bowden cable -2- to retainer by turning it -arrow b-.
– Release clip -3- and remove from lid lock -4- -arrow d-.
– Operate release mechanism -6- -arrows e-.

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-arrow c-.
nents.
Specified torques
2.4.4 Removing and installing power latching

system
Removing
2. Tailgate 85
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Note
actuating the emergency release by hand ⇒ Operating Manual.

– Disconnect connector -5- on power latching system -1-.
– Lift Bowden cable retainer -4- out of power latching system
-1-.
– Lift Bowden cable ball head -3- out of mounting -arrow b-.
– Turn retaining clip -2- 90° -arrow c-.
– Pull power latching system -1- off retaining clip -2-.

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Note
♦ The retaining clips -2- remain installed.

♦ If a new power latching system -1- is installed ⇒ page 88 , the retaining clips -2- must be removed.
Installing
– Fit power latching system -1- onto retaining clips -2-.

– Turn retaining clips -2- 90° -arrow c-.
– Fit Bowden cable ball head -3- onto mounting -arrow b-.
– Insert Bowden cable retainer -4- in power latching system
-1- -arrow a-.
– Connect connector -5- to power latching system -1-.
nents.
2. Tailgate 87
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2.4.5 Installing new power latching system
Note
The existing retaining clips -2- must be removed.
– Push retaining clips -2- installed on new power latching sys‐

tem into holes in rear lid -arrows c-.
– Fit Bowden cable ball head -3- onto mounting -arrow a-.
– Insert Bowden cable retainer -4- in power latching system
-1- -arrow b-.
– Connect connector -5- to power latching system -1-.
nents.

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2.5 Removing and installing operating

mechanism
⇒ a2.5.1 nd installing handle, without reversing camera”, page
89
⇒ a2.5.2 nd installing handle, with reversing camera”, page 91
2.5.1 Removing and installing handle, with‐

out reversing camera
Note
The brand badge can be renewed individually ⇒ page 452 .
2. Tailgate 89
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Removing
– Detach connector -4- from handle connection -1-.
– Slightly turn handle -1- -arrow a-, and remove it from rear lid
-2- -arrow b-.
In case of electrical malfunction, rear lid can be opened us‐
ing lock emergency release. Emergency release is accessible
through an aperture in rear lid trim.
Installing

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– Insert handle -1- in rear lid -arrow a- and turn slightly

-arrow b-.
– Attach connector -4- to handle.
nents.
Specified torques
♦ Bolts ⇒ o2.1.1 verview - rear lid”, page 64
2.5.2 Removing and installing handle, with

reversing camera
2. Tailgate 91
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Note
The brand badge can be renewed individually ⇒ page 452 .

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Removing
– Separate electrical connectors -6-.
– Slightly turn handle -1- -arrow a-, and remove it from rear lid
-3- -arrow b-.
– Pull water drain hose -4- off handle -arrow c-.
In case of electrical malfunction, rear lid can be opened us‐
ing lock emergency release. Emergency release is accessible
through an aperture in rear lid trim.
General information and work instructions for the reversing
camera -7- and the gearbox -2- ⇒ Communication; Rep. gr. 91;
Reversing camera system
Installing
– Insert handle -1- in rear lid -arrow a- and turn slightly

-arrow b-.
2. Tailgate 93
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– Attach water drain hose -4- to handle -arrow c-.

– Secure electrical connectors -6-.
nents.
Specified torques
♦ Bolts ⇒ o2.1.1 verview - rear lid”, page 64
2.6 Removing and installing hinges

Removing

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– Lower moulded headliner in area of hinge mounting ⇒ Gen‐

eral body repairs, interior; Rep. gr. 70; Roof trims; Removing
and installing moulded headliner.
– Moulded headliner can now be lowered sufficiently to allow
hexagon nut -4- to be unscrewed without damage occurring
to moulded headliner.
– Loosen hexagon nut -4- and bolts -2-. Do not unscrew com‐
pletely.
Note
♦ Mask off the edge of the roof and the upper edge of the rear lid to prevent the paintwork from being
damaged.
♦ For the following procedure a 2nd mechanic is required to support the rear lid in the area indicated by the
-arrow-.
♦ The gas struts -5- remain installed.
– Unscrew hexagon nut -4- and bolts -2-.

– Pull out hinge -1-.
Installing
2. Tailgate 95
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Hinge -1- installation is carried out in reverse order of removal.
Note
♦ Make sure that washer -3- is correctly seated.

♦ Recreate all seals which have been broken.
Specified torques
♦ Hexagon nut and bolts ⇒ o2.1 verview - rear lid”, page 64 .


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Removing
– Remove trim for rear lid lock ⇒ General body repairs, interi‐
or; Rep. gr. 70; Luggage compartment trims; Removing and
installing trim for rear lid lock.
– Unscrew hexagon nuts -2- and remove striker pin -1- from
lock carrier.
2. Tailgate 97
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Installing
– Mount striker pin -1- with hexagon nuts -2- onto lock carrier.
Specified torques
♦ Hexagon nut ⇒ o2.1 verview - rear lid”, page 64
2.8 Removing and installing rear lid seal

In the factory a sealant is applied to the rear lid seal, the seal is
fitted to the body flange and then rolled on.
Note
♦ When the seal is removed, the sealant on the inside of the

seal will be spread and the flanks will be bent out slightly.
If the seal is then refitted, sealing and firm seating are no
longer guaranteed.
♦ Therefore, each seal that is completely removed must be
replaced with a seal known as a “tap-on seal”.
♦ If a seal has been partially removed, squeeze sides of seal
together before installing.

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Removing
– Pull seal -1- off body flange -2-.
Installing
– Align seal -1- with vulcanised point for securing the gas strut
-arrows-.
– Press seal -1- evenly onto body flange by hand.
2.9 Removing and installing gas strut

Removing
Note
The rear lid must be supported when a gas strut is removed. One gas strut alone cannot support an open
rear lid.
2. Tailgate 99
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– Open rear lid and brace it open.
NOTICE
Risk of damage to spring clip caused by levering it out too far.
The spring clip may break.
– Never lever spring clip completely out of ball socket.
– Position a small screwdriver -3- beneath spring clips -2-.

– Raise spring clips -2- until spring clips can be moved over
ball sockets.
– Pull off gas strut -1- from ball-head pins -4- -arrows-.
After removing gas strut, slide spring clips -2- back immediately.
– When the gas strut is disposed, gas needs to be released
from gas strut ⇒ page 101 .
Installing

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• The spring clips -2- are pushed onto the ball sockets of the
gas strut -1-.
– Push ball sockets of gas strut -1- onto ball-head pins -5- until
ball sockets engage audibly with the ball-head pins.
Specified torques
♦ Ball-head pin ⇒ o2.1 verview - rear lid”, page 64
2.10 Releasing gas from gas strut

⇒ g2.10.1 as from gas strut”, page 101
⇒ g2.10.2 as from gas strut with cover”, page 102
2.10.1 Releasing gas from gas strut
Note
Only components that have been depressurised may be disposed of through the normal channels.
2. Tailgate 101
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CAUTION
Risk of eye injury caused by flying swarf.
Risk of eye injury or eye irritation.
– Cover area around holes with cloth.

– Saw cylinder of gas strut -1- at notch -2- or drill open
-arrow b-.
– Saw cylinder of gas strut -1- at a distance of 20 mm
-dimension a- from edge of housing or drill open -arrow c-.
– Feed oil and cleaning clothes into existing method of dispos‐
al.
2.10.2 Releasing gas from gas strut with cover
Note
Only components that have been depressurised may be disposed of through the normal channels.

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CAUTION
Risk of eye injury caused by flying swarf.
Risk of eye injury or eye irritation.
– Saw housing -2- of gas strut -1- at cutting line shown -3- and
remove.
– Cover area around hole with cloth.
– Saw cylinder of gas strut -5- at a distance of 50 mm
-dimension a- from ball socket or drill open -arrow b-.
– Feed oil and cleaning clothes into existing method of dispos‐
al.
– Saw through compression spring -4- at 3 positions -6- and
rotate inwards -arrow c-.
The gas strut is now depressurised and can be disposed of.
2. Tailgate 103
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2.11 Removing and installing drive unit for

rear lid -VX69-
Removing
Note
♦ Sensor in motor 1 for rear lid -G745- is integrated in rear lid drive unit -V444-.
♦ If rear lid drive is removed, rear lid must be supported.
♦ Installed on the right-hand side is a gas strut with cover.
– Detach C-pillar trim ⇒ General body repairs, interior; Rep.

gr. 70; Trims, interior; Removing and installing C-pillar trim.
– Lower moulded headliner at rear ⇒ General body repairs,
interior; Rep. gr. 70; Roof trims; Removing and installing
moulded headliner.
– Disconnect electrical connectors -5- for wires of rear lid drive
on C-pillar or on inside of roof cross member.
– Pull out wires with rubber grommet -4-.

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– Support rear lid.
NOTICE
Risk of damage to spring clip caused by levering it out too far.
The spring clip may break.
– Never lever spring clip completely out of ball socket.
– Push drive towards ball-head pin.

– Guide a screwdriver -6- under spring clips -2- -arrow a-.
– Spring clip -2- opens as screwdriver is inserted enough to al‐
low ball socket to be moved over ball-head pin -3- -arrow b-.
– Pull rear lid drive -1- off ball head pins -3-.
After removing rear lid drive, pull out screwdriver -6- again im‐
mediately.
Spring clip -2- glides back to installation position.
Installing
• Ball-head pins -3- installed.
2. Tailgate 105
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• Spring clip -2- pushed back.

– Push drive -1- with ball sockets onto ball studs -3- -arrows-
until they engage audibly.
– Rout wires with rubber grommet -4-, and push in rubber
grommet firmly.
– Join electrical connectors for wires of rear lid drive -1-.
If the rear lid drive unit -VX69- is renewed, start the respective
function ⇒ Vehicle diagnostic tester.
Specified torques
♦ Ball-head pin ⇒ o2.1 verview - rear lid”, page 64
2.12 Removing and installing rear lid control unit -J605-
Removing
– Remove left luggage compartment side trim ⇒ General body
repairs, interior; Rep. gr. 70; Luggage compartment trims;
Removing and installing luggage compartment side trim.
– Raise locking device -3- -arrows a-.

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– Press control unit -1- out of openings -arrow b-

Installing
– Push control unit -1- into openings until retaining hook -3-
engages.
– Secure electrical connectors -2-.
If the rear lid control unit -J605- is renewed, start the respective
function ⇒ Vehicle diagnostic tester.
2. Tailgate 107
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3 Tank flap unit

⇒ o3.1 verview - tank flap unit”, page 108
⇒ a3.2 nd installing tank flap unit”, page 108
⇒ a3.3 nd installing fuel tank flap”, page 112
3.1 Assembly overview - tank flap unit
1 - Tank flap unit

ling ⇒ page 108
2 - Tank flap
ling ⇒ page 108
3 - Bolt
❑ Qty. 1
❑ 1.5 Nm
4 - Tank filler flap locking mo‐
tor -V155-
ling ⇒ page 174
5 - Water drain hose
❑ Routed between wheel
housing and wheel
housing liner
6 - Electrical connector
7 - Seal
3.2 Removing and installing tank flap unit


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♦ Removal wedge set -VAS 895 015-
Removing
Note
The removal and installation procedure for the tank flap unit on vehicles with reducing agent filler neck is no
different than that shown here.
– For easier insertion of the wedges, spray the edge of tank

flap unit -3- with soapy water.
– Screw off tank cover.
– Unscrew bolt -2-.
3. Tank flap unit 109

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– Insert wedge No. 26 -5- from removal wedge set -VAS 895
015- between edge of tank flap unit -3- and side panel
-arrow a-.
– Press edge of tank flap unit -1- upwards until retaining hook
-6- behind side panel is released -arrow f-.
– Guide wedge No. 4 -4- from removal wedge set -VAS 895
015- into gap between tank flap unit -1- and side panel,
and leave it there to make sure that tank flap unit remains
pushed outwards.
– After this, use wedge No. 26 -2- from removal wedge set
-VAS 895 015- to release locking devices in sequence indi‐
cated by -arrows b through d-.
Note
Make sure that the tank flap unit does not strike the side panel -arrow c-.
– Pull tank flap unit -1- downwards slightly and swing out from
side panel -4- -arrow a-.
When doing this, upper retaining hooks are released.

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– Pull out tank flap unit -1- towards rear -arrow b-.
– Guide water drain hose -3- together with tank flap unit out of
side panel -4-.
Installing
Note
Make sure that the tank flap unit does not strike the side panel -arrow c-.
– Insert water drain hose -3- through opening in tank flap unit
-1- and then pull it through as far as it will go.
– Push water drain hose -3- into side panel -4-.
– Insert tank flap unit -1- into side panel -arrow d-.
– Swing tank flap unit -1- into side panel -arrow e- until retain‐
ing hooks engage.
– Pull sleeve over filler neck -2-.
• Check function of release components.

T-Roc 2018 ➤
Specified torques
♦ Bolt ⇒ o3.1 verview - tank flap unit”, page 108
3.3 Removing and installing fuel tank flap

Removing
– Push tank flap -1- out of catches of tank flap unit -2-
-arrow a-.
– Remove tank flap -arrows b-.
Installing
Install in reverse order of removal, observing the following:

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– Position tank flap -1- on tank flap unit -2- -arrows a-.
– Push tank flap into catches of tank flap unit -arrow b-.

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57 – Front doors, door components, central locking

1 Door
⇒ o1.1 verview - door”, page 114
⇒ a1.2 nd installing inner door seal”, page 117
⇒ a1.3 nd installing outer door seal”, page 119
⇒ a1.4 nd installing door”, page 120
⇒ d1.5 oor”, page 123
⇒ s1.6 triker pin”, page 126
⇒ a1.7 nd installing door arrester”, page 128
1.1 Assembly overview - door
Note
♦ The illustrations show the left-hand side. The procedure for the right-hand side is basically the same.
♦ After renewal of A-pillar, the specified torque for bolts -2 and 5- as well as for -14 and 17- changes.
114 Rep. gr.57 - Front doors, door components, central locking

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1 - Rear door
ling ⇒ page 120
2 - Bolt
❑ Loosening once to ad‐
just the door is permit‐
ted. Always renew oth‐
erwise.
❑ 50 Nm
Note
♦ After renewal of A-pillar the

specified torque changes.
♦ Specified tightening torque after
renewal of A-pillar: 20 Nm + 90°
3 - Door hinge
❑ Hinge is split into two. Upper and lower sections can be renewed individually if necessary.
❑ Lower part is secured to hinge upper part with bolt -8-.
4 - Cap
❑ For bolt -8-
5 - Bolt
❑ Installed from inside vehicle.
❑ Loosening once to adjust the door is permitted. Always renew otherwise.
❑ For loosening and reattaching, dash panel is not removed
❑ To remove and install, the dash panel must be removed ⇒ General body repairs, interior; Rep. gr. 70;
Dash panel; Removing and installing dash panel
❑ 50 Nm
1. Door 115
T-Roc 2018 ➤
Note

6 - Cap
❑ For bolts -7- and -16-
7 - Bolt
❑ 50 Nm
8 - Bolt
❑ Connects upper part of hinge -3- to bottom part of hinge -6-
❑ 23 Nm
9 - Door hinge
❑ Upper part is secured to hinge lower part with bolt -5-.
10 - Bolt
❑ 30 Nm
11 - Bolts
❑ Qty. 2
❑ 9 Nm
12 - Door arrester
13 - Door hinge
14 - Bolt
❑ For removal and installation, A-pillar lower trim must be removed ⇒ General body repairs, interior;
Rep. gr. 70; Trims, interior; Removing and installing A-pillar gap cover
❑ 50 Nm
Note

renewal of A-pillar: 20 Nm +90°
15 - Door hinge
16 - Bolt
❑ 50 Nm
17 - Bolt

T-Roc 2018 ➤
❑ 50 Nm
Note

renewal of A-pillar: 20 Nm +90°
1.2 Removing and installing inner door

seal
During production, a sealant is applied to the inner door seals,
which are then placed on the door flange and rolled on.
Note
♦ When removing the seal, the sealant is distributed across

the inside of the seal. The sides are bent upwards slightly
when this is being done. If the seal is then refitted, sealing
and firm seating are no longer guaranteed.
♦ Therefore, each seal that is completely removed must be
renewed with a so-called “tap-on seal”.
♦ If a seal has been partially removed, squeeze sides of seal
together before installing.
♦ Removal and installation are described only for the left door
inner seal. The procedure for the right-hand side is basically
the same.
♦ For reasons of clarity, the front door is shown in removed
state.
Removing
1. Door 117
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– Remove sill panel trim ⇒ General body repairs, interior; Rep.

gr. 70; Trims, interior; Removing and installing sill panel trim.
– To remove inner door seal, remove pillar trims as required
⇒ General body repairs, interior; Rep. gr. 70; Trims, interior;
Overview of fitting locations – trims, interior.
– Pull inner door seal -2- off body flange.
Installing

T-Roc 2018 ➤
– Start installing door inner seal -2- at top radius of door aper‐
ture -arrow-.
– Align vulcanised point -3- above lower hinge.
– Install pillar trims ⇒ General body repairs, interior; Rep.
gr. 70; Trims, interior.
– Install sill panel strip ⇒ General body repairs, interior; Rep.
gr. 70; Trims, interior; Removing and installing sill panel
strip.
1.3 Removing and installing outer door seal
1. Door 119
T-Roc 2018 ➤
Removing
– Pull off door seal -1- from door -2- with clips -3-.
Installing
– Check clips -3- for damage and renew if necessary.
– Press door seal -1- on door -2- together with the clips -3-.
Clips -2- must be pressed in as far as stop.
1.4 Removing and installing door

♦ Door alignment tool -3320-
♦ Universal joint for 3320 -3320/1-
♦ Bit for 3320 -3320/2-
♦ Bit for 3320 -3320/3-
♦ Bit -3410-

T-Roc 2018 ➤
♦ Removal wedge -3409-
Note
The removal and installation sequence is for the rear left door.
Removal and installation of the rear right door are similar.
Removing
1. Door 121
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– Disconnect battery earth cable ⇒ Electrical system; Rep.

gr. 27; Battery; Disconnecting and connecting battery.
– Press wedge -T10383/1- between bellows -3- and locking
element -arrow a-.
– Push locking element upwards -2- with wedge -T10383/1-
-arrow b- and separate electrical connector -3- from coupling
station -arrow c-.
– Undo screws -7- from hinges.
– Unscrew bolt -4- for door arrester -5-.
– Push door retaining strip -5- inwards -arrow d-.
– Lift front door -1- upwards -arrow f- so that hinge -6- is
released from hinges -7-.
Installing

T-Roc 2018 ➤
Installation is carried out in the reverse order of removal. To this

end, the following should be observed:
– Prior to installing the front door, the door retaining strap must
be folded towards the inside of the vehicle in order to avoid
damage to the paintwork.
Note
After door installation the hinge arms must be flush one above the other.
– Adjust front door -1- ⇒ page 123 .

– Observe front door shut lines -1- ⇒ Body Repairs; Rep.
gr. 00; Body panel gaps/shut lines; Body - middle.
– Connect battery earth cable ⇒ Electrical system; Rep. gr. 27;
Battery; Disconnecting and connecting battery.
Specified torques
Door arrester and hinges ⇒ page 114 .
1.5 Adjusting door

1. Door 123
T-Roc 2018 ➤

♦ Bit for 3320 -3320/2-
♦ Bit for 3320 -3320/3-
♦ Bit -3410-
Note
♦ Only the adjustment for the left front door is described. The adjustment of the right front door is similar.
♦ Vehicle must be standing on its wheels when front door adjustment is performed.
♦ The front door is correctly adjusted when all shut lines are even when closed. it is not protruding too far
♦ Dimensions for checking gaps/shut lines ⇒ Body Repairs; Rep. gr. 00; Body panel gaps/shut lines; Body -
middle.
♦ After installing or alignment, carry out corrosion protection measures on hinges and screws/bolts.

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Adjusting shut lines

To be able to adjust shut lines correctly, bolts -2-, -3-, -5- and
-6- in A-pillar must be loosened.
– In order to gain access to bolt -3- on driver side, detach fuse
carrier and lower it ⇒ Electrical system; Rep. gr. 97; Relay
carriers, fuse holders, E-boxes; Removing and installing re‐
lay and fuse holder behind dash panel on driver side.
– For bolt -3-, glove compartment on front passenger side
must be removed ⇒ General body repairs, interior; Rep.
gr. 68; Compartments/covers; Removing and installing glove
compartment.
– For loosening bolt -6-, lower A-pillar trim must be removed
Removing and installing A-pillar gap cover.
Adjusting for flush fitting
In order to adjust flushness correctly, bolts -4- and -5- must be
loosened.
Use door alignment tool -3320- with appropriate bit for this.
1. Door 125
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Note
Other measures, such as raising the front door, will prove pointless. Subsequent pressure from above will
cause the door to sink again at the front.
Adjust striker pin ⇒ page 126 .
Note
After renewal of A-pillar the specified torque changes ⇒ page 114 .
Specified torques
Hinges ⇒ page 114
1.6 Adjusting striker pin

Note
♦ Threaded plate -1- of striker pin is secured in pillar using a method which differs from the previous
method.
♦ Bow outside of threaded plate is welded firmly to pillar. Webs to threaded plate are plastically deformable.
♦ Greater forced has to be applied so that position of striker pin -2- can be adjusted when bolts -3- are
loosened.

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Note
♦ The front door must lock fully when closing without any additional force being required and must not have
any play.
♦ The front door must not be pushed up or down as a result of the striker pin adjustment.
By adjusting the striker pin the alignment of the front door with
the side panel or the rear door can be adjusted -arrow a- and
-arrow b- (wind noise).
– Loosen striker pin -2- by loosening bolts -3- in B-pillar.
Note
Greater forced has to be applied so that position of striker pin -2- can be adjusted when bolts -3- are
loosened.
– Tighten bolts -3- of striker pin -2-.
1. Door 127
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Specified torques
Component Specified torques
Striker 20 Nm
1.7 Removing and installing door arrester

Note
The description of removal and installation only applies to the

left wing. The procedure for the right-hand side is basically the
same.
Removing

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– Remove front door trim ⇒ General body repairs, interior;

Rep. gr. 70; Front door trims; Removing and installing front
door trim.
– Remove self-adhesive cover or front loudspeaker ⇒ Commu‐
nication; Rep. gr. 91; Sound system; Overview of fitting loca‐
tions - sound system.
– Unscrew bolt -2- in A-pillar.
– Unscrew bolts -3- and remove door arrester -1- through the
opening of the loudspeaker -arrow a-.
Installing
1. Door 129
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Installation is carried out in the reverse order of removal.

Specified torques
Door arrester ⇒ page 114

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2 Door components
⇒ o2.1 verview - door components”, page 131
⇒ o2.2 verview - window regulator”, page 133
⇒ o2.3 verview - door handle and door lock”, page 133
⇒ a2.4 nd installing window regulator motor”, page 135
⇒ a2.5 nd installing window regulator”, page 137
⇒ a2.6 nd installing inner door cover”, page 140
⇒ a2.8 nd installing cap on door handle”, page 145
⇒ a2.9 nd installing lock cylinder”, page 151
⇒ a2.10 nd installing door handle”, page 154
⇒ a2.11 nd installing mounting bracket”, page 158
⇒ a2.12 nd installing door lock”, page 160
⇒ a2.13 nd installing window channel”, page 165
⇒ a2.14 nd installing window slot outer seal”, page 168
⇒ a2.15 nd installing window slot inner seal”, page 170
2.1 Assembly overview - door components
Note
The illustrations show the left-hand side. The procedure for the right-hand side is basically the same.
2. Door components 131

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1 - Stickers
❑ Qty. 3
❑ 15 mm x 50 mm
❑ If necessary, manufac‐
ture using commercial‐
ly available textile ad‐
hesive tape.
❑ Stickers must cover the
openings completely
2 - Window channel
ling ⇒ page 165
3 - Rear door
ling ⇒ page 120
4 - Window slot inner seal
ling ⇒ page 170
5 - Stickers
❑ Diameter 32 mm
❑ Apply adhesive labels
without creases
hesive tape.
openings completely
6 - Dampers
❑ Self-adhesive
❑ Installing:
– Cut to size if required, 200 mm x 100 mm Position as shown in illustration. Distance to next insulation
10 mm.
– Warm using hot air blower -V.A.G 1416- and push on to outer door panel with force.
7 - Dampers
❑ Self-adhesive
❑ Installing:
– Cut to size if required, 250 mm x 160 mm without creases. Position as shown in illustration.
8 - Seal
9 - Inner door cover
10 - Bowden cable
11 - Stickers
❑ 15 mm x 30 mm
❑ Apply adhesive labels without creases
❑ If necessary, manufacture using commercially available textile adhesive tape.
❑ Stickers must cover the openings completely

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12 - Stickers
❑ Diameter 40 mm
❑ Apply adhesive labels without creases
❑ Stickers must cover the openings completely
13 - Dampers
❑ 50 mm x 20 mm, position as shown in diagram.
14 - Window slot outer seal
2.2 Assembly overview - window regulator
1 - Window regulator
ling ⇒ page 137
2 - Lock nut
❑ Qty. 4
❑ 7.5 Nm
3 - Window regulator motor -
V14/V15-
ling ⇒ page 135
4 - Bolt
❑ Qty. 3
❑ 3 Nm
5 - Clip
❑ For securing cable
2.3 Assembly overview - door handle and door lock
Note

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1 - Door handle
ling ⇒ page 154
2 - Bolt
❑ 1.5 Nm
❑ Bearing plate is loos‐
ened from door when
this bolt is loosened
ling ⇒ page 158
4 - Bowden cable
❑ From door lock -1- to
mounting bracket -3-
5 - Bowden cable
❑ From inner door handle
to door lock -1-
❑ With grommet to pas‐
sage on cover.
6 - Bolt
❑ Qty. 2
❑ 18 Nm
Note
The bolts are microencapsulated

and must be renewed each time
they are unscrewed.
7 - Door lock
8 - Bolt
❑ 3 Nm
❑ For lock cylinder.
9 - Lock cylinder
❑ Only installed on driver door.
10 - Carrier
11 - Cap

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2.4 Removing and installing window regu‐

lator motor
Note
♦ Removal and installation are described only for the left mo‐
tor. Removal and installation of the right motor are similar.
♦ The door control unit -J386/J387- -5- is separated from win‐
dow regulator motor -V14/V15- -1-.
♦ The door control unit -J386/J387- is clipped into door ⇒ page
173 .
Removing

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door trim.
– Tape up door window to prevent it from sliding down.
– Switch off ignition and all electrical consumers. Withdraw
ignition key.
– Disconnect connector -3-.
– Remove bolts -2- (qty. 3).
– Remove window regulator motor -1- from mounting brackets
of cable drum.
Installing

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– Position window regulator motor -1- on mounting brackets of

cable drum. Move door window up and down slightly so that
the splines between window regulator motor and cable drum
engage more easily.
– Tighten bolts -2-.
– Connect connector -3-.
– The work procedure and notes on the automatic window
raising and lowering system as well as on the excess-force
limitation feature can be found in ⇒ Maintenance; Booklet .
The remaining installation steps are carried out in the reverse
sequence of removal.
Specified torques
♦ Bolts ⇒ o2.2 verview - window regulator”, page 133

lator

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Note
Removal and installation are described only for the left window
regulator. Removal and installation of the right window lifter
mechanism are similar.
Removing

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1
door trim.
– Remove window regulator motor ⇒ page 135 .
– Remove inner door cover ⇒ page 140 .
– Remove door window ⇒ page 347 .
– Release locking hook of cable drum -4- and insert into door.
– Unscrew hexagon nuts -5- and insert studs of window regu‐
lator into door.
– Remove cap -3- or pull off duct tape -3-.
– Loosen hexagon nuts -2-, do not remove.
– Loosen clip -6- and push inwards.
– Push window regulator upwards slightly -arrow b- and press
into door with hexagon nuts -arrow a-.
– Push window regulator in door downwards and forwards
slightly -arrow c-.
– Push together rails of window regulator -1- slightly -arrows d-
– Guide window regulator -1- through opening in door
-arrow e- to remove.
Installing

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– Push together rails of window regulator -1- slightly -arrows a-

– Insert window regulator -1- through opening in door
-arrow b- and move to mounting position -arrow c-.
– Insert studs of window regulator through door inner panel
-arrow e- and guide downwards -arrow d-.
– Tighten hexagon nuts -2 and 5-.
– Press cable drum against door inner part until locking devi‐
ces -4- engage audibly.
– Attach clip -6- to door.
– Install window regulator motor ⇒ page 135
– Install door window ⇒ page 347
Specified torques
♦ Hexagon nuts ⇒ o2.2 verview - window regulator”, page 133

cover

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♦ Scraper set -VAS 6845-
Note
Removal and installation are described only for the left cover.
The procedure for the right-hand side is basically the same.
Removing

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door trim.
– Push cover -1- downwards with force -arrow a-.
– Using scraper -VAS 6845/Nr.3- -2-, lever out cover in upper
area -arrow b-
– Pull cover -1- upwards out of door -arrow c-.
Note
♦ The removed inner door cover is not reinstalled. Always install a new inner door cover.
♦ If required for subsequent work, pull cable -3- with grommet -2- out of cover -1-. Separate connector at
grommet (if there is one).
Installing
Note
If the inner door cover has been removed or detached, it must

always be renewed.

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– Fit cable -3- together with grommet -2- into cover -1-.
– Attach grommet -2- to cover -1-.
– Insert cover -1- in door -arrow a-.
– Engage cover -1- around circumference -arrows b-.
Note
♦ Check proper seating of cover by pressing with fingers around circumference.

♦ If fitted, join electrical connector at grommet.


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♦ Bit -3410-
Note
Removal and installation are described only for the right door
striker pin. The procedure for the right-hand side is basically the
same.
Removing
– Unscrew bolts -2- and remove striker pin -1-.
Installing
Note
A bent striker pin (square U-shape) must be installed.
– Position striker pin -1- on B-pillar -3- with the U-shape facing
inwards. Tighten bolts -2-.

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Specified torques
Striker 20 Nm
2.8 Removing and installing cap on door

handle
⇒ a2.8.1 nd installing cap for door handle, with lock cylinder”,
page 145
⇒ a2.8.2 nd installing cap for door handle, without lock cylinder”,
page 147
2.8.1 Removing and installing cap for door

handle, with lock cylinder
Note
♦ When removing lock cylinder cover cap, the screwdriver

should not be turned and the screwdriver should not be used
as a lever.
♦ The lock cylinder and cover cap for lock cylinder are only
installed on the driver side.
Removing

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– Pull door handle away from door.

– Push a small screwdriver -3- slightly -arrow a- into opening
on underside of lock cylinder cover cap.
– Pull lock cylinder housing cover cap -1-, together with small
screwdriver, off door lightly from underside -arrow b-.
– Push cap upwards off lock cylinder.
Installing

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– Pull door handle -1- away from door.

– Push lock cylinder cover cap -2- at a slight angle from above
-arrow a- onto lock cylinder.
– Push lock cylinder cover cap -2- onto door -arrow b- until
cover cap engages in lock cylinder.
2.8.2 Removing and installing cap for door

handle, without lock cylinder
Note
The cover cap is installed when no lock cylinder is fitted.
Removing
♦ Assembly tool -T10539-

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– Remove plug.
– Insert assembly tool -T10539- -4- with marking facing up‐
wards approximately 17 mm into retaining hook -3- of
mounting bracket. To attain the dimension, 2 resistances
must be overcome in the bearing bracket.
– Turn assembly tool -T10539- -4- in retaining hook by 90°
-arrow b-, and pull it out by approx. 5 mm -arrow c- until
hook disengages.

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Pull door handle -2- off door -arrow a-.

– Pull cover cap -1- out of mounting bracket -arrow b-.
Installing

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• Pull door handle -2- off door -arrow a-.

– Push cover cap -1- into mounting bracket -arrow b-.

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– Slightly press cover cap -1- onto door.

– Insert assembly tool -T10539- or screwdriver -4- as far as
retaining hook -3- of mounting bracket.
– Push in assembly tool -T10539- or screwdriver -4- approx.
5 mm -arrow b- until retaining hook engages.
– Secure plug.
2.9 Removing and installing lock cylinder


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Note
♦ The removal and installation sequence is only for the left

lock cylinder. The procedure for the right-hand side is basi‐
cally the same.
♦ Different covers -4 and 6- might be installed.
Removing

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– Remove cap for lock cylinder ⇒ page 145 .

– Lift cover -4 and 6-.
– Unscrew bolt -7- onto stop.
– Press in bolt -7- with locking element -8- -arrow a-. Only then
is the lock cylinder released.
– Pull out lock cylinder housing -1- perpendicular to door
-arrow b- from mounting bracket -3-.
Installing

– Push lock cylinder housing -5- into mounting bracket -4- at a
right-angle -arrow a-.
– Screw bolt -3- into mounting bracket. While doing this, lock‐
ing mechanism is pulled automatically into installation posi‐
tion.
– Install screw -2-.

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Note
During installation, lock cylinder housing must be pressed against outer door panel.

• It is essential that a functional check is then performed with
the door open.
Specified torques
♦ Bolts ⇒ o2.3 verview - door handle and door lock”, page 133
2.10 Removing and installing door handle

⇒ a2.10.1 nd installing door handle”, page 154
⇒ a2.10.2 nd installing door handle with keyless entry system”,
page 156
2.10.1 Removing and installing door handle

Removing
Volkswagen Technical Site: http://vwts.ru http://vwts.info

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– Depending on version, remove cap for or without lock cylin‐

der ⇒ page 145 and lock cylinder ⇒ page 151 .
– Pull door handle -1- towards rear slightly -arrow a- until it
comes out of support for mounting bracket -2-.
– Swivel door handle in direction of -arrow b-.
– Remove door handle from bearing bracket at a right angle
-arrow c-.
Installing
– Insert door handle -1- at right angle -arrow a- in mounting

bracket.
– Swing door handle -1- towards door -arrow b-.
– Press door handle forwards -arrow c- into support for mount‐
ing bracket.
– It is essential that a functional check is then performed with
the door open.

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2.10.2 Removing and installing door handle

with keyless entry system
Removing
Note
The removal and installation sequence is only for the left door
handle. The procedure for the right-hand side is basically the
same.
For general information and work instructions for the door han‐
dle with keyless entry system refer to ⇒ Electrical system; Rep.
gr. 94; Entry and start authorisation system.
– Pull door handle -1- towards rear slightly -arrow a- until it
comes out of support for mounting bracket -2-.

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– Open locking mechanism on connector -4- using a screw‐

driver -3- -arrow d-.
– Remove door handle from mounting bracket -2-, keeping
door handle at right angles to mounting bracket -arrow c-.
Installing
– Seat door handle -1- in mounting bracket, whereby handle
must be at right angles to door -arrow b-.
Connector -4- for keyless entry system is attached as door han‐
dle is inserted -arrow a-.
– Swing door handle -1- towards door -arrow c-.
– Press door handle forwards -arrow d- into support for bear‐
ing bracket -2-.
the door open.

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2.11 Removing and installing mounting

bracket
Removing
Note
Removal and installation are described only for the left mount‐
ing bracket. The procedure for the right-hand side is basically
the same.

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door trim.
– Remove door handle ⇒ page 154 .
– Remove mounting bracket -1- from door.
Detach cable
– Slightly swing aside retainer -3- -arrow a-.
– Lift pin of cable -2- out of mounting.
Installing

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Attaching cable
Note
Make sure the connector -5- for the keyless entry system is firmly seated.
– Push pin of cable -2- into mounting -arrow b-.
– Guide door handle bracket -1- into door -arrow c-.
– Tighten bolt -4-.
Specified torques
2.12 Removing and installing door lock


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♦ Bit -T10054-
Note
lock. The procedure for the right-hand side is basically the
same.
♦ The door window must be closed for subsequent work.
♦ The bolts are microencapsulated and must be renewed each
time they are unscrewed.
Removing

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door trim.
– If fitted, disconnect connector.
– Remove door lock -1- from door -arrow-.
Note
Cables can be detached if this is necessary for subsequent work.
Detach cable from mounting bracket

– Remove cover ⇒ page 163 .
– Turn cable -5- through 90° -arrow a- and take out of holder.
– Swivel cable -arrow b- upwards until cable can be threaded
out of eye in door lock -1- -arrow c-.

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Detach cable from interior door handle

– Turn cable -4- by 90° and take it out of holding device.
– Swivel cable -arrow d- so far until cable can be threaded out
of eye in door lock -1- -arrow e-.
Removing cover
– Disengage hook -3- in -direction of arrow a-.

– Use the hook to pull cover -1- out of door lock -2- -arrow b-.
– Pull cover -1- upwards -arrow c- from door lock -2-.
Installing
Note
The bolts are microencapsulated and must be renewed each time they are unscrewed.

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– Attach removed cables -4- and -5- to door lock -1-.

– Install cover ⇒ page 164 .
– Insert door lock -1- into door.
– If fitted, connect connector.
– Screw in bolts -2-.
– Clip cap -3- in.
the door open.
Only if the cables are adjusted and locked correctly, the door
lock can be unlocked and opened properly.
Specified torques
Fitting cover

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– Push cover -1- onto retainer -3- on door lock -2- -arrow a-.
– Engage hook -4- with door lock -2- -arrow b-.
2.13 Removing and installing window chan‐

nel
Note

window channel. Removal and installation of the right win‐
dow channel are similar.
♦ Do not bend window channel when removing!
Removing

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– Remove window slot inner seal ⇒ page 168 .

– Remove window slot outer seal ⇒ page 168 .
– Peel sealing lip of window channel -1- off the door flange
from the inside.
– Pull window channel -1- out of mountings on door
-arrows a and b-.
– Pull window channel -1- -arrows c- off flange -2- uniformly all
around it.
Installing

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– Spray window channel with soapy water to facilitate installa‐

tion.
– Insert window channel -1- into mountings on door
-arrows c and b-.
– Fit window channel -1- from rear towards front onto door
flange -arrows a-.
– Fold sealing lip of window channel onto door flange -2- from
the inside -arrows-.
Note
To prevent wind noise, ensure window channel -1- seats evenly when installing.


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2.14 Removing and installing window slot

outer seal
Removing
Note
♦ The core of the window slot outer seal is a metal insert.

♦ If it is bent or distorted, the window slot outer seal can no
longer be straightened out. It will remain “wavy”.
♦ Therefore, the window slot outer seal must be pulled off and
pressed on evenly, without bending or distorting it.
♦ Removal and installation are only described for the left win‐
dow slot outer seal. Removal and installation of the right
window slot outer seal are similar.
– Slightly detach window slot outer seal -1- evenly from door
flange -2- using wedge -T10039/1- -arrows a-. Make sure
not to bend the side strip.

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– Pull out window slot outer seal -1- behind exterior mirror -3-
-arrow b-.
Installing
Note
♦ The use of assembly aid is allowed.

♦ The use of striking tools is not allowed for installing the window slot outer seal.
– Push window slot outer seal -1- behind exterior mirror -3-
-arrow a-.
– Align window slot outer seal -1- with B-pillar and press it
uniformly and by hand onto door flange-2- -arrows b-.

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inner seal
Note
Removal and installation are only described for the left window
slot inner seal. Removal and installation of the right window slot
outer seal are similar.
Removing
door trim.
– Lift window slot inner seal -1- uniformly off flange -2- without
bending or distorting it -arrows a-.
Installing
– Centre window slot inner seal -1- and press it evenly onto
front door flange -2- by hand.

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3 Central locking
⇒ o3.1 f fitting locations - central locking”, page 171
⇒ a3.2 nd installing driver door control unitJ386 and front pas‐
senger door control unitJ387”, page 173
⇒ a3.3 nd installing tank filler flap locking motorV155”, page 174
⇒ a3.4 nd installing ignition key battery”, page 175
⇒ a3.5 nd installing cap on ignition key”, page 177
3.1 Overview of fitting locations - central locking
3. Central locking 171

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1 - Onboard supply control

unit -J519-
❑ Location: Under dash
panel on driver side.
❑ Removing ⇒ Electrical
system; Rep. gr. 97;
Control units; Overview
of fitting locations - con‐
trol units.
2 - Alarm horn -H12-
❑ Removing ⇒ Electrical
system; Rep. gr. 96;
Anti-theft alarm system;
Removing and instal‐
ling alarm horn H12.
3 - Coupling station
❑ Fitting location: right A-
pillar
❑ To separate connec‐
tions, release bellows
at pillar.
4 - Front passenger door con‐
trol unit -J387-
ling ⇒ page 173
5 - Front right door lock
❑ Door lock is secured to
inner part of door.
❑ Electric central locking
is integrated into door
lock.
❑ Removing ⇒ page 160
❑ Fitting location: right B-
pillar.
❑ To separate connections, release bellows at pillar.
7 - Driver door control unit -J386-
8 - Rear right door lock
❑ Door lock is secured to inner part of door.
❑ Electric central locking is integrated into door lock.
9 - Right connector point
❑ Location: behind C-pillar trim
❑ Remove and install ⇒ General body repairs, interior; Rep. gr. 70; Trims, interior; Removing and
installing C-pillar trim.
10 - Release element with button
❑ Location: Bolted to rear lid.
11 - Rear lid lock
❑ Location: bolted to rear lid

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12 - Left connector point

❑ Location: behind C-pillar trim
❑ Remove and install ⇒ General body repairs, interior; Rep. gr. 70; Trims, interior; Removing and
installing C-pillar trim.
13 - Rear left door lock
14 - Rear left door control unit -J388-
❑ Location: left B-pillar
16 - Front left door lock
17 - Driver door control unit -J386-
18 - Central switch for window regulators
❑ Fitting location: in door trim
❑ Remove and install central switch for window regulator ⇒ Electrical system; Rep. gr. 96; Controls;
Overview of fitting locations - controls in front doors.
19 - Central locking button
❑ Fitting location: in door trim
❑ Remove and install button for central closing ⇒ Electrical system; Rep. gr. 96; Controls; Overview of
fitting locations - controls in front doors.
❑ Location: left A-pillar
21 - Bonnet contact switch -F266-
❑ Contact switch for anti-theft alarm system
❑ Location: on lid lock.
3.2 Removing and installing driver door

control unit -J386- and front passenger
door control unit -J387-
Note
If a new door control unit is installed, the additional functions

and the excess force limitation feature have to be coded!

T-Roc 2018 ➤
Removing
– Release retaining hooks -4- from outside -arrow a-.
– Push control unit -1- upwards -arrow b- and remove from
door -arrow c-.
Installing
– Check seals -3- for damage, and renew them as necessary.
– Place control unit -1- in mounting holes and push down‐
wards.
– Push retaining hook -4- into hole until it engages.
– Attach connectors -2-.
– A new control unit -1- must be coded using ⇒ Vehicle diag‐
nostic tester.
3.3 Removing and installing tank filler flap locking motor -V155-

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Removing
– Remove fuel tank flap unit ⇒ page 108 .
– Pull tank filler flap locking motor -V155- -1- out of side panel
-3- -arrows a-.
– Disconnect electrical connector -2-.
Installing
– Join electrical connector -2-.
– Push tank filler flap locking motor -V155- -1- into side panel
-3- -arrow b-.
3.4 Removing and installing ignition key

battery
Removing
– Folding out key bit -1- -arrow a-.

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– Use a small screwdriver -3- to raise the cover of battery

compartment -2- -arrow b-.
– Use a small screwdriver -3- to lift battery -1- out of battery
compartment -2- -arrow-.
Installing
Note
♦ Before installing battery, always press any key once.

♦ This resets the transmitter unit so that it can detect a new
battery.
Ensure correct polarity and mounting position when installing

battery. The positive pole is marked.
– Insert battery -1- into battery compartment -2- by pressing
slightly -arrow a-.
– Assemble cover of battery compartment -3- and transmitter

unit -arrow b-.

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– The ignition key must be synchronised now ⇒ page 177 .

Synchronizing ignition key
– Remove cap for lock cylinder -3- ⇒ page 145 .

– Hold ignition key -2- on lock cylinder -1-, and press “Open”
button.
– Unlock vehicle with the ignition key -2- via lock cylinder -1-
within a minute.
3.5 Removing and installing cap on ignition key

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Removing
– Lift off cover for battery compartment ⇒ page 175 .
– Push cap -2- out from the ignition key laterally -arrow-.
Installing
Note
Use the screw -1- to cut the thread in on a new cap.
– Push cap -2- laterally onto the ignition key.

– Install screw -1-.
– Press cover onto battery compartment

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58 – Rear doors, door components

1 Door
⇒ o1.1 verview - door”, page 179
⇒ a1.2 nd installing door”, page 182
⇒ d1.3 oor”, page 184
⇒ s1.4 triker pin”, page 187
⇒ a1.5 nd installing door arrester”, page 189
⇒ a1.6 nd installing inner door seal”, page 191
⇒ a1.7 nd installing outer door seal”, page 194
1.1 Assembly overview - door
Note
♦ After renewal of B-pillar, the specified torque for bolts -2 and 5- as well as for -14 and 17- changes.
1. Door 179
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1 - Rear door
ling ⇒ page 182
2 - Bolt
❑ Loosening once to ad‐
just the door is permit‐
ted. Always renew oth‐
erwise.
❑ Installed from inside ve‐
hicle.
❑ To remove and install,
B-pillar lower trim must
be removed first.
❑ 50 Nm
Note

3 - Door hinge
❑ The hinge is split.
4 - Cap
❑ For bolt -8-.
5 - Bolt
❑ To remove and install, B-pillar lower trim must be removed first.
❑ 50 Nm
Note
180 Rep. gr.58 - Rear doors, door components

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6 - Cap
❑ For bolt -7-.
7 - Bolt
❑ Always renew, loosening it once to adjust door is allowed.
❑ 50 Nm
8 - Bolt
❑ Connects upper part of hinge to bottom part of hinge.
❑ 23 Nm
9 - Door hinge
10 - Bolt
❑ 30 Nm
11 - Bolt
❑ Qty. 2
❑ 9 Nm
12 - Door arrester
13 - Door hinge
14 - Bolt
❑ 50 Nm
Note

15 - Door hinge
16 - Bolt
❑ Always renew, loosening it once to adjust door is allowed.
❑ 50 Nm
17 - Bolt
❑ 50 Nm
1. Door 181
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Note

1.2 Removing and installing door

♦ Bit for 3320 -3320/2-
♦ Bit for 3320 -3320/3-
♦ Bit -3410-
Note
The removal and installation sequence is described for the rear

left door only. Removal and installation of the rear right door are
similar.
Removing

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– Press wedge -T10383/1- between bellows -3- and locking

element -2- -arrow a-.
– Push locking element upwards -2- with wedge -T10383/1-
-arrow b- and separate electrical connector -3- from coupling
station -arrow c-.
– If fitted, remove covers of bolts -7-.
– Loosen bolts -7- at hinges -arrow e-, but do not remove
them.
– Unscrew bolt -4- for door arrester -5-.
– Push door retaining strip -5- inwards -arrow d-.
– Lift front door -1- with upper parts of hinges -6- upwards
-arrow f- out of lower parts of hinges.
Installing
1. Door 183
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Installation is carried out in the reverse order of removal. To this

end, the following should be observed:
• The door retaining strap -6- must have been pushed inwards
-arrow d-.
• After installing rear door, the hinge arms must be flush one
above the other.
– Adjust rear door -1- ⇒ page 184 .
– Observe front door shut lines -1- ⇒ Body Repairs; Rep.
gr. 00; Body panel gaps/shut lines; Body - middle.
Specified torques
♦ ⇒ o1.1 verview - door”, page 179
1.3 Adjusting door

♦ Bit for 3320 -3320/2-
♦ Bit for 3320 -3320/3-

T-Roc 2018 ➤

♦ Bit -3410-
Note
♦ Vehicle must be standing on its wheels when front door adjustment is performed.
♦ The rear door is correctly adjusted when all shut lines are even when closed. it is not protruding too far
♦ For checking gaps/shut lines refer to ⇒ Body Repairs; Rep. gr. 00; Body panel gaps/shut lines; Body -
middle.
♦ After installing or alignment, carry out corrosion protection measures on hinges and screws/bolts.
1. Door 185
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Adjusting shut lines

To be able to adjust gaps correctly, bolts -2-, -3-, -6- and -7- on
B-pillar must be loosened.
– The B-pillar lower trim must be removed for bolts -3 and 7-.
Adjusting for flush fitting
In order to adjust flushness correctly, bolts -5- and -9- must be
loosened.
Use door alignment tool -3320- with appropriate bit for this.
Note
Other measures, such as raising the rear door, will prove pointless. Subsequent pressure from above will
cause the door to sink again at the back.

Specified torques

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1.4 Adjusting striker pin

♦ Bit -3410-
Note
♦ Bow outside of threaded plate -1- is welded firmly to pillar. Webs to threaded plate are plastically
deformable.
♦ Greater forced has to be applied so that position of striker pin -2- can be adjusted when bolts -3- are
loosened.
1. Door 187
T-Roc 2018 ➤
Note
♦ The rear door must lock fully when closing without any additional force being required and must not have
any play.
♦ The rear door must not be pushed up or down as a result of the striker pin adjustment.
Striker pin can be used to align rear door flush with side panel
(to prevent wind noise) -arrows-.
– Loosen striker -2- by loosening bolts -3- in C-pillar.
Note
Greater forced has to be applied so that position of striker pin -2- can be adjusted when bolts -3- are
loosened.
– Tighten bolts -3- of striker pin -2-.

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Striker 20 Nm
1.5 Removing and installing door arrester

Note
Removal and installation are described only for the left door
arrester. The procedure for the right-hand side is basically the
same.
Removing
1. Door 189
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– Remove rear door trim ⇒ General body repairs; interior; Rep.

gr. 70; Rear door trims; Removing and installing rear door
trim.
– Pull off self-adhesive cover.
♦ For models without loudspeaker pull off self-adhesive cover
and remove door retaining strap through opening for loud‐
speaker -arrow c-.
♦ For models with loudspeaker detach inner door cover ⇒
page 204 and remove through this opening.
– Unscrew bolt -2- in B-pillar.
– Remove screws -3- and remove door retaining strap -1-.
Installing

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Installation is carried out in the reverse order of removal.

Specified torques

seal
During production, a sealant is applied to the door seals, which
are then placed on the door flange and rolled on.
1. Door 191
T-Roc 2018 ➤
Note
♦ When removing the door seal, the sealant is distributed

across the inside of the door seal. The sides are bent up‐
wards slightly when this is being done. If the door seal is
then refitted, sealing and firm seating are no longer guaran‐
teed.
♦ Therefore, each door seal which has been removed com‐
pletely must be replaced by a “tap-on seal”.
♦ If a door seal has been partially removed, squeeze sides of
door seal together before installing.
seal. The procedure for the right-hand side is basically the
same.
♦ For reasons of clarity, the rear door is shown removed.
Removing
– Remove sill panel trim ⇒ General body repairs, interior; Rep.

gr. 70; Trims, interior; Removing and installing sill panel trim.

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– To remove inner door seal, remove pillar trims as required

Overview of fitting locations – trims, interior.
– Pull door seal -1- off body flange -2-.
Installing
Note
Do not kink vulcanised point -3-.
– Start installing door seal -1- at top radius of door aperture

-arrows-.
– Align vulcanised point -3- between hinges.
– Press door seal -1- onto body flange -2-.
– Install pillar trims ⇒ General body repairs, interior; Rep.
gr. 70; Trims, interior.
– Install sill panel strip ⇒ General body repairs, interior; Rep.
gr. 70; Trims, interior; Removing and installing sill panel
strip.
1. Door 193
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1.7 Removing and installing outer door

seal
⇒ a1.7.1 nd installing outer door seal”, page 194
1.7.1 Removing and installing outer door

seal
Note
Removal and installation are described only for the left door
seal. Removal and installation of the right door seal are analo‐
gous.
Removing
– Pull off door seal -1- from door -3- with clips -2-.
– Pull door seal -1- out of window guide -arrow a-.
Installing
– Check clips -2- for damage and renew if necessary.

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– Insert door seal -1- into window guide -arrow b-

– Press door seal -1- on door -3- together with the clips -2-.
Clips -2- must be pressed in as far as stop.
1. Door 195
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2 Door components
⇒ o2.1 verview - door components”, page 196
⇒ o2.3 verview - door handle and door lock”, page 198
⇒ a2.4 nd installing window regulator motor”, page 199
⇒ a2.5 nd installing window regulator”, page 202
⇒ a2.6 nd installing inner door cover”, page 204
⇒ a2.8 nd installing cap on door handle”, page 208
⇒ a2.9 nd installing door handle”, page 212
⇒ a2.10 nd installing mounting bracket”, page 214
⇒ a2.11 nd installing door lock”, page 217
⇒ a2.12 nd installing window channel”, page 221
⇒ a2.13 nd installing window slot outer seal”, page 224
⇒ a2.14 nd installing window slot inner seal”, page 226
2.1 Assembly overview - door components
Note

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1 - Window channel
ling ⇒ page 221
2 - Stickers
❑ Qty. 2
❑ 15 mm x 50 mm
hesive tape.
3 - Window slot outer seal
ling ⇒ page 224
4 - Rear door
ling ⇒ page 182
5 - Window slot inner seal
ling ⇒ page 226
6 - Stickers
❑ Qty. 2
❑ Diameter 32 mm
hesive tape.
7 - Dampers
❑ Self-adhesive
❑ Installing:
– Cut to size if required,
250 mm x 160 mm without creases. Position as shown in illustration.
8 - Inner door cover

9 - Door joint seal
10 - Stickers
❑ Qty. 1
❑ Diameter 40 mm
11 - Stickers
❑ Qty. 1
❑ 15 mm x 30 mm
2.2 Assembly overview - window regulator

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ling ⇒ page 202
2 - Lock nut
❑ Qty. 1 top
❑ 7.5 Nm
3 - Lock nut
❑ Qty. 1 bottom
❑ 6 Nm
4 - Retaining hooks for cable
drum
❑ Qty. 3
❑ Mounting for window
regulator motor
❑ Specified torque of win‐
dow regulator motor
bolts: 3 Nm
2.3 Assembly overview - door handle and door lock
Note

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1 - Door lock
ling ⇒ page 217
2 - Bolt
❑ 1.5 Nm
❑ For locking bar in
mounting bracket.
ling ⇒ page 214
4 - Carrier
5 - Cap
ling ⇒ page 208
6 - Door handle
ling ⇒ page 212
7 - Bolt
❑ 1.5 Nm
❑ Bearing plate is loos‐
ened from door when
this bolt is loosened
8 - Bowden cable
❑ From door lock -1- to
mounting bracket -3-
9 - Bowden cable
❑ From inner door handle
to door lock -1-
❑ With grommet to pas‐
sage on cover.
10 - Cap
11 - Bolt
❑ Qty. 2
❑ 18 Nm
Note
The bolts are microencapsulated

and must be renewed each time
they are unscrewed.

lator motor

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Note
regulator motor. Removal and installation of the right window
regulator motor are similar.
Removing

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trim.
– Tape up door window to prevent it from sliding down.
– Switch off ignition and all electrical consumers. Withdraw
ignition key.
– Remove bolts -2- (qty. 3).
– Remove window regulator motor -1- from mounting brackets
of cable drum -4-.
Installing
Note
If a new window regulator motor is installed (door control unit),

the additional functions and the excess force limitation feature
have to be coded!
– Fit window regulator motor -1- onto mounting brackets of

cable drum -4-. Move door window up and down slightly so

T-Roc 2018 ➤
that the splines between window regulator motor and cable

drum engage more easily.
– A new window regulator motor (door control unit) must be
coded using ⇒ Vehicle diagnostic tester.
– The work procedure and notes on the automatic window
raising and lowering system as well as on the excess-force
limitation feature can be found in ⇒ Maintenance; Booklet .
Specified torques
♦ Mounting bracket ⇒ o2.2 verview - window regulator”, page
197

lator
Note
regulator. Removal and installation of the right window lifter
mechanism are similar.
Removing

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trim.
– Detach door window from window regulator. Do not remove
it ⇒ page 351 .
– Move door window upwards, and secure it in place.
– Remove window regulator motor ⇒ page 199 .
– Release locking hook of cable drum -4- and insert into door.
– Unscrew lower hexagon nut -3- and insert threaded studs of
window regulator into door.
– Loosen upper hexagon nuts -2-, do not remove.
– Slightly push window regulator upwards in door -arrow a-,
and guide it into door.
– Turn window regulator -1- 90° -arrow b-, and remove it
through opening in door -arrow c-.
Installing

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– Insert window regulator -1- through opening in door

-arrow a-, and swing it to installation position -arrow b-.
– Insert studs of window regulator into inner door panel, and
guide them downwards -arrow c-.
– Tighten hexagon nuts -2 and 3-.
– Press cable drum against door inner part until locking devi‐
ces -4- engage audibly.
– Install window regulator motor ⇒ page 199

– Install door window ⇒ page 351
Specified torques
♦ Window regulator ⇒ o2.2 verview - window regulator”, page
197

cover

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♦ Scraper set -VAS 6845-
Note
Removal and installation are described only for the left cover.
The procedure for the right-hand side is basically the same.
Removing

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trim.
– Push cover -1- downwards -arrow a-.
– Using scraper -VAS 6845/Nr.3-, lever out cover -1- in upper
area -arrow b-
– Pull cover -1- upwards out of door -arrow c-.
Installing
– Insert cover -1- into door -2- -arrow a-.

– Engage cover -1- around circumference -arrows b-.
Note
Check proper seating of cover by pressing with fingers around circumference.


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♦ Bit -3410-
Note
striker pin. The procedure for the right-hand side is basically the
same.

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Removing
– Unscrew bolts -2- and remove striker pin -1-.
Installing
– Fit striker pin -1-, and tighten bolts -2-.
Component Specified tor‐
ques
Striker 20 Nm
2.8 Removing and installing cap on door

handle
♦ Assembly tool -T10539-
Removing

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– Remove plug.
– Insert assembly tool -T10539- with marking facing upwards
approximately 27 mm into retaining hook of mounting brack‐
et. To attain the dimension, 2 resistances must be overcome
in the bearing bracket.
– Turn assembly tool -T10539- -4- in retaining hook by 90°
-arrow a-, and pull it out by approx. 5 mm -arrow b- until
hook disengages.

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– Pull door handle -2- off door -arrow a-.

– Pull cover cap -1- out of mounting bracket -arrow b-.
– Release door handle -2- again.
Installing

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– Push cover cap -1- into mounting bracket -arrow b-.

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– Slightly press cover cap -1- onto door.

– Insert assembly tool -T10539- or screwdriver -4- as far as
locking hook of bearing bracket -3-.
– Push in assembly tool -T10539- or screwdriver -4- approx.
5 mm -arrow b- until retaining hook engages.
– Release door handle -2- again.
– Secure plug.
2.9 Removing and installing door handle
Note
The removal and installation sequence is only for the left door
handle. The procedure for the right-hand side is basically the
same.
Removing

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– Remove cap ⇒ page 208 .

– Pull out door handle -1- backwards slightly -arrow a- from
support for mounting bracket.
– Pull door handle -1- out of door handle bracket -2- -arrow c-.
Installing

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– Insert door handle -1- at right angle -arrow a- in mounting

bracket.
– Swing door handle -1- into door -arrow b-.
– Press door handle forwards -arrow c- into support for door
handle bracket -2-.
Installing cover cap ⇒ page 208
• It is essential that a functional check is then performed with
the door open.
2.10 Removing and installing mounting

bracket

T-Roc 2018 ➤
Note
Removal and installation are described only for the right mount‐
ing bracket. The procedure for the right-hand side is basically
the same.
Removing

T-Roc 2018 ➤

trim.
– Push door handle bracket -1- slightly towards rear, and re‐
move it from door.
Detach cable
– Lift pin of cable -2- out of mounting.
Installing
Note
Make sure the connector -5- for the keyless entry system is firmly seated.

T-Roc 2018 ➤
Attaching cable
– Push pin of cable -2- into mounting -arrow b-.
– Guide door handle bracket -1- into door -arrow c-.
Specified torques
♦ Mounting bracket ⇒ o2.3 verview - door handle and door
lock”, page 198
2.11 Removing and installing door lock

♦ Bit -3410-
Note
lock. The procedure for the right-hand side is basically the
same.
♦ The door window must be closed for subsequent work.
♦ The bolts are microencapsulated and must be renewed each
time they are unscrewed.
Removing

T-Roc 2018 ➤

trim.
– If fitted, disconnect connector.
– Remove door lock -1- from door -arrow-.
Note
Cables can be detached if this is necessary for subsequent work.
Detach cable from mounting bracket

– Remove cover ⇒ page 219 .
– Turn cable -5- 90° and take out of holder -arrow a-.
– Swivel cable -arrow b- so far until cable can be threaded out
of eye in door lock -1- -arrow c-.

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Detach cable from interior door handle

– Turn cable -4- by 90° and take it out of holding device.
– Swivel cable -arrow d- so far until cable can be threaded out
of eye in door lock -1- -arrow e-.
Removing cover
– Disengage hook -3- in -direction of arrow a-.

– Use the hook to pull cover -1- out of door lock -2- -arrow b-.
– Pull cover -1- upwards -arrow c- from door lock -2-.
Installing
Note
The bolts are microencapsulated and must be renewed each time they are unscrewed.

T-Roc 2018 ➤
– Attach removed cables -4- and -5- to door lock -1-.

– Install cover ⇒ page 220 .
– Insert door lock -1- into door -arrow f-.
– If fitted, connect connector.
– Screw in bolts -2-.
– Clip cap -3- in.
– It is essential to perform a functional check.
• Only if the cables are adjusted and locked correctly, the door
lock can be unlocked and opened properly.
Specified torques
♦ ⇒ o2.3 verview - door handle and door lock”, page 198
Fitting cover

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– Push cover -1- onto retainer -3- on door lock -2- -arrow a-.
– Engage hook -4- with door lock -2- -arrow b-.
2.12 Removing and installing window chan‐

nel
Note

window channel. Removal and installation of the right win‐
dow channel are similar.
♦ Do not bend window channel when removing!
Removing

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– Remove B-pillar trim ⇒ page 380 .
– Pull front window guide -1- off door -arrow b-.
– Pull rear window guide -1- with clip -4- off door -arrow b-.
– Pull out window guide -1- from outer door seal -5- -arrow c-.
– Peel sealing lip of window channel -1- off the door flange -2-
from the inside.
– Pull out window guide -1- from mountings of door -arrows a-.
– Pull off window guide -1- with clip -3- evenly -arrows b- all
around door flange -2-.
Installing

T-Roc 2018 ➤
– Spray window channel with soapy water to facilitate installa‐

tion.
– Push window channel -1- into mountings on door -arrows a-.
– Fit window guide -1- with clip -3- on door -arrow b-.
– Fit window channel -1- all around onto door flange -2-
-arrows b-, and press it on.
– Push window guide -1- in outer door seal -5- -arrow c- and
engage clip -4- firmly.
– Fold sealing lip of window channel onto door flange from the
inside.
Note
To prevent wind noise, ensure window channel -1- seats evenly when installing.


T-Roc 2018 ➤

outer seal
Note
♦ The core of the window slot outer seal is a metal insert.

♦ If it is bent or distorted, the window slot outer seal can no
longer be straightened out. It will remain “wavy”.
♦ Therefore, the window slot outer seal must be pulled off and
pressed on evenly, without bending or distorting it.
♦ Removal and installation are only described for the left win‐
dow slot outer seal. Removal and installation of the right
window slot outer seal are similar.
– Slightly detach window slot outer seal -1- evenly from door
flange -2- using wedge -T10039/1- -arrows a-. Make sure
not to bend the side strip.
– Push window slot outer seal -1- towards front out of door
-arrow b-.

T-Roc 2018 ➤
Installing
Note
♦ The use of assembly aid is allowed.

♦ The use of striking tools is not allowed for installing the window slot outer seal.
– Push window slot outer seal -1- at front end into door
-arrow a-.
– Press window slot outer seal -1- evenly onto door flange -2-
by hand.

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inner seal
Note
Removal and installation are only described for the left window
slot inner seal. Removal and installation of the right window slot
outer seal are similar.
Removing
trim.
– Lift window slot inner seal -1- evenly off flange -2- without
bending or distorting it -arrows-.
Installing
– Centre window slot inner seal -1- and press it evenly onto
front door flange -2- by hand.

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60 – Sunroof
1 Sliding sunroof
⇒ o1.1 verview - sliding sunroof”, page 227
⇒ o1.2 verview - sliding sunroof seals”, page 229
⇒ a1.3 nd installing sunroof panel”, page 229
⇒ a1.4 nd installing rear sunroof panel”, page 233
⇒ s1.5 unroof panel”, page 238
⇒ a1.6 nd installing sliding sunroof seals”, page 242
⇒ a1.7 nd installing wind deflector”, page 247
⇒ a1.8 nd installing sunroof motorV1”, page 250
⇒ a1.9 nd installing sunroof roller blind motorV260”, page 252
⇒ a1.10 nd installing sunroof roller blind control unitJ394”, page
254
⇒ a1.11 nd installing sliding sunroof adjustment control
unitJ245”, page 255
⇒ a1.12 nd installing sunroof roller blind”, page 256
⇒ a1.13 nd installing sliding sunroof frame”, page 261
⇒ w1.14 ithout current”, page 265
1.1 Assembly overview - sliding sunroof
1. Sliding sunroof 227

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1 - Front glass panel

ling ⇒ page 229
2 - Bolt
❑ Qty. 8
❑ 7 Nm
3 - Bolt
❑ Qty. 4
❑ 7 Nm
4 - Rear glass panel
ling ⇒ page 233
Adjusting ⇒ page 240
5 - Sunroof roller blind

ling ⇒ page 256
6 - Bolt
❑ Qty. 2
❑ 8 Nm
7 - Sliding roof frame
ling ⇒ page 261
❑ With cables and tilt
mechanism
8 - Motor for sliding roller
blind -V260-
ling ⇒ page 252
❑ With separate control
unit
9 - Bolt
❑ Qty. 2
❑ 8 Nm
10 - Control unit
❑ Removing and installing sliding sunroof adjustment control unit -J245- ⇒ page 255
❑ Removing and installing sunroof roller blind control unit - J394- ⇒ page 254
11 - Sliding sunroof motor - V1-
❑ With separate control unit
12 - Bolt
❑ Qty. 2
❑ 8 Nm
13 - Wind deflector
14 - Spring
15 - Bolt
❑ For securing assembly frame.
228 Rep. gr.60 - Sunroof

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❑ Qty. 16
❑ 8 Nm
1.2 Assembly overview - sliding sunroof seals
1 - Rear glass panel

2 - Additional seal for rear lid
ling ⇒ page 242
3 - Outer seal for rear lid
ling ⇒ page 242
4 - Exterior seal
ling ⇒ page 242
5 - Panel flange
6 - Inner seal
❑ Positioned on assembly
frame.
7 - Sliding roof frame
8 - Front glass panel
1.3 Removing and installing sunroof panel


T-Roc 2018 ➤
Removing
– Open glass panel -2- until trims -1- are accessible.

– Slide interior trims -1- out towards rear in
-direction of arrow-.
Note
To unscrew bolts, use a magnetic tool so that bolts do not fall into mechanism of panoramic sliding roof.

T-Roc 2018 ➤
– Pull seal -3- from assembly frame.

– Unscrew bolts -2- from glass panel -1- on left and right.
– Lift out glass panel -1- upwards.
Installing
Note
♦ New bolts must always be used when installing glass panel.

♦ To screw in bolts, use a magnetic tool so that bolts do not fall into panoramic sliding roof guide.

T-Roc 2018 ➤
– If necessary, shift tilting mechanism on both sides until tilt

mechanism has lowered completely.
– Insert glass panel -1- from above into tilting mechanism and
screw in bolts -2- but do not tighten.
– Adjusting front glass panel ⇒ page 238 .

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– Place trim -1- on glass panel -2- and push onto fasteners.
Note
♦ After the glass panel has been replaced, a basic setting must be performed.
♦ The roll-back function is disabled during the basic setting process.
♦ The basic setting is carried out with the ⇒ Vehicle diagnostic tester.
Specified torques
♦ Bolts for front glass panel ⇒ o1.1 verview - sliding sunroof”,
page 227
1.4 Removing and installing rear sunroof

panel

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Removing
Note
To unscrew bolts, use a magnetic tool so that bolts do not fall into panoramic sliding roof guide.
– Remove front glass panel ⇒ page 229 .

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– Unscrew bolts -4- from glass panel -3- on left and right.
– Lift rear glass panel -1- in front area and swing under panel
flange -2- -arrows a-.
– Lift out rear glass panel -1- upwards -arrows b-.
Installing
Note
♦ New bolts must always be used when installing glass panel.

♦ To screw in bolts, use a magnetic tool so that bolts do not fall into panoramic sliding roof guide.

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– Guide rear glass panel -1- upwards at an angle -2- into
opening -arrows a-.
– Swivel rear glass panel -1- downwards under panel flange
-arrow b-.
– Insert rear glass panel -1- in roof aperture and align.

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– Insert bolts -2-; do not tighten.

– Install front glass panel ⇒ page 229 .
– Adjusting rear glass panel -1- ⇒ page 238 .
– After adjusting rear glass panel, tighten bolts.
– Press seal -3- onto assembly frame.
Note
♦ After the glass panel has been replaced, a basic setting must be performed.
Specified torques
♦ Bolts for rear glass panel ⇒ o1.1 verview - sliding sunroof”,
page 227

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1.5 Adjusting sunroof panel

⇒ h1.5.1 eight adjustment”, page 238
⇒ f1.5.2 ront glass panel”, page 239
⇒ r1.5.3 ear glass panel”, page 240
1.5.1 Checking height adjustment

Note
♦ The front glass panel is adjusted at the front edge only and the rear glass panel is adjusted at the rear
edge only.
♦ To achieve the best possible optical appearance, ensure that adjustments on left and right are uniform
(symmetrical).
♦ The arrow in the illustration points in direction of normal travel.

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Checking height adjustment

– Check adjustment of front glass panel -1- and rear glass
panel -2- with a depth gauge.
♦ Dimension -a-: 1.5 ± 1 mm
♦ Dimension -b-: 1 ± 1 mm
♦ Dimension -c-: 1 ± 1 mm
If measured values differ from specifications, respective glass
panel must be adjusted.
♦ Adjusting front glass panel ⇒ page 239
♦ Adjusting rear glass panel ⇒ page 240
1.5.2 Adjusting front glass panel
Note
The glass panel height adjustment is performed after the glass panel has been closed from slide open
position.

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– Remove trim ⇒ page 229 .

– Loosen only bolts -4- on left and right for front glass panel
-2-.
– Adjust front glass panel -2- according to dimensions ⇒ page
238 .
– Installing trim ⇒ page 229 .
– Position seal -5- on assembly frame.
Specified torques
♦ Bolts for front glass panel ⇒ o1.1 verview - sliding sunroof”,
page 227
1.5.3 Adjusting rear glass panel

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– Pull inner seal -5- off assembly frame.

– Loosen bolts -4- for rear glass panel -3-.
– Adjust rear glass panel -3- according to dimensions ⇒ page
238 .
– Tighten bolts on left and right -4-.
– Position seal -5- on assembly frame.
Specified torques
♦ Bolts for rear glass panel ⇒ o1.1 verview - sliding sunroof”,
page 227

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1.6 Removing and installing sliding sunroof

seals
⇒ a1.6.1 nd installing the exterior seal”, page 242
⇒ a1.6.2 nd installing outer seal for rear glass panel”, page 245
⇒ a1.6.3 nd installing additional seal for rear glass panel”, page
246
1.6.1 Removing and installing the exterior

seal
♦ Roller -T10563-
♦ Adhesive residue remover -VAS 6349-
♦ If a seal is installed for the first time on a new vehicle or
a newly painted surface, the procedure described in the
⇒ Paintwork manual ⇒ Paintwork repairs ⇒ Paint finish ⇒
Mouldings & film should be observed.
♦ If a seal is removed and reinstalled, only use adhesive re‐
mover to remove the adhesive remains in installation area.
♦ The drying time of the adhesive remover is 5 minutes.
grease.
♦ Seal must be bonded in place immediately after cleaning.

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Minimum curing period
Note
♦ There are special requirements for renewing seals with dou‐

ble-sided adhesive tape.
♦ Further work in the area of the seal may be carried out after
the maximum adhesive strength has been reached.
For the double-sided adhesive tape of the seal, the minimum

drying time is 3 hours.
The minimum drying time is the period from bonding in the seal
until the installation of the assembly frame. During this time, the
vehicle must be kept at room temperature (at least 18°C).
Removing
Note
Seal cannot be removed without damage.

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– Remove assembly frame ⇒ page 261 .

– Pull exterior seal -1- with bonding area -3- from roof -2-.
Installing
– Follow installation instructions ⇒ page 242 .

– Remove any adhesive residue with adhesive strip remover
-VAS 6349-.
– Entire bonding surface on roof cut-out -2- must be free of
dust and grease.
– Clean complete bonding area with cleaning solution -D 009
401 04-.
– Centre new exterior seal -1- with joint -arrows- to centre of
rear roof cut-out.
– Pull off protective film from adhesive tape -3- in sections and
press seal onto roof -2-.

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Note
Do not stretch or puncture seal.
– Using roller -T10563- -4-, press on exterior seal firmly and

evenly around circumference twice -arrow a-.
– Observe minimum drying time ⇒ page 243 .
– Install assembly frame ⇒ page 261 .
1.6.2 Removing and installing outer seal for rear glass panel
Removing
– Remove rear glass panel ⇒ page 233 .
– Pull off seal -1- in side area -4- from rear glass panel -2- to
side -arrow b-.
– Pull off seal -1- in front area -3- from rear glass panel -2-
upwards -arrow a-.

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Installing
– To ensure that seal slides into mounting bracket more easily,
it is sprayed with a soap and water solution.
– Press seal -1- in front area -3- from above into glass panel
mounting -1-.
– Press seal -1- in side area -4- into glass panel mounting -1-.
– Install rear glass panel ⇒ page 233 .
1.6.3 Removing and installing additional seal for rear glass panel
Removing
– Pull off seal -3- from rear glass panel -2- upwards -arrow a-.
Installing
– To ensure that seal slides into mounting bracket more easily,
it is sprayed with a soap and water solution.
– Press seal -1- from above into glass panel mounting -1-.

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1.7 Removing and installing wind deflector

Removing
– Open front glass panel completely.

– Detach hook spring -2- -arrow a-.
– Push wind deflector frame -1- forwards with support bow -3-
-arrow b- and remove from guide.

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– Release all hooks -4- (Qty. 15) -arrow-.

– Remove wind deflector -1- with net -2- and frame -3- from
mounting.
Installing

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– Press frame -3- of wind deflector -1- into mounting -arrow-.

– All hooks -4- (Qty. 15) must engage.

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– Insert wind deflector frame -1- with support bow -3- into
guide and push backwards -arrow b-.
– Hook in hook spring -2- -arrow a-.
1.8 Removing and installing sunroof motor

-V1-
Removing

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– Remove front lights and operating unit ⇒ General body re‐

pairs, interior; Rep. gr. 68; Compartments/covers; Removing
and installing storage compartment in roof headliner.
– Lower sliding roof motor -1- slightly and tilt out to rear.
Installing

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With front glass panel removed:

– If necessary, push tilt mechanism fully forwards on both
sides until it is completely lowered.
– Install sliding roof motor -1- and tighten bolts -3-.
Note
♦ After the motor has been replaced, a basic setting must be performed.
Specified torques
♦ Bolts for sunroof motor ⇒ o1.1 verview - sliding sunroof”,
page 227
1.9 Removing and installing sunroof roller

blind motor -V260-

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Removing
– Lower moulded headliner and place on head restraints

⇒ General body repairs, interior; Rep. gr. 70; Roof trim.
– Disconnect connector -4- on sun blind motor -1-.
– Remove sunroof roller blind motor -1-.

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Installing
– Before installing roller blind motor, roller blind must be
aligned parallel.
– Measure and adjust distance -dimension a- between blind
brace -1- and blind cassette -2-.
Note
♦ After the motor has been replaced, a basic setting must be

performed.
♦ The roll-back function is disabled during the basic setting
process.
♦ The basic setting is carried out with the ⇒ Vehicle diagnostic
tester.
Specified torques
♦ Bolts for roller blind motor ⇒ o1.1 verview - sliding sunroof”,
page 227

blind control unit -J394-
Note
The sunroof roller blind control unit -J394- is integrated in the

sliding sunroof adjustment control unit -J245-.

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Removing
– Release retaining hooks -3- -arrows a-.
– Slightly lift control unit -1- and pull out of bracket -arrows b-.
– Disconnect connectors -2- from control unit -1-.
Installing
– Code new control unit ⇒ Vehicle diagnostic tester.

adjustment control unit -J245-
Note
Integrated in the sliding sunroof adjustment control unit -J245-

is the sunroof roller blind control unit -J394-.

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Removing
– Slightly lift control unit -1- and pull out of bracket -arrows b-.
– Disconnect connectors -2- from control unit -1-.
Installing
Install in reverse order of removal.
– Code new control unit. ⇒ Vehicle diagnostic tester

blind

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Removing
Note
In the event of power failure, sun blind can be moved by turning sun blind motor with a commercially
available hexagon key to removal position (fully open) ⇒ page 265 .
– Move sun blind to fully open position -arrows-.

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– Remove moulded headliner ⇒ General body repairs, interior;

Rep. gr. 70; Roof trim.
– Remove front glass panel ⇒ page 229 .
– Remove assembly frame ⇒ page 261 .
– Remove roller blind motor ⇒ page 252 .
– Push roller blind -2- completely towards rear -arrows- by
hand.
– Unscrew bolts on left and right -1-.
– Push roller blind -3- completely towards rear -arrow a- paral‐

lel by hand.
– Tilt roller blind at front and lift out of assembly frame
-arrow b-.
Installing

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– Guide roller blind -3- into assembly frame from above at an

angle.
– Pull roller blind -3- into guide rails parallel by hand.

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– Install roller blind motor ⇒ page 252 .
– Install assembly frame ⇒ page 261 .
– Install front glass panel ⇒ page 229 .
– Install moulded headliner ⇒ General body repairs, interior;
Note
♦ After the roller blind has been replaced, a basic setting must be performed.

Sun blind 6 Nm

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frame
Removing
Note
A second mechanic is required for removing and installing as‐

sembly frame.

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– Pull off water drain hoses -4- from supports -arrows a-.
– Disconnect connector to wiring harness on sliding roof mo‐
tor.
– Unscrew bolts -3- for assembly frame and lift assembly
frame out of vehicle with the help of at least one second
mechanic.
Installing

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– Lift assembly frame -1- into vehicle with the help of at least a
second mechanic.
– When bolting assembly frame -1-, use 2 cylindrical pins (re‐
versed drill bits ∅ 10 mm) to centre at front, rear and side
centring holes -arrows b- and to roof.
– Screw in bolts -2-, but do not tighten.
– Connect all water drain hoses -4-.

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– Tighten numbered bolts in the specified sequence -1 to 5-.

– Tighten remaining bolts -arrows- in any sequence.
Note
♦ After the assembly frame has been replaced, a basic setting must be performed.
Specified torques
♦ Bolts for assembly frame ⇒ o1.1 verview - sliding sunroof”,
page 227

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1.14 Operating without current
1.14.1 Glass panel
Note
♦ In the event of power failure, front glass panel near to sliding sunroof motor can be moved by hand using
a commercially available hexagon key.
♦ Greater force is necessary since motor is not uncoupled from drive.
♦ Front glass panel must only be moved manually until its front edge is flush with front edge of rear glass
panel. If glass panel is moved further backwards, mechanism cables may hook off.

– Insert hexagon key into bolt -4- of sliding roof motor -1-.
When turning by hand, greater force is necessary since motor is
not uncoupled from drive.

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1.14.2 Sun blind
Note
♦ In the event of power failure, sunroof sun blind can be

moved by hand on sunroof sun blind motor using a commer‐
cially available hexagon key.
♦ Greater force is necessary since motor is not uncoupled
from drive.

– Insert hexagon key -4- into bolt of sun blind motor -1-.
When turning by hand, greater force is necessary since motor is
not uncoupled from drive.

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2 Water drain hoses
2.1 Assembly overview - water drain hoses
1 - Front water drain hose

ling ⇒ page 267
❑ Cleaning ⇒ page 268
2 - Clip
❑ Qty. 3 at front on each
side
❑ Qty. 8 at rear on each
side
3 - Marking
4 - Drainage grommet
5 - Rear water drain hose
ling ⇒ page 267
❑ Cleaning ⇒ page 268
2.2 Removing and installing water drain hoses
Note
Front water drain hoses are not cleaned.
2. Water drain hoses 267

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Front water drain hoses

The front water drain hoses -1- are routed in the A-pillars and
end in the plenum chamber.
– Water drain hoses -1 and 5- must be pushed in up to mark‐
ing -3- in drainage grommets -4-.
Rear water drain hoses
The rear water drain hoses -5- are routed through the D-pillars
and end in the rear wheel housings.
– Remove wheel housing liner ⇒ page 443 .
– Water drain hoses -1 and 5- must be pushed in up to mark‐
ing -3- in drainage grommets -4-.
2.3 Cleaning water drain hoses


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♦ Cleaning and fitting tool -VAS 6620-
Front water drain hoses

The front water drain hoses are routed in the A-pillars and end
in the plenum chamber.
Rear water drain hoses
The rear water drain hoses run through the D-pillars and end in
the rear wheel housings.
2. Water drain hoses 269

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– Remove wheel housing liner ⇒ page 443 .

– Cleaning is carried out from wheel housing using cleaning
and insertion tool -VAS 6620-.

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63 – Bumpers
1 Bumper, front
⇒ o1.1 verview - bumper cover”, page 271
⇒ o1.2 verview - impact bar”, page 277
⇒ a1.3 nd installing bumper cover”, page 279
⇒ b1.5 umper cover”, page 292
1.1 Assembly overview - bumper cover

⇒ o1.1.1 verview - bumper cover”, page 271
⇒ o1.1.2 verview – bumper cover, R-Line”, page 273
⇒ o1.1.3 verview – bumper cover, R model”, page 275
1.1.1 Assembly overview - bumper cover
Note
Minor differences may be encountered in respect of bumper cover, depending on vehicle model.
1. Bumper, front 271

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1 - Reinforcing piece
❑ Left and right
❑ Engages in front side of
bumper cover and bol‐
ted
❑ Can only be removed
with front bumper cover
removed
2 - Bolt
❑ Qty. 4
❑ Bolted to lock carrier.
❑ 2.0 Nm
3 - Radiator grille
ling ⇒ page 358
4 - Bolt
❑ Qty. 3
❑ Bolted to bumper cover
❑ 2.0 Nm
5 - Bracket
❑ Left and right
6 - Lock nut
❑ 2.0 Nm
7 - Expanding nut
❑ Left and right
8 - Bolt
❑ Left and right
❑ Points upwards
❑ 2.0 Nm
9 - Bolt
❑ Bolted to wheel housing liner.
❑ 2.0 Nm
10 - Bumper cover upper part
❑ Material PP/EPDM
11 - Trim strip
❑ Left and right
❑ Engaged in front bumper cover
❑ Can only be removed with front bumper cover removed
12 - Centre trim strip
❑ Left and right
13 - Bolt
❑ 2.0 Nm
272 Rep. gr.63 - Bumpers

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14 - Trim for daytime running light

❑ Left and right
❑ Engages in front side of bumper cover and bolted
15 - Fog light trim
❑ Left and right
❑ Pulled off forwards
16 - Bumper cover lower part
❑ With spoiler and centre ventilation grille
17 - Bolt
❑ 2.0 Nm
18 - Bolt
❑ Qty. 3
❑ Bolted to lock carrier.
❑ 2.0 Nm
19 - Clip
❑ With clips or screws depending on version
20 - Number plate holder
❑ Installed only in selected models available in selected markets
21 - Cover for towing eye
1.1.2 Assembly overview – bumper cover, R-Line

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1 - Bolts
❑ Qty. 4
❑ 2 Nm
2 - Radiator grille
ling ⇒ page 358
3 - Decorative trims
❑ Qty. 2
ling ⇒ page 279
4 - Adaptive cruise control
unit -J428-
tem; Rep. gr. 27;
Adaptive cruise control;
Overview of fitting loca‐
tions - adaptive cruise
control
5 - Trim strip
❑ Centre
ling ⇒ page 279
6 - Bolts
❑ Qty. 8
❑ 2 Nm
7 - Bracket
❑ Qty. 2
8 - Nuts
❑ Qty. 4
❑ 2 Nm
9 - Nuts
❑ Qty. 2
10 - Bolts
❑ Qty. 2
❑ 2 Nm
11 - Trim
❑ Qty. 2
❑ For daytime running light
12 - Bolts
❑ Qty. 6
❑ 2 Nm
13 - Support members
❑ Qty. 2
14 - Bumper cover
❑ Upper part

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❑ Repair ⇒ page 292
15 - Bolts
❑ Qty. 6
❑ 2 Nm
16 - Frame
❑ Qty. 2
❑ For fog light.
❑ Qty. 2
18 - Trim
❑ Qty. 2
❑ For fog light.
❑ Depending on equipment
20 - Clips
❑ Qty. 5
21 - Connecting strip
22 - Spoiler
23 - Bolts
❑ Qty. 6
❑ 2 Nm
24 - Trim strip
❑ Centre
25 - Trim
26 - Bolts
❑ Qty. 3
❑ 2 Nm
27 - Cover
❑ For towing eye.
1.1.3 Assembly overview – bumper cover, R model

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1 - Bolts
❑ Qty. 4
❑ 2 Nm
2 - Radiator grille
ling ⇒ page 358
3 - Bolts
❑ Qty. 4
❑ 2 Nm
unit -J428-
tem; Rep. gr. 27;
control
5 - Trim strip
❑ Centre
ling ⇒ page 291
❑ Qty. 2
ling ⇒ page 290
7 - Guide profiles
❑ Qty. 2
ling ⇒ page 282
8 - Expanding nuts
❑ Qty. 2
9 - Bolts
❑ Qty. 2
❑ 2 Nm
10 - Nuts
❑ Qty. 2
❑ 2.5 Nm
11 - Bolts
❑ Qty. 4
❑ 2 Nm
12 - Ventilation grille
❑ Centre
13 - Support members
❑ Qty. 2
14 - Bumper cover

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15 - Bolts
❑ Qty. 6
❑ 2 Nm
16 - Cover parts
❑ Qty. 2
17 - Front spoiler
18 - Bolts
❑ Qty. 9
❑ 2 Nm
19 - Cover strip
❑ Centre
20 - Connecting strip
21 - Clips
❑ Qty. 5
❑ Depending on equipment
23 - Cover
❑ For towing eye.
1.2 Assembly overview - impact bar
Note

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1 - Impact bar
Note
♦ Push impact bar as far back as

possible in parallel motion.
♦ Bolts -2- must be located
in same position at top and
bottom in elongated holes
-dimension a-.
♦ The crash response of the vehi‐
cle is affected by the positions
of the bolts in the elongated
holes.
2 - Bolt
❑ 8 Nm
3 - Bolt
❑ 55 Nm
4 - Lock nut

T-Roc 2018 ➤
❑ 2.0 Nm
5 - Foam element
❑ Inserted in impact bar
6 - Pop rivet
❑ Left and right
❑ Insert with special pop rivet pliers -V.A.G 1753A-
7 - Pedestrian protection
8 - Air deflector element, centre
1.3 Removing and installing bumper cover


T-Roc 2018 ➤
Removing
Note
♦ The bumper cover is removed together with the radiator grille.

♦ The wheel arch trim is detached from the fasteners only. The clips in the wing are not released.
♦ Observe instructions and specifications for work on adaptive cruise control unit -J428- -8- under ⇒ Electri‐
cal system; Rep. gr. 27; Adaptive cruise control; Overview of fitting locations - adaptive cruise control.
– Unscrew bolts -2- from radiator grille.

– Unscrew bolts -3- and bolt pointing upwards -4- on wheel
housing.
– Unscrew bolts -3 and 8- from below.
– Push wheel arch trim -5- from inside out of fasteners -6- in
bumper -arrows a-.
chanic.
– Pull bumper cover -7- out of guide fasteners on left and right
of wing -arrows b-.

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– Pull bumper cover -7- off vehicle in parallel movement

-arrows c-.
– Disconnect connector -1- for adaptive cruise control unit -
J428- -9-.
– If fitted, disconnect hose coupling of washer fluid lines
⇒ Electrical system; Rep. gr. 92; Headlight washer system;
Assembly overview - headlight washer system.
– If fitted, separate connector of electrical components.
General information and work instructions for the parking aid
can be found in ⇒ Electrical system; Rep. gr. 94; Parking aid.
General information and work instructions for the Park Assist
system can be found in ⇒ Electrical system; Rep. gr. 94; Park
Assist system.

Installing
Further installation requires the assistance of a second me‐
chanic.

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– Install adaptive cruise control unit -J428- -8- ⇒ Electrical sys‐

tem; Rep. gr. 27; Adaptive cruise control; Overview of fitting
locations - adaptive cruise control.
– Join connector -10- for adaptive cruise control unit -J428-
-9-.
– If present, connect connectors to electrical components.
– Guide bumper cover -2- onto lock carrier -arrows a- in a
parallel movement until locking devices engage.
– Press bumper cover -2- onto guide brackets -1- on wing on
left and right until they engage with each other -arrow b-.
– Tighten bolts -5 and 6- for wheel housing liner.
– Tighten bolts -6 and 7- from underneath.
– Engage wheel arch trim -3- in bumper cover -arrows c-.
– Observe gaps/shut lines ⇒ Body Repairs; Rep. gr. 00; Panel
gaps; Body – front.
Specified torques
♦ ⇒ o1.1 verview - bumper cover”, page 271
1.4 Removing and installing add-on parts

⇒ a1.4.1 nd installing guide, R model”, page 282
⇒ a1.4.2 nd installing support, R model”, page 283
⇒ a1.4.3 nd installing air intake grille, R model”, page 284
⇒ a1.4.4 nd installing trim strip, R model”, page 285
⇒ a1.4.5 nd installing cover section, R model”, page 287
⇒ a1.4.6 nd installing connecting strip, R model”, page 288
⇒ a1.4.7 nd installing front spoiler, R model”, page 288
⇒ a1.4.8 nd installing trim strip, R model”, page 290
1.4.1 Removing and installing guide, R mod‐

el

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Removing
– Remove bumper cover ⇒ page 279 .

– Unscrew nuts -4-.
– Release catches -2- with removal wedge -3409-. When do‐
ing this, hold guide -1- under tension.
– Remove guide -1-.
Installing
Specified torques
♦ Assembly overview – bumper cover, R model ⇒ page 275
1.4.2 Removing and installing support, R

model
♦ Torque screwdriver -VAS 6494-

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Removing

– Remove fog light ⇒ Electrical system; Rep. gr. 94; Fog
lights; Removing and installing fog lights.
– Disconnect electrical connectors -4-.
– Lay wiring harness -5- aside.
• The following work steps must be performed by a second
mechanic.
– Have a second mechanic secure bumper cover.
ing this, hold reinforcement -1- under tension.
– Remove reinforcement -1-.
Installing
Specified torques
1.4.3 Removing and installing air intake

grille, R model

T-Roc 2018 ➤
Removing

mechanic.
ing this, hold ventilation grille -1- under tension.
– Remove ventilation grille -1-.
Installing
1.4.4 Removing and installing trim strip, R

model

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Removing

– Remove air intake grille ⇒ page 284 .
mechanic.
ing this, keep trim strip -1- and front spoiler -2- under ten‐
sion.
– Remove trim strip -1- along with front spoiler.

T-Roc 2018 ➤

ing this, hold trim strip -1- under tension.
– Remove trim strip -1-.
Installing
1.4.5 Removing and installing cover section,

R model
Removing

– Remove trim strip ⇒ page 285 .

T-Roc 2018 ➤

mechanic.
ing this, hold cover section -1- under tension.
– Remove cover section -1-.
Installing
1.4.6 Removing and installing connecting

strip, R model
Removing

mechanic.
ing this, hold connecting strip -1- under tension.
– Remove connecting strip -1-.
Installing
1.4.7 Removing and installing front spoiler, R

model

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Removing

– Remove air intake grille ⇒ page 284 .
mechanic.
ing this, keep front spoiler -1- and trim strip -2- under ten‐
sion.
– Remove front spoiler -1- along with trim strip.

T-Roc 2018 ➤

ing this, hold trim strip under tension.
– Remove front spoiler -1-.
Installing
1.4.8 Removing and installing trim strip, R

model
Removing

– Remove centre trim strip ⇒ page 291 .
mechanic.

T-Roc 2018 ➤

ing this, hold trim strip -1- under tension.
– Remove trim strip -1-.
Installing
1.4.9 Removing and installing centre trim

strip, R model
Removing

mechanic.
ing this, hold centre trim strip -1- under tension.
– Detach centre trim strip -1-.
Installing

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1.5 Repairing bumper cover

⇒ b1.5.1 umper cover”, page 292
⇒ h1.5.2 older for parking aid sender”, page 292
⇒ r1.5.3 etainer for parking aid sender”, page 296
1.5.1 Repairing bumper cover
Note
♦ If bumper cover is damaged, determine whether plastic can

be repaired before renewing bumper.
♦ Vehicles with pedestrian protection have crash sensors in‐
stalled in the bumper cover.
♦ With this equipment, the bumper cover may not be repaired.
The bumper cover must be renewed in this instance.
Description under: ⇒ General Information; Body Repairs, Gen‐

eral Body Repairs; Plastic repair procedures.
1.5.2 Installing holder for parking aid sender

♦ Installation tool for PDC bracket -VAS 6614-
♦ Attachment device for PDC holder -VAS 6614/7-
Materials
♦ Cleaning solution ⇒ Electronic parts catalogue
“ETKA”
Note
Observe manufacturer's instructions enclosed in the packaging.
Installing brackets
Note
The brackets are installed after the bumper cover has been painted.

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The markings for the bracket -1- can be found on the inside of
the bumper cover.
– If there are no markings, the centre point -2- must be deter‐
mined.
– The holes must be drilled from the inside to the outside with
the drill bit -VAS 6614/4- -3- from the supplied tool kit.

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– Fit screw-hole punch -VAS 6614/9- with bolt head -1-, wash‐
er -2- and counter-support -3- from inside of bumper cover
-5-.
– Screw on punch -4-, not quite as far as bumper cover.
– Press punch -4- against bumper cover.
– Tighten hole puncher -1-.
Note
Do not permit the punch -4- to turn on the paint of the bumper cover.
– Pull punch -4- through material of bumper cover -5- -arrows-

by turning bolt head -1-.
– Remove hole punch and make next holes.
– Thoroughly clean bumper cover and bracket with cleaning
solution.

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– Thoroughly clean bonding surfaces on bumper cover -4-.

– Push bracket -2- onto centring pin -1-.
– Pull off backing from double-sided adhesive tape -3- on re‐
tainer.
– Insert centring pin -1- into hole until the bracket is touching
the bumper cover -4-.
– Press bracket forcefully against bonding surface -3-.
– Removing centring pin and repeat the procedure for all
brackets.
– Further work can carried out on bumper cover only after
minimum curing period 1)
.
1) Minimum curing period
Do not carry out any further work on the bumper cover or brack‐
ets until the minimum curing period of 2 hours has expired.
The minimum curing period must be observed so that the adhe‐
sive tape can develop its full adhesive strength.
In this time, the bumper cover must remain where it is. Do not
move it.

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1.5.3 Installing retainer for parking aid send‐

er
♦ Drill bit -VAS 6614/4-

♦ Screw-hole punch 28.2 mm -VAS 895 013-
♦ Thermal clip bonder -VAS 6872-
♦ Hand set -VAS 6872/1-
♦ Clip, M-shaped -VAS 6872/3-

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Stamping holes
Note
♦ Stamping holes is described for the left side. The procedure for the right-hand side is basically the same.
♦ The park assist brackets are installed after the bumper cover has been painted.
♦ The contact surface of the park assist brackets must not be painted ⇒ Paintwork manual.
The markings -1- for the park assist brackets can be found on
the inside of the bumper cover.
– Hole must be drilled from inside out with drill bit -VAS
6614/4- -3- from tool kit supplied.

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– Fit screw-hole punch 28.2 mm -VAS 895 013- with bolt head
-1-, washer -2- and counter-support -3- from inside of bump‐
er cover -5-.
– Screw on hole punch -4- from outside of bumper cover -5-.
– Tighten bolt head -1-.
Note
The punch -4- must not turn on the paint of the bumper cover.
– Punch -4- is pulled through material of bumper cover -5- in

direction of -arrow- by turning bolt head -1-.
– Remove hole punch and make hole on left side.

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Installing brackets for park assist steering
Note
♦ Installation of the park assist bracket is described for the left-hand side. The procedure for the right-hand
side is basically the same.
♦ The spacer on the hand unit -VAS 6872/1- must be set with precision.
♦ If the setting is too low, the bracket will not be secured properly.
♦ If the setting is too high, the clips will leave marks on the bumper cover -1-.
♦ 4 clips have to be attached on each side. The respective locations are shown in the illustration.
– Attach clip, M-shape -VAS 6872/3- in spacer -2- in direction

of -arrow b-.
– Set distance -a- to exactly 3 mm.
– Install park assist bracket -3- in hole punched in bumper
cover -1-.
– Install clips in direction of -arrow a-, allowing them to melt in
without pressure using hand unit -VAS 6872/1-.

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– Once spacer -2- rests against surface, switch off hand unit
-VAS 6872/1-.
– Allow the clip to cool down for 10 s. Do not move the hand
unit -VAS 6872/1- during this time.
– After the cooling period has elapsed, pull off hand unit -VAS
6872/1- and fit next clip.
– After all clips have been secured, cut off ends of clips.
– Install park assist bracket -3- on left-hand side.

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2 Bumper, rear
⇒ o2.1 verview - bumper cover”, page 301
⇒ o2.2 verview - impact bar”, page 305
⇒ a2.3 nd installing bumper cover”, page 306
⇒ a2.4 nd installing impact bar”, page 309
⇒ b2.6 umper cover”, page 316
2.1 Assembly overview - bumper cover

⇒ o2.1.1 verview - bumper cover”, page 301
⇒ o2.1.2 verview – bumper cover, R-Line”, page 303
⇒ o2.1.3 verview – bumper cover, R model”, page 304
2.1.1 Assembly overview - bumper cover
Note
2. Bumper, rear 301

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1 - Centre guide profile

❑ Adjusted in relation to
rear lid -2- with spacer
-3-
2 - Tailgate
3 - Spacer
❑ Folded out for adjust‐
ment -arrow a-
4 - Guide profile
❑ Left and right with tail
light
5 - Outer guide profile
❑ Left and right
6 - Lock nut
❑ Qty. 2 per guide profile
❑ 3.5 Nm
7 - Wheel arch cover
❑ Engaged in bumper
cover
8 - Protective sheet
❑ Transparent protective
film
❑ Bonded to bumper cov‐
er on left and right
❑ Qty. 4, 10 mm × 20 mm
9 - Bolt
❑ Left and right
❑ Points upwards
❑ Bolted to side panel.
❑ 2.0 Nm
10 - Bolt
❑ 2 Nm
11 - Cover
❑ Left and right
❑ Engaged in bumper cover and secured with bolts
❑ Only remove when bumper cover is removed
12 - Reflector
❑ Left and right
❑ Engages in cover.
13 - Bumper cover lower part
❑ Engaged in bumper cover upper part
14 - Trim
❑ Left and right

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15 - Cap
16 - Bolt
❑ 2 Nm
17 - Spreader rivet
❑ Qty. 4
18 - Trim, middle
19 - Bumper cover upper part
❑ Engaged in bumper cover lower part
20 - Lock nut
❑ Qty. 4
❑ 3.5 Nm
2.1.2 Assembly overview – bumper cover, R-Line
2. Bumper, rear 303

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1 - Bumper cover
❑ Upper part
ling ⇒ page 306
2 - Bolts
❑ Qty. 2
❑ 2 Nm
3 - Bolts
❑ Qty. 6
❑ 2 Nm
4 - Covers
❑ Qty. 2
ling ⇒ page 306
5 - Reflector
❑ Qty. 2
ling ⇒ page 306
6 - Bumper cover
❑ Lower part
ling ⇒ page 306
7 - End plates
❑ Qty. 2
ling ⇒ page 306
8 - Trim
❑ Qty. 2
9 - Bolts
❑ Qty. 2
❑ 2 Nm
10 - Cover
❑ For towing eye.
11 - Diffuser
12 - Clips
❑ Qty. 4
2.1.3 Assembly overview – bumper cover, R model

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1 - Bumper cover
ling ⇒ page 306
2 - Bolts
❑ Qty. 2
❑ 2 Nm
3 - Bolts
❑ Qty. 6
❑ 2 Nm
4 - Cover
❑ For towing eye.
5 - Cover parts
❑ Qty. 2
ling ⇒ page 311
6 - Reflector
❑ Qty. 2
ling ⇒ page 313
7 - Nuts
❑ Qty. 4
❑ 3.5 Nm
8 - Bracket
❑ Diffuser
❑ Qty. 2
ling ⇒ page 314
9 - Bracket
❑ Wheel housing liner adapter
❑ Qty. 2
10 - Diffuser
11 - Bolts
❑ Qty. 4
❑ 2 Nm
12 - Spreader rivets
❑ Qty. 2
2.2 Assembly overview - impact bar
Note
2. Bumper, rear 305

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1 - Impact bar
ling ⇒ page 309
❑ Vehicles with towing
bracket ⇒ page 454
2 - Bolts
❑ Qty. 4 right
❑ Qty. 3 left
❑ 20 Nm + 90°
3 - Cap
❑ Not with towing bracket
2.3 Removing and installing bumper cover


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Removing
Note
The removal and installation procedures for the bumper cover may vary slightly, depending on vehicle
model.
– Remove tail lights in side panel ⇒ Electrical system; Rep.

gr. 94; Tail lights; Removing and installing tail light.
– Remove bolts -6- on left and right sides in area of wheel
housing liner.
– Unscrew bolts -7- from underneath.
– Remove spreader rivets -8- from underneath.
– Push wheel arch trim -3- from inside out of fasteners -5- in
bumper -arrows a-.
– Unscrew bolts -4- on left and right.
chanic.
– Pull bumper cover -9- out of guide fasteners on left and right
-2- of side panel -arrows b-.
2. Bumper, rear 307

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– Pull bumper cover -9- off vehicle in parallel movement

-arrows c-.
– If fitted, disconnect connectors of electrical components.
General information and work instructions for the parking aid
can be found in ⇒ Electrical system; Rep. gr. 94; Parking aid.
General information and work instructions for the Park Assist
system can be found in ⇒ Electrical system; Rep. gr. 94; Park
Assist system.
Installing
Further installation requires the assistance of a second me‐
chanic.
If not present, attach protective film -5-. Qty. 4 10 mm × 20 mm
on left and right.
– If present, connect connectors to electrical components.
– Guide bumper cover -9- onto vehicle in a parallel movement
-arrows a-.
– Press bumper cover -9- onto centre guide profile -1-.

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– Press bumper cover -9- onto guides on left and right -2- of
side panel until they engage with each other -arrow b-.
– Tighten bolts -5, 6 and 7-.
– Secure spreader rivets -8-.
– Engage wheel arch trim -3- in bumper cover -arrows c-.
– Observe gaps/shut lines ⇒ Body Repairs; Rep. gr. 00; Panel
gaps; Body – rear.
Specified torques
♦ ⇒ o2.1 verview - bumper cover”, page 301
2.4 Removing and installing impact bar
Removing
– Lift out impact bar -1- with guides -4- upwards -arrows- from
tabs -3- in cross panel.
– Remove impact bar -1- from vehicle.
2. Bumper, rear 309

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Installing

– Guide impact bar -1- up to vehicle.
– Guide guides -4- of impact bar -1- from top to bottom
-arrows- into tabs -3- in cross panel.
– Install bumper cover ⇒ page 306 .
Specified torques
♦ ⇒ o2.2 verview - impact bar”, page 305

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2.5 Removing and installing add-on parts

⇒ a2.5.1 nd installing cover section, R model”, page 311
⇒ a2.5.2 nd installing diffuser, R model”, page 312
⇒ a2.5.3 nd installing reflector, R model”, page 313
⇒ R2.5.4 emoving and installing holder for wheel housing liner
adapter bracket, R model”, page 313
⇒ R2.5.5 emoving and installing diffuser holder, R model”, page
314
2.5.1 Removing and installing cover section,

R model
Removing

mechanic.
ing this, hold cover section -1- under tension.
2. Bumper, rear 311

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– Remove cover section -1-.

Installing
2.5.2 Removing and installing diffuser, R

model
Removing

mechanic.
ing this, hold diffuser -1- under tension.
– Remove diffuser -1-.
Installing

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2.5.3 Removing and installing reflector, R

model
Removing

mechanic.
ing this, hold reflector -1- under tension.
– Remove reflector -1-.
Installing
2.5.4 Removing and installing holder for

wheel housing liner adapter bracket, R
model
2. Bumper, rear 313

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Removing

mechanic.
ing this, hold wheel housing liner adapter holder -1- under
tension.
– Remove holder for wheel housing liner adapter -1-.
Installing
2.5.5 Removing and installing diffuser hold‐

er, R model

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Removing

– Remove diffuser holder -1-.
Installing
Specified torques
2. Bumper, rear 315

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2.6 Repairing bumper cover

⇒ b2.6.1 umper cover”, page 316
⇒ s2.6.2 ender retainer for parking aid”, page 316
⇒ b2.6.3 rackets for park assist steering”, page 321
2.6.1 Repairing bumper cover
Note
♦ If bumper cover is damaged, determine whether plastic can

be repaired before renewing bumper.
♦ On vehicles with lane change assist, lane change assist
control units -J769 / J770- are located behind bumper cover.
♦ With this equipment, the bumper cover may not be repaired
in this area. The bumper cover must be renewed in this
instance.
Description under: ⇒ General Information; Body Repairs, Gen‐

eral Body Repairs; Plastic repair procedures.
2.6.2 Installing sender retainer for parking

aid
♦ Locating pins -VAS 6614/8-

♦ Punch 26.5 mm -VAS 895 003-
Materials
♦ Cleaning solution ⇒ Electronic Parts Cata‐
logue (ETKA)
Installing brackets

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Installing brackets
Note
♦ The brackets are installed after the bumper cover has been painted.
♦ Observe manufacturer's instructions enclosed in the packaging.
♦ Observe minimum curing period of 30 minutes.
The markings for the bracket -1- can be found on the inside of
the bumper cover.
– The holes must be drilled from the inside to the outside with
the drill bit -VAS 6614/4- -3- from the supplied tool kit.
2. Bumper, rear 317

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– Fit screw-hole punch -VAS 6614/9- -1-, washer -2- and

counter-support -3- from inside of bumper cover -5-.
– Tighten screw-hole punch -1-.
Note
Do not permit the punch -4- to turn on the paint of the bumper cover.

– Remove screw-hole punch and make next holes.
– Thoroughly clean bumper cover and bracket with cleaning
solution.

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– Note alignment of brackets after aligning sensors -arrows-.

– Refer to diagram for alignment of sensors.
– Connections of outer sensors -1- point towards outside
-arrows-.
– Connections of inner sensors -1- point towards inside
-arrows-.
2. Bumper, rear 319

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– Thoroughly clean bonding surfaces on bumper cover -4-.

– Push bracket -2- onto centring pin -1-.
– Pull off backing from double-sided adhesive tape -3- on re‐
tainer.
– Insert centring pin -1- into hole until the bracket is touching
the bumper cover -4-.
– Press bracket forcefully against bonding surface -3-.
– Removing centring pin and repeat the procedure for all
brackets.
– Further work can carried out on bumper cover only after
minimum curing period 2)
.
2) Minimum curing period
Do not carry out any further work on the bumper cover or brack‐
ets until the minimum curing period of 2 hours has expired.
The minimum curing period must be observed so that the adhe‐
sive tape can develop its full adhesive strength.
In this time, the bumper cover must remain where it is. Do not
move it.

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2.6.3 Installing brackets for park assist steer‐

ing
♦ Thermal clip bonder -VAS 6872-
♦ Drill bit -VAS 6614/4-
♦ Hand set -VAS 6872/1-
♦ Clip, M-shaped -VAS 6872/3-
♦ Screw-hole punch 26.5 mm -VAS 895 003-
Stamping holes
Note
♦ Stamping holes is described for the left side. The procedure for the right-hand side is basically the same.
♦ The park assist brackets are installed after the bumper cover has been painted.
♦ The contact surface of the park assist brackets must not be painted ⇒ Paintwork manual.
2. Bumper, rear 321

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The markings -1- for the park assist brackets can be found on
the inside of the bumper cover.
– Hole must be drilled from inside out with drill bit -VAS
6614/4- -3- from tool kit supplied.
– Fit hole punch 26.5 mm -VAS 895 003- -1-, washer -2- and
counter-support -3- from inside of bumper cover -5-.
– Tighten bolt head -1-.
Note
The punch -4- must not turn on the paint of the bumper cover.

– Remove screw-hole punch and make hole on other side.

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Installing brackets for park assist steering
Note
♦ Installation of the park assist bracket is described for the left-hand side. The procedure for the right-hand
side is basically the same.
♦ The spacer on the hand unit -VAS 6872/1- must be set with precision.
♦ If the setting is too low, the bracket will not be secured properly.
♦ If the setting is too high, the clips will leave marks on the bumper cover -1-.
♦ 4 clips have to be attached on each side. The respective locations are shown in the illustration.
– Attach clip, M-shape -VAS 6872/3- in spacer -2- in direction

of -arrow b-.
– Set distance -a- to exactly 3 mm.
– Install park assist bracket -3- in hole punched in bumper
cover -1-.
– Install clips in direction of -arrow a-, allowing them to melt in
without pressure using hand unit -VAS 6872/1-.
2. Bumper, rear 323

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– Once spacer -2- rests against surface, switch off hand unit
-VAS 6872/1-.
– Allow the clip to cool down for 10 s. Do not move the hand
unit -VAS 6872/1- during this time.
– After the cooling period has elapsed, pull off hand unit -VAS
6872/1- and fit next clip.
– After all clips have been secured, cut off ends of clips.
– Install park assist bracket -3- on left-hand side.

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64 – Glazing
1 Repair notes
⇒ c1.1 uring periods for bonded windows”, page 325
⇒ r1.2 epair”, page 325
⇒ i1.3 nstructions for bonded windows”, page 326
⇒ o1.4 ld undamaged windows for fitting”, page 327
⇒ n1.5 ew windows for installing”, page 328
⇒ b1.6 ody flange for fitting”, page 330
⇒ o1.7 ff excess adhesive”, page 331
1.1 Minimum curing periods for bonded

windows
Note
♦ There are special requirements for renewing bonded win‐

dows.
♦ The vehicle is safe to use only after the minimum curing
period has elapsed.
2-pack window adhesive

The minimum curing period for 2-pack window adhesive is 2
hours for all windows.
The specified minimum curing period remains the same even if
1-pack window adhesive needs to be used for additional residu‐
al work or for sealing purposes.
Minimum curing period is the time from bonding the window
until vehicle may be used. During this time, the vehicle must be
standing on a level surface at room temperature (at least 15°C).
1-pack window adhesive
The minimum curing period for 1-pack window adhesive is 6
hours for all windows.
Minimum curing period is the time from bonding the window
until vehicle may be used. During this time, the vehicle must be
standing on a level surface at room temperature (at least 15°C).
1.2 Window repair
Note
♦ Before renewing windscreen, explore possibilities of repair‐

ing damage to glass.
♦ Damaged windscreens can be repaired with the window re‐
pair kit -VAS 6092-.
♦ This damage must remain within a certain size or position.
♦ Each window repair kit comes with a set of instructions.
1. Repair notes 325

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♦ Window repair kit -VAS 6092-
1.3 Installation instructions for bonded win‐

dows
⇒ i1.3.1 nstructions”, page 326
⇒ 1.3.2 , page 326
1.3.1 Fitting instructions

– Apply adhesive sealing material -1- in continuous bead,
holding applicator at right angle to window -2-.
♦ Adhere to the specified dimensions for the adhesive beads.

♦ Using 2 suction lifters -V.A.G 1344-, install glass pane in
window aperture, align to centre and press in onto spacing
lip.
♦ Replace stickers (e.g. for airbag) if there were any.
1.3.2 Materials
Note
The part numbers of the materials can be found in the ⇒ Elec‐

tronic parts catalogue (ETKA).
♦ 2-pack window adhesive 1) 2) 3) 6)
326 Rep. gr.64 - Glazing

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♦ 1-pack window adhesive 1) 2) 5) 6)
♦ Activator 1) 6)
♦ Glass and paint primer 1) 6)
♦ Cleaning solution 1) 6)
♦ Primer applicator 1) 6)
♦ Adhesive remover 1) 6)
♦ Cutting cord 357 853 999 6) 7
♦ Wire reel 7
VAS 6452/1
♦ Cutting cord 7
6888/1
1) Observe instructions for use on the information sheet provi‐

ded by the manufacturer.
2) Observe minimum curing period ⇒ page 325 .
3)Double cartridge gun -VAS 5237- must be used to apply
these materials.
5)Small cartridge, 180 ml, for sealing and/or when a 400 ml
double cartridge alone is not sufficient.
6) The part numbers of the materials can be found in the ⇒ Elec‐
tronic parts catalogue (ETKA).
7 The cutting cords stated above can be used alternatively to
the cutting wires, and vice versa. They are designated for single
use.
1.4 Preparing old undamaged windows for

fitting
Note
♦ Side windows without centring pins can be installed.

♦ Centring pins are only relevant for production.
♦ If required, the window can be fixed in place with adhesive
tape during the minimum curing period.
Cutting back adhesive bead

♦ If an undamaged window is being re-used, cut back the re‐
sidual adhesive sealant to 1 to 2 mm shortly before bonding
it back in.
♦ Do not damage primer and ceramic coating when doing this.
1. Repair notes 327

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♦ Keep bonding surface free of dirt and grease.

♦ Do not treat bonding surface with activator, glass/paint pri‐
mer or cleaning solution immediately after cutting back.
♦ The remaining material is required as a base for better adhe‐
sion of the new adhesive sealing material to be applied.
• Exception: if bonding is performed later than one day after
cutting back adhesive bead, the remaining residual material
must be activated with activator.
– Apply activator evenly in one stroke using applicator.
NOTICE
Risk of damage to paintwork structure caused by activator.
– Apply activator precisely onto adhesive bead, and do not
spill any activator.
Allow to air dry for approx. 10 minutes.
1.5 Preparing new windows for installing
Note
♦ The application area for the adhesive bead is not precoated

or primed.
♦ The relevant area is a ceramic coating.
♦ No windows are precoated.
♦ The sealing lip is included with a new windscreen.
– Using cleaning solution, clean edge of window all round to a

width of 20 mm.
– Then rub edge of window dry using a lint-free cloth.
– Using applicator -1-, apply glass and paint primer -2- evenly
in one pass.

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♦ Allow to air dry for approx. 10 minutes.
1. Repair notes 329

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Note
The distance between glass/paint primer as well as adhesive bead and the outer edge of the windscreen
differs in the lower area of the windscreen.
– Up to -dimension a- = 150 mm measured from lower edge of

windscreen the distance between the adhesive bead and the
outer edge is -dimension b- = 6 mm.
– From this point down to the bend the distance amounts to
-dimension d- = 20 mm.
– At half distance between dimension a and the bend
-dimension c- must be 10 mm.
1.6 Preparing body flange for fitting

♦ Cut back residual adhesive sealant to 1 … 2 mm shortly
before bonding window back in.
♦ Do not damage primer and paintwork structure when doing
this.
♦ Keep bonding surface free of dirt and grease.

♦ Do not treat bonding surface with activator, glass/paint pri‐
mer or cleaning solution immediately after cutting back.
♦ The remaining material is required as a base for better adhe‐
sion of the new adhesive sealing material to be applied.
– Cut back remaining material on body flange with U-shaped
blade -V.A.G 1561/3-, but do not remove completely.
• Exception: if bonding is performed later than one day after
cutting back adhesive bead, the remaining residual material
must be activated with activator.
– Apply activator evenly in one stroke using applicator.
NOTICE
Risk of damage to paintwork structure caused by activator.
– Apply activator precisely onto adhesive bead, and do not
spill any activator.
♦ If the window flange has been repaired or partially renewed,

the area concerned must be cleaned and primed again after
painting.
– Clean metal flange all around using cleaning solution.
– Then rub edge of window dry using a lint-free cloth.
– Apply glass/paint primer evenly in one pass onto paintwork
structure using applicator.

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Note
It is possible that a laser weld seam lies outside the area of the
adhesive bead. In this case, the exposed weld seam must be
sealed with glass adhesive before bonding the window.
– If laser weld seam -3- on metal flange -4- is not covered by

existing adhesive bead -1-, coat laser weld seam -3- with
glass/paint primer -3-. Then fill laser weld seam with glass
adhesive -1-.
Touching up paint damage

Paint structure must be restored after damage to the paintwork
according to specifications in the “Paint” workshop manual.
1.7 Cleaning off excess adhesive

– Use adhesive remover -D 002 000. 10- as cleaning agent.
Safety precautions must be observe for all work procedures.
Note
♦ When cleaning the vehicle interior, do not press freshly in‐

stalled window outwards.
♦ Otherwise, the window will be detached.
– First, clean the painted surface roughly with a dry cloth.

Remove residue using adhesive remover -D 002 000. 10-.
– Cleaning plastic trim: Allow adhesive sealant to cure (ap‐
prox. 1 hour) and then peel off.
1. Repair notes 331

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2 Windscreen
⇒ o2.1 verview - windscreen”, page 332
⇒ a2.2 nd installing windscreen”, page 333
2.1 Assembly overview - windscreen
1 - Windscreen
ling ⇒ page 333
2 - Spacer
❑ Qty. 4
3 - PUR adhesive sealant
❑ Cross section of
bead: width = 7 mm
-dimension a-, height =
10 mm -dimension b-
(including precoating,
residual material on
window glass and win‐
dow flange).
❑ Minimum curing period
⇒ page 325 .
❑ Adhesive bead starts
and ends at -arrow-
4 - Body flange
❑ Touch up paintwork
damage.
5 - Gaps/shut lines
❑ Must be uniform.
6 - Windscreen adjuster
❑ Left and right
❑ Removed after adhe‐
sive has hardened
7 - Windscreen seal
❑ Is part of windscreen
ling plenum chamber
cover ⇒ page 20

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2.2 Removing and installing windscreen

⇒ a2.2.1 nd installing windscreen”, page 333
⇒ b2.2.2 roken windscreen”, page 340
2.2.1 Removing and installing windscreen
Note
♦ The removal of a bonded window is described using the

Removal kit for flush bonded windows -V.A.G 1474 A-.
♦ Alternatively, you can also use the cutting tool for bonded
windows -VAS 6452-.
♦ Another alternative is to use the window removal set -VAS
6888-.

♦ Removal kit for flush bonded windows -V.A.G 1474 A- or
Removal kit for flush bonded windows -VAS 6452-
♦ Suction lifter -V.A.G 1344-
♦ Cutting tool -V.A.G 1351-
♦ Windscreen removal kit -V.A.G 1755-
♦ Hand-cartridge gun -V.A.G 1628-
♦ Cartridge heater -V.A.G 1939-
♦ Electric cutter -V.A.G 1561 A-

♦ Blade -V.A.G 1561/2-
♦ Blade -V.A.G 1561/8-
♦ Blade -V.A.G 1561/19-
2. Windscreen 333
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♦ Double cartridge gun -VAS 5237-
Removing
– Remove A-pillar upper trims on left and right ⇒ General body
repairs, interior; Rep. gr. 70; Trims, interior; Removing and
installing A-pillar trim.
– Remove left and right sun visors ⇒ General body repairs,
interior; Rep. gr. 68; Equipment; Removing and installing
sun visor.
– Remove interior mirror ⇒ General body repairs, interior; Rep.
gr. 68; Interior mirror; Removing and installing interior mirror.
– If present, remove rain and light detection sensor ⇒ Electri‐
cal system; Rep. gr. 92; Windscreen wiper system; Remov‐
ing and installing rain and light detection sensor.
– If present, remove front camera ⇒ Electrical system; Rep.
gr. 96; Front camera for driver assist systems; Removing
and installing front camera for driver assist systems
– Lower moulded headliner in area of windscreen ⇒ General
body repairs, interior; Rep. gr. 70; Roof trims; Removing and
installing moulded headliner.
– Moulded headliner can now be lowered sufficiently to allow
windscreen to be cut out without damage occurring to moul‐
ded headliner.

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Only for vehicles with windscreen heater

– Unscrew securing nut -6-.
– Bond cable -5- to windscreen.
– Separate electrical connectors -1 and 3-.
– Bond cables -2 and 4- to windscreen.
2. Windscreen 335
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– Slide suitable covering film -V.A.G 1474/8- between wind‐

screen and dash panel.
– Pull end of cutting cord -1- through adhesive sealing material
into inside of vehicle using awl -V.A.G 1474/2-.
– Secure inside end of cutting cord against falling out using
Pull toggle -V.A.G 1351/1- -3-.

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– Insert cutting cord -2- into window flange using tube -1-.
– Place cutting cord around the front windscreen.
– Ensure that cutting cord lies under front windscreen in cor‐
ners.
2. Windscreen 337
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– Attach the ends of cords -4- on removal kit for flush bonded
windows -VAS 6452- -1-.
– Put cutting cord around suction cups of reel device -arrow-.
– Use plastic wedge -2- to press cutting cord against wind‐
screen while cutting in order to have clearance at window
flange and dash panel.

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– Position removal kit for flush bonded windows -VAS 6452- at

lower corners of windscreen.
– Change permanently position of left removal kit for flush
bonded windows -VAS 6452- from “position I”to “position III”
and cut windscreen free.
– Change position of right removal kit for flush bonded win‐
dows -VAS 6452- from “position IV”to “position VI” and cut
windscreen free.
– Use 2 suction lifters -V.A.G 1344- to lift off windscreen from
vehicle.
Installing
– On vehicles with front camera for driver assist systems -
R242-, install front camera ⇒ Electrical system; Rep. gr. 96;
Front camera for driver assist systems; Removing and instal‐
ling front camera for driver assist systems, and calibrate
front camera ⇒ Running gear, axles, steering; Rep. gr. 44;
Front camera for driver assist systems; Calibrating front
camera for driver assist systems.
– Preparing old undamaged window for glazing ⇒ page 327 .
– Preparing new window for glazing ⇒ page 328 .
– Preparing body flange for glazing ⇒ page 330 .
2. Windscreen 339
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– Installation instructions ⇒ page 326 .

– Minimum curing period ⇒ page 325 .
– After inserting, secure windscreen on roof using adhesive
tape.
2.2.2 Removing broken windscreen

Removal of a broken windscreen is performed in the same
manner as the removal a broken rear window ⇒ page 345 .

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3 Rear windscreen
⇒ o3.1 verview - rear window”, page 341
⇒ a3.2 nd installing rear window”, page 342
3.1 Assembly overview - rear window
1 - Rear windscreen
ling ⇒ page 342
2 - Body flange
3 - PUR adhesive sealant
❑ Cross section of
bead: width = 7 mm
-dimension a-, height =
10 mm -dimension b-
(including precoating,
residual material on
window glass and win‐
dow flange).
❑ Minimum curing period
⇒ page 325 .
❑ Adhesive bead starts
and ends at -arrow a-
4 - Spacer
5 - Connector for window
heater
❑ Left and right
6 - Side spoiler
3. Rear windscreen 341

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3.2 Removing and installing rear window

⇒ a3.2.1 nd installing rear window”, page 342
⇒ b3.2.2 roken rear window”, page 345
3.2.1 Removing and installing rear window
Note
♦ The removal of a bonded window is described using the

Removal kit for flush bonded windows -V.A.G 1474 A-.
♦ Alternatively, you can also use the cutting tool for bonded
windows -VAS 6452-.
♦ Another alternative is to use the window removal set -VAS
6888-.

♦ Removal kit for flush bonded windows -V.A.G 1474 A- or
Removal kit for flush bonded windows -VAS 6452-
♦ Suction lifter -V.A.G 1344-
♦ Cutting tool -V.A.G 1351-
♦ Windscreen removal kit -V.A.G 1755-
♦ Hand-cartridge gun -V.A.G 1628-
♦ Cartridge heater -V.A.G 1939-

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Removing
Note
If the rear window is reused, make sure that the electrical connections for the rear window heating are not
damaged.
– Remove spoiler ⇒ page 361 .

– Pull off connectors for rear window heating and window aer‐
ial.
– Using the awl -V.A.G 1474/2- pull cutting cord -1- inwards
through adhesive sealant at the location -arrow- shown in
the illustration.
– Use the pull toggle -V.A.G 1351/1- to secure end of cutting
cord before pulling it out.
– Lay cutting cord around rear window and guide second end
of cord inwards.
– Attach end of cutting cord to removal kit for flush bonded
windows -VAS 6452- or reel device -V.A.G 1654 A-.

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Note
It is essential to use the protective film or the plastic strip -V.A.G 1474/15- in order to protect the metal
flange.
– Carefully guide protective film -4- or plastic strip -V.A.G

1474/15- between rear window and metal flange.
– Place reel device -V.A.G 1654 A- in indicated position.
– Convert reel device -V.A.G 1654 A- accordingly and cut rear
window free towards sides starting in upper area.
– Use wedge -V.A.G 1474/5- to press cutting cord -3- against
rear window glass while cutting in order to have clearance at
body flange.
– Remove rear window from rear lid.
Installing
– Preparing old undamaged window for glazing ⇒ page 327 .
– Preparing new window for glazing ⇒ page 328 .

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– Preparing body flange for glazing ⇒ page 330 .

– Installation instructions ⇒ page 326 .
– Minimum curing period ⇒ page 325 .
3.2.2 Removing broken rear window

– Protect body and interior from glass splinters.
– Remove pieces of glass up to adhesive sealing material.
– Pull off connections for rear window heating and aerial.
– Cover flange -2- all round with textile-reinforced adhesive
tape.
CAUTION
Risk of injury to hands and eyes caused by glass splinters.
Risk of cuts.
– Cut through adhesive material (with glass remains) in win‐

dow aperture using electric cutter -V.A.G 1561 A- and U-
shaped blade -V.A.G 1561-.

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4 Door windows
⇒ o4.1 verview - front door window”, page 346
⇒ o4.2 verview - rear door window”, page 346
⇒ a4.3 nd installing front door window”, page 347
⇒ a4.4 nd installing rear door window”, page 351
⇒ a4.5 nd installing fixed rear door window”, page 355
4.1 Assembly overview - front door window
1 - Door window
ling ⇒ page 347
2 - Stickers
❑ Diameter 28 mm
hesive tape.
openings completely
3 - Locking lug
❑ Part of mounting for
door window
❑ Qty. 2
❑ For securing the door
window on window reg‐
ulator
4.2 Assembly overview - rear door window

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1 - Fixed door window

ling ⇒ page 355
2 - Locking lug
❑ Qty. 2
❑ Component part of
fixed door window
3 - Rear door window
ling ⇒ page 351
4 - Window regulator motor
ling ⇒ page 199
5 - Bolt
❑ Qty. 3
❑ 3 Nm
6 - Spreader pin
❑ Together with spreader
plug for securing door
window.
7 - Spreader plug
❑ Together with spreader
pin for securing door
window.
ling ⇒ page 221
9 - Stickers
❑ Qty. 2
❑ Diameter 28 mm
10 - Bolt
❑ Qty. 2
❑ 6 Nm
4.3 Removing and installing front door win‐

dow
4. Door windows 347

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Note
window. The left side is similar.
Removing

door trim.
– Remove door inner cover -3- ⇒ page 140 .
– Lever out cable feed.
– Lower door window -2- until retaining hooks -4- for door
window are accessible.

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Note
♦ If this part of the work cannot be done due to a fault in the window regulator motor, the window regulator
motor can be removed -7-.
♦ The door window can then be pushed to the required working position.
– Carefully press locking hooks -4- through opening in the win‐

dow. Lift door window slightly to prevent it from falling back
again in retaining hook.
– Lift door window -1- upwards out of window regulator.

– Lift door window -1- from behind and swing forwards out of
window channels -2- -arrow-.
Installing
4. Door windows 349

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– Insert door window -1- into window channels -2- -arrow-.
Note
Ensure that door window is properly located in window channel.
– Guide door window without force into mounting for door win‐
dow of window regulator.
– Align door window with rear window frame.

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– Press door window -2- into mounting for door window until
the retaining hooks -7- in the door window engage.
– Before the inner door cover, the cable feed and the door trim
are installed, carry out a functional check.
4.4 Removing and installing rear door win‐

dow
Removing
4. Door windows 351

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trim.
– Lift out plug -8-.
– Lower door window -1- until spreader pin -3- and spreader
plug -4- in cut-out of window regulator -2- are accessible.
Note
If work is not possible due to a malfunction caused by electric window regulator, window regulator motor -5-
is unbolted -7-. Window can then be pushed to required working position.
– Screw 5 mm bolt (approx. 70 mm long) into spreader pin -3-,

and pull bolt together with spreader pin out of spreader plug
-4-.
– Screw an 8 mm bolt (approx. 80 mm long) into spreader plug
-4-.

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Note
When screwing bolt into spreader plug, do not apply excessive pressure on plug. It otherwise falls inwards
into door.
– Pull spreader plug -4- out of window regulator guide -2- and,
in doing so, out of door window.

– Remove trim -2- ⇒ page 380 .
– Pull front part of window channel out of mounting.
– Pull door window -1- initially in a straight line -arrow a- and
then upwards at an angle -arrows b- towards vehicle exterior
out of window slot.
4. Door windows 353

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Installing
Note
♦ When installing door window, always renew spreader plug

and spreader pin.
♦ Before inserting spreader plug -2- and spreader pin -3-,
check window glass -9- for damage.
– Insert spreader plug -4- and centre it in the middle with the
window glass -1- removed.
– Press spreader pin -3- flush into spreader plug -4-.
– Insert door window -1- into door and push into window regu‐
lator guide.
– Make door window -1- engage in window regulator -2- by
pressing slightly from above.
– Then perform remaining installation in reverse order of re‐
moval.
– Carry out functional check before fitting door trim.

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4.5 Removing and installing fixed rear door

window
Removing
– Remove door trim panel ⇒ General body repairs, interior;

Rep. gr. 70; Rear door trim panels; Removing and installing
rear door trim panel.
– Remove window channel ⇒ page 221 .
– Pull off sticker -6-.
– Pull seal -8- off metal flange.
– Guide release tool -T10236- -2- one after the other under
both clips -1- -arrows a-.
4. Door windows 355

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Note
At lower clip -1-, guide tool -2- over clip and then push against door frame.
– When doing this, push door window -4- slightly outwards

-arrow b- until clips -1- are pushed out of door -7-.
– Then, pull door window -4- with web -3- upwards -arrow b-
out of door -7-.
Installing
– Slide door window -6- into door -arrow a-.

– Push door window against door -4- until clips -1- engage
audibly -arrows b-.
– Pull seal -5- around flange.
– Attach sticker -3- free of creases.

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Specified torques
♦ Fixed rear door window ⇒ o4.2 verview - rear door window”,
page 346 .
4. Door windows 357

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66 – Exterior equipment
1 Radiator grille and front trim
⇒ o1.1 verview – radiator grille”, page 358
⇒ a1.2 nd installing radiator grille”, page 358
1.1 Assembly overview – radiator grille
1 - Radiator grille
ling ⇒ page 358
2 - Bolts
❑ Qty. 4
❑ 2 Nm
unit -J428-
tem; Rep. gr. 27;
control
4 - Electrical connector
5 - Badge
❑ Brand badge
ling ⇒ page 449
6 - Badge
❑ R-Line
ling ⇒ page 449
7 - Bolt
❑ 2 Nm
1.2 Removing and installing radiator grille

Removing
358 Rep. gr.66 - Exterior equipment

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– Pull out radiator grille from fasteners -arrows b- starting from
right-hand side -arrow a-.
– Detach connector -4- from adaptive cruise control unit -
J428-.
If necessary, remove adaptive cruise control unit -J428- -3-
⇒ Electrical system; Rep. gr. 27; Adaptive cruise control; Over‐
view of fitting locations - adaptive cruise control.
Installing
1. Radiator grille and front trim 359

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– Install adaptive cruise control unit -J428- -3- and fit electrical
connector ⇒ Electrical system; Rep. gr. 27; Adaptive cruise
control; Overview of fitting locations - adaptive cruise control.
– Insert radiator grille -1- in front bumper cover.
– With slight pressure, push radiator grille -1- into catches -6-
of bumper cover -arrows a-.
– Align radiator grille -arrows b-.
– Insert brand badge -4- in radiator grille -arrow c- and engage
-arrow d-.
Specified torques
♦ Radiator grille ⇒ o1.1 verview – radiator grille”, page 358

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2 Spoiler
⇒ o2.1 verview - spoiler”, page 361
⇒ a2.2 nd installing spoiler”, page 361
2.1 Assembly overview - spoiler
1 - Roof spoiler
ling ⇒ page 361
2 - Clip
❑ Qty. 5
3 - Threaded stud
❑ Qty. 3
❑ Part of roof spoiler
4 - Hose to washer jet
For notes on hose of win‐
dow washer system refer to
⇒ Electrical system; Rep.
gr. 92; Rear window washer
system; Assembly overview -
rear window washer system.
5 - Electrical connector for

high-level brake light
6 - Centring mandrel
❑ Qty. 2
7 - Cap
❑ Qty. 4
8 - Connector for hose to
washer jet
9 - Bolt
❑ Micro-encapsulated; re‐
new after each removal
❑ Qty. 2
❑ 4.0 Nm
10 - Lock nut
❑ Self-locking; renew af‐
ter each removal
❑ Qty. 3
❑ 6.0 Nm
11 - Cap
12 - High-level brake light
❑ Removing and installing ⇒ Electrical system; Rep. gr. 94; High-level brake light; Assembly overview -
high-level brake light
2.2 Removing and installing spoiler

Removing
2. Spoiler 361
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gr. 70; Luggage compartment trims; Assembly overview -
upper rear lid trim.
– Lift out cover cap -4-.
– Unscrew hexagon nuts -3- and remove from stud.
– Unscrew bolts on left and right -2-.
– Pull out roof spoiler -1- with force upwards -arrows a- from
clips -5-.
– Disconnect hose -8- and electrical wire -6-.
For notes on hose of window washer system refer to ⇒ Electri‐
cal system; Rep. gr. 92; Rear window washer system; Assem‐
bly overview - rear window washer system.
For notes on electrical wiring of high-level brake light refer to
⇒ Electrical system; Rep. gr. 94; High-level brake light; Assem‐
bly overview - high-level brake light.
Installing

T-Roc 2018 ➤
– Attach hose -8- and electrical wire -6-.

For notes on hose of window washer system refer to ⇒ Electri‐
cal system; Rep. gr. 92; Rear window washer system; Assem‐
bly overview - rear window washer system.
For notes on electrical wiring of high-level brake light refer to
⇒ Electrical system; Rep. gr. 94; High-level brake light; Assem‐
bly overview - high-level brake light.
– Bring roof spoiler -1- into installation position using pins -5-.
– Press roof spoiler -1- forcibly onto rear lid -arrows b- until
clips -5- engage.
– Place hexagon nuts -3- onto studs and tighten.
– Specified torque ⇒ page 361
2. Spoiler 363
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3 Mouldings, trims, extensions

⇒ o3.1 verview - trim strips”, page 364
⇒ o3.2 verview - wheel arch covers”, page 365
⇒ o3.3 verview – wheel arch covers, R model”, page 365
⇒ o3.4 verview - side member trim”, page 366
⇒ a3.5 nd installing cover”, page 367
⇒ a3.7 nd installing B-pillar trim on door”, page 378
⇒ a3.8 nd installing trim strip”, page 381
⇒ a3.9 nd installing entry moulding”, page 388
⇒ a3.10 nd installing wheel arch covers”, page 390
⇒ a3.11 nd installing side member trim”, page 399
3.1 Assembly overview - trim strips
1 - C-pillar trim strip

ling ⇒ page 385
2 - Removal aid for adhesive
tape
3 - Grommet
4 - Centring pin
5 - Side panel
6 - Adhesive tape
7 - Seal
8 - Guide

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3.2 Assembly overview - wheel arch covers
Note
♦ The illustrations show the left-hand side. The right side is analogous.
♦ Different versions depending on model version; for allocation refer to ⇒ Electronic parts catalogue ETKA
1 - Front wheel arch cover

ling ⇒ page 390
2 - Bolts
❑ Qty. 1 at front and rear
❑ 2 Nm
3 - Locking lug
4 - Clips
5 - Grommets
6 - Edge protector
❑ At front and rear.
7 - Rear wheel arch cover
ling ⇒ page 390
3.3 Assembly overview – wheel arch covers, R model
3. Mouldings, trims, extensions 365

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ling ⇒ page 390
2 - Bonding surface
❑ Wing trim
3 - Trim
❑ Wings
ling ⇒ page 396
4 - Clips
❑ Qty. 2
5 - Wheel arch extension
ling ⇒ page 398
6 - Clips
❑ Qty. 5
7 - Bolts
❑ Qty. 2
❑ 2 Nm
8 - Grommets
❑ Qty. 16
9 - Wheel arch extension
ling ⇒ page 398
ling ⇒ page 398
3.4 Assembly overview - side member trim

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1 - Side member trim

ling ⇒ page 399
2 - Spreader rivet
❑ Qty. 5
3 - Clip
❑ Qty. 7 or 13 depending
on type
4 - Adhesive tape
❑ Part of moulding.
5 - Grommet
❑ Qty. 5 for spreader rivet
-2-
6 - Grommet
❑ Qty. 7 or 13 for clip -3-
depending on type
7 - Bolt
❑ Qty. 2
❑ Specified torque:
1.5 Nm
8 - Bonding surface
3.5 Removing and installing cover

⇒ a3.5.2 nd installing front door cover”, page 368
⇒ a3.5.3 nd installing front door cover, R model”, page 371
⇒ a3.5.4 nd installing rear door cover”, page 373
⇒ a3.6 nd installing rear trim cover for door, R model”, page 376


T-Roc 2018 ➤
♦ Covers or chrome strips in covers cannot be removed intact.

Various versions, for allocation see ⇒ Electronic parts cata‐
logue (ETKA).
♦ If a cover is installed for the first time on a new vehicle or on
newly painted surfaces, the procedure in ⇒ Workshop man‐
ual “Paint”; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒ Mouldings
& film should be observed.
♦ If a cover is removed and reinstalled, use only adhesive
remover to remove the adhesive residue in the installation
area.
grease.
♦ The cover must be bonded in place immediately following
cleaning.
3.5.2 Removing and installing front door cov‐

er

T-Roc 2018 ➤

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Removing
Note
♦ The removal and installation procedures for front door cover may have to be revised slightly depending
on model variations.
♦ The removal and installation sequence is for the front left door cover only. Removal and installation of the
front door cover on the right are similar.
– Unscrew bolts -5- on inner side of door -4-.

– Heat up cover in area of bonding surfaces -6- using hot air
blower -V.A.G 1416-.
– Pull off cover -1- from door until bond of adhesive tape is
released.
– Pull cover further out of grommets -2- -arrows a-.
– Pull cover -1- downwards -arrows b- from door.
Installing

T-Roc 2018 ➤
Follow installation instructions ⇒ page 367 .

– Check grommets -3- and clips -2- for damage, and renew
them if necessary.
– Push cover -1- from below onto door -4- -arrows a-.
– Press cover -1- with clips -2- into grommets -3- -arrows b-.
– Pull off protective film -6- from adhesive tape -7-.
– Press on cover -1- forcefully in area of adhesive tape sec‐
tions -7-.
– Tighten bolts -5- on inner side of door.
Specified torques
Component Specified torque
Front door moulding 2 Nm
3.5.3 Removing and installing front door cov‐

er, R model

T-Roc 2018 ➤
Removing
– Unscrew bolt -2- on inside at front from cover -1-.

– Unscrew bolts -3- on inside at rear from cover -1-.
– Heat up cover -1- in area of bonding surface -3- using hot air
– Pull out cover from fasteners -2-.
– Detach cover -1-.
Installing


T-Roc 2018 ➤
them if necessary.
– Push cover -1- from below onto door.
– Press cover with clips -2- into grommets -3-.
– Press on cover firmly in area of adhesive tape.
– Tighten bolts on inside of door.
Specified torques
Bolts for cover 2 Nm
3.5.4 Removing and installing rear door cov‐

er

T-Roc 2018 ➤
Removing
Note
♦ The removal and installation procedures for rear door cover may have to be revised slightly depending on
model variations.
♦ The removal and installation sequence is for the rear left door cover only. Removal and installation of the
rear door cover on the right are similar.
– Unscrew bolts -5- on inner side of door -4-.

– Heat up cover in area of bonding surfaces -6- using hot air
– Pull off cover -1- from door until bond of adhesive tape is
released.
– Pull cover -1- out of grommets -2- -arrows a-.
– Pull cover -1- downwards -arrows b- from door.

T-Roc 2018 ➤
Installing
them if necessary.
– Push cover -1- from below onto door -5- -arrows a-.
– Press cover -1- with clips -2- into grommets -3- -arrows b-.
– Press on cover -1- forcefully in area of adhesive tape sec‐
tions -7-.
– Tighten bolts -4- on inner side of door.
Specified torques
Rear trim cover for door 2 Nm

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3.6 Removing and installing rear trim cover

for door, R model
Removing
– Unscrew bolt -2- on inside at front from cover -1-.

– Unscrew bolts -3- on inside at rear from cover -1-.

T-Roc 2018 ➤
– Heat up cover -1- in area of bonding surface -3- using hot air
– Pull out cover from fasteners -2-.
– Detach cover -1-.
Installing

them if necessary.
– Push cover -1- from below onto door.
– Press cover with clips -2- into grommets -3-.
– Press on cover firmly in area of adhesive tape.
– Tighten bolts on inside of door.
Specified torques
Bolts for cover 2 Nm

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3.7 Removing and installing B-pillar trim on

door
⇒ a3.7.1 nd installing B-pillar trim on front door”, page 378
⇒ a3.7.2 nd installing B-pillar trim on rear door”, page 380
3.7.1 Removing and installing B-pillar trim on

front door
Removing
Note
Removal and installation are described only for the left side. Removal and installation of the right side are
similar.
– Run door window down to bottom position.

– Pull window channel -3- in area of B-pillar trim -1- out of door
frame -arrow a-.

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– Unscrew bolts and unclip spreader rivet -2-.

– Push B-pillar trim -1- downwards -arrow b- and pull off door
frame slightly in upper area -arrow c-. In doing so, guide
hooks are released from door -4-.
– Pull B-pillar trim -1- upwards out of window slot -arrow d-.
Installing
– Guide B-pillar trim -1- downwards into window slot -arrow a-.
– Push B-pillar trim -1- upwards -arrow c- until guide hook
engages in door -4- -arrow b-.
– Press in bolt with spreader rivet -2- and insert window chan‐
nel -3- into B-pillar trim -arrow d-.

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3.7.2 Removing and installing B-pillar trim on

rear door
Removing
Note
Removal and installation are described only for the left side. Removal and installation of the right side are
similar.
– Run door window down to bottom position.

– Pull window channel -3- in area of B-pillar trim-1- out of door
frame.
– Unscrew bolt and unclip spreader rivet -2-.
– Push B-pillar trim -1- downwards -arrow a- and pull off door
frame slightly in upper area -arrow b-. In doing so, guide
hooks are released from door -4-.
– Pull B-pillar trim -1- upwards out of window slot -arrow c-.

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Installing
– Guide B-pillar trim -1- downwards into window slot -arrow a-.
– Push B-pillar trim -1- upwards -arrow c- until guide hook
engages in door -4- -arrow b-.
– Press in bolt and spreader rivet -2- and insert window chan‐
nel -3- into B-pillar trim -arrow d-.
3.8 Removing and installing trim strip

⇒ a3.8.1 nd installing window channel trim strip of front door”,
page 381
⇒ a3.8.2 nd installing window channel trim strip of rear door”,
page 382
⇒ a3.8.4 nd installing C-pillar trim strip”, page 385
3.8.1 Removing and installing window channel trim strip of front door

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Removing
– Detach trim strip -1- from support bracket -3- and pull out of
window guide -2-.
Installing
– Push trim strip -1- into window guide -2- until window guide
engages in support bracket -3-.
3.8.2 Removing and installing window channel trim strip of rear door

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Removing
– Detach trim strip -1- from support bracket -3- and pull out of
window guide -2-.
Installing
– Push trim strip -1- into window guide -2- until window guide
engages in support bracket -3-.
– Check height of trim strip in relation to front and rear trim
strip, adjust trim strip as necessary ⇒ page 383 .
3.8.3 Adjusting trim strip of rear door window guide

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Note
♦ Position -arrows a- of rear trim strip -2- is set with clip -1- in relation to front -4- and rear trim strip -5-.
♦ The clip -1- comes in 3 different height increments.
♦ The trim strip is installed in the centre position with clip -1 B- (yellow).
♦ The trim strip is installed 0.5 mm higher than the centre position with clip -1 A- (red).
♦ The trim strip is installed 0.5 mm lower than the centre position with clip -1 C- (green).
– Secure clips -1 B- at front and rear in trim strip -2-.

– Install trim strip with clips in window guide -3- ⇒ page 382
and check position -arrows a-.
– If position to front or rear trim strip -4 and 5- is incorrect, it
can be adjusted with a different clip -1 B or 1 C- upwards or
downwards -arrow b-.

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3.8.4 Removing and installing C-pillar trim

strip
♦ If a trim strip is installed for the first time on a new vehicle

or on newly painted surfaces, the procedure in ⇒ Workshop
manual “Paint”; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒ Mould‐
ings & film should be observed.
♦ If a trim strip is removed and reinstalled, use only adhesive
remover to remove the adhesive residue in the installation
area.
grease.
♦ The trim must be bonded in place immediately following
cleaning.

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Removing
Note
♦ The trim strip cannot be removed without it being damaged.

♦ Removal and installation are described only for the left side.
Removal and installation of the right side are similar.

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– Mask off surrounding parts to protect against damage.

– Before removing, heat trim strip -1- in bonding surface area
with hot air blower -V.A.G 1416-.
– Carefully guide removal wedge -3409- -3- between side pan‐
el -2- and trim strip -1- -arrow a-.
– As soon as adhesive joint comes loose, pull trim strip -1- off
side panel -arrows b-.
Installing

– Guide trim strip -1- with centring pin -5- into grommet -3-
-arrow a-.
– Align trim strip -1- with guides -6- to side panel -4-.
– Pull off backing of adhesive tape -7- using pull-off aid -2-.
– Press trim strip on in area of adhesive surfaces -6- with force
-arrows b-.

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3.9 Removing and installing entry mould‐

ing
⇒ a3.9.2 nd installing outer sill panel trim”, page 388

♦ If a sill panel trim is installed for the first time on a new ve‐
hicle or on newly painted surfaces, the procedure in ⇒ Work‐
shop manual “Paint”; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒
Mouldings & film should be observed.
♦ If the sill panel trim is removed and reinstalled, only use
adhesive remover to remove the adhesive remains in instal‐
lation area.
grease.
♦ The sill panel trim must be bonded in place immediately after
cleaning.
3.9.2 Removing and installing outer sill panel

trim

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Removing
Note
♦ Sill panel trim cannot be removed without being damaged.

♦ Different versions depending on model version; for allocation refer to ⇒ Electronic parts catalogue ETKA
♦ Removal and installation are described only for the left side. Removal and installation of the right side are
similar.
– Heat sill panel trim -1- using hot air blower -V.A.G 1416-,
and pull it off sill.
Installing
– Installation instructions ⇒ page 388
– Pull off backing.
– Align front end of outer sill panel trim -1- with front end of
inner sill panel trim -arrows-.

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– Make sure that dimension -a- of 12 mm between metal

flange and sill panel trim is adhered to over the entire length
of the sill panel trim.
– Smooth down using plastic scraper with paper towel wrap‐
ped around it.
3.10 Removing and installing wheel arch

covers
⇒ a3.10.2 nd installing front wheel arch cover”, page 391
⇒ a3.10.3 nd installing rear wheel arch cover”, page 393
⇒ a3.10.4 nd installing wing trim, R model”, page 396
⇒ a3.10.5 nd installing front wheel arch extension, R model”,
page 398
⇒ a3.10.6 nd installing rear wheel arch extension, R model”,
page 398

When removing cover, adhesive tape may become damaged.

If using new adhesive tape as prescribed in ⇒ Electronic parts
catalogue (ETKA), the trim strip can be reused.
– Check clips for damage and renew if necessary.
If a sill panel trim is installed for the first time on a new vehicle
or on newly painted surfaces, the procedure in ⇒ Workshop
manual “Paint”; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒ Mouldings
& film should be observed.
The Paint manual can be found on the ServiceNet under Serv‐
ice systems; Repair; Paint manual.
If a cover is removed and reattached, use only adhesive remov‐
er to remove the adhesive residue.
– Remove existing adhesive residue of adhesive tape using
• Bonding surfaces must be free of dust and grease.
• Install cover immediately after cleaning.
• Do not remove protective foil until immediately before instal‐
lation.
• The working temperature is approx. 21°C.

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3.10.2 Removing and installing front wheel

arch cover
Removing

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Note
♦ Removal and installation are described only for the left wheel arch cover. The removal and installation of
the right wheel arch cover are similar.
♦ Slight discrepancies may need to be allowed for depending on the type of engine.
♦ If retaining hooks -3- are damaged during removal of wheel arch cover -1-, install a new wheel arch trim.
– Remove front wheel housing liner ⇒ page 439 .

– Press together retaining hooks -3- -arrows a- and push out
of bumper cover -arrows b-.
– Press together clips -5- -arrows d-.
Note
Pliers or a 7 or 8 mm socket bit work well as an aid to do this.
– Pull wheel arch cover -1- off wing -arrows c-.

– Pull wheel arch cover -1- out of side member trim -6-
-arrow e-.
Installing
Note
♦ If the retaining hooks -3- are damaged, a new wheel arch

trim must be installed.
♦ If the clips -5-, grommets -4- or seal -6- are damaged, these
must be renewed.
♦ If wheel arch covers are to be reinstalled, replace adhesive
tape -7- with 1 mm thick double-sided adhesive tape.
♦ For R-Line equipment, please replace adhesive tape -8- with
1 mm thick double-sided adhesive tape.

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– Renew damaged clips -5- and grommets -4-.
– Remove backing from double-sided adhesive tape -7-.
– For R-Line equipment, please remove protective film of dou‐
ble-sided adhesive tape -8-.
– Guide wheel arch cover -1- into side member trim -9-
-arrow a-.
– Guide wheel arch cover -1- with joint in end plate -1- of wing
-arrow- thoroughly.
– Press wheel arch cover -1- with clips -5- into grommets -4-
on vehicle -arrows b-.
– Push retaining hooks -3- into bumper cover -arrows c-.
Specified torques
♦ ⇒ o3.2 verview - wheel arch covers”, page 365
3.10.3 Removing and installing rear wheel

arch cover

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Removing

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Note
♦ Removal and installation are described only for the left wheel arch cover. The removal and installation of
the right wheel arch cover are similar.
♦ Slight discrepancies may need to be allowed for depending on the type of engine.
♦ If retaining hooks -5- are damaged during removal of wheel arch cover -1-, install a new wheel arch
cover.
– Remove rear wheel housing liner ⇒ page 443 .

– Press together retaining hooks -5- -arrows a- and push out
of bumper cover -arrows b-.
– Press clips -2- together -arrows c-.
Note
Pliers or a 7 or 8 mm socket bit work well as an aid to do this.
– Pull off wheel arch cover -1- from side panel -arrows d-.
– Pull wheel arch cover -1- out of side member trim -6-
-arrow e-.
Installing
Note
If the retaining hooks -5- or seal -7- are damaged, a new wheel
arch trim must be installed.

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– Renew damaged clips -2- and grommets -4-.
– Guide wheel arch cover -1- into side member trim -6-
-arrow a-.
– Press cover -1- with clips -2- into grommets -4- on vehicle
-arrows b-.
– Push retaining hooks -5- into bumper cover -arrows c-.
Specified torques
♦ ⇒ o3.2 verview - wheel arch covers”, page 365
3.10.4 Removing and installing wing trim, R

model

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Removing
– Heat up wing trim -1- in area of bonding surface -3- using

hot air blower -V.A.G 1416-.
ing this, hold wing trim -1- under tension.
– Detach wing trim -1-.
Installing

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arch extension, R model
Removing
– Release clips -3- and -4-.

– Remove front flared wheel arch -1- from wheel arch -2-.
Installing
– Offer up front flared wheel arch and position -arrow-.
3.10.6 Removing and installing rear wheel

arch extension, R model
Removing
– Unclip clips -3-.

– Remove rear flared wheel arch -1- from wheel arch -2-.

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Installing
– Offer up rear flared wheel arch and position -arrow-.
3.11 Removing and installing side member

trim
Note
♦ Before removing the side member trim, heat it up using hot

air blower -V.A.G 1416-.
♦ Adhesive remover -D 002 000 10- must be used exclusively.
grease.
♦ The side member trim must be bonded in place immediately
following cleaning.
♦ Remove protective foil immediately before installation.

Removing
Note
♦ Removal and installation are described only for the left side member trim. The removal and installation of
the right side member trim are similar.
♦ Due to double-sided adhesive tape, the side member trim cannot be removed without damage

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– Unscrew bolts -4- at front and rear.

– Unscrew spreader rivets -6-, and pull them out of grommets.
– Mask off surrounding parts to protect against damage.
– Heat up side member trim -1- in area of adhesive tape -5-
using hot air blower -V.A.G 1416-.
– Carefully guide removal wedge -3409- -3- between side
member -1- and side member trim -arrow a-.
– As soon as adhesive joint works loose, pull side member
trim -1- off side member -arrow c- with force.
– This also causes clips -2- to be released from grommets.
Installing

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– Observe assembly instructions for bonding ⇒ page 399 .

– Check all grommets -2 and 3-, clips -7- and spreader rives
-6- for damage, and renew them if necessary.
– Fit side member trim -1- with clips -7- into grommets
-2 and 3- and push firmly into place.
– Using removal aid -5-, pull protective film off adhesive tape
-8-.
– Press side member trim in area of adhesive tape -5- firmly
onto side member.
Specified torques
♦ Bolts ⇒ page 366

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4 Noise insulation
⇒ o4.1 verview - noise insulation”, page 402
4.1 Assembly overview - noise insulation

⇒ o4.1.1 verview - short noise insulation”, page 402
⇒ o4.1.2 verview - long noise insulation”, page 402
⇒ o4.1.3 verview - noise insulation extension”, page 403
⇒ o4.1.4 verview - skid plate”, page 404
4.1.1 Assembly overview - short noise insulation
Note
Slight discrepancies may need to be allowed for depending on the type of engine.
1 - Short noise insulation

❑ To remove:
– Unscrew bolts -2- and
-3-.
– Pull out noise insulation

off lock carrier to the
back.
2 - Bolt
❑ 3 each on left and right
❑ 2.0 Nm
3 - Bolt
❑ 3 on lock carrier
❑ 2 Nm
4.1.2 Assembly overview - long noise insulation

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1 - Long noise insulation

❑ To remove:
– Unscrew bolts -2-, -3-
and -4-.

back.
2 - Bolt
❑ Qty. 3 or 5
❑ 6.0 Nm
3 - Bolt
❑ 2.0 Nm
4 - Bolt
❑ 3 on lock carrier
❑ 2 Nm
5 - Lock carrier
4.1.3 Assembly overview - noise insulation extension
4. Noise insulation 403

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1 - Noise insulation extension

❑ To remove:
– Release clips -2- and
unscrew bolts -3-.
– Remove noise insula‐

tion from subframe.
2 - Clip
❑ Qty. 3
3 - Bolt
❑ Qty. 2
❑ 6.0 Nm
4 - Subframe
4.1.4 Assembly overview - skid plate
Note

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1 - Skid plate
❑ To remove:
– Unscrew bolts -2-, -3-
and -4-.

back.
2 - Bolt
❑ 2.0 Nm
3 - Bolt
❑ 20 Nm
4 - Skid plate bracket
❑ Left and right
5 - Bolt
❑ Qty. 1 each on left and
right
❑ 20 Nm
6 - Clip
❑ Qty. 2
7 - Bolt
❑ Qty. 3
❑ 20 Nm
4. Noise insulation 405

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5 Underbody cladding
⇒ o5.1 f fitting locations - underbody cladding”, page 406
⇒ o5.2 verview - bracing on underbody”, page 407
⇒ a5.3 nd installing underbody cladding”, page 407
⇒ a5.4 nd installing tunnel cross-piece”, page 414
5.1 Overview of fitting locations - underbody cladding
1 - Underbody cladding
❑ Left
ling ⇒ page 407
2 - Nut
❑ Captive
❑ Qty. 6 for underbody
cladding on each side
-1 and 7-
❑ Qty. 1 for left under‐
body cladding exten‐
sion -3-
❑ Qty. 3 for rear under‐
body cladding -4-
❑ Qty. 6 for long centre
underbody cladding -8-
❑ 2.0 Nm
3 - Underbody cladding exten‐
sion
❑ Left
4 - Rear underbody cladding
ling ⇒ page 412
5 - Bolt
❑ Qty. 2 for underbody
cladding on each side
-1 and 7-
❑ Qty. 2 for left under‐
body cladding exten‐
sion -3-
❑ Qty. 2 for rear under‐
body cladding -4-
❑ Qty. 3 for right under‐
body cladding extension -6-
❑ 2 Nm
6 - Underbody cladding extension
❑ Right
7 - Underbody cladding
❑ Right
8 - Centre underbody cladding

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5.2 Assembly overview - bracing on underbody
1 - Front tunnel cross-piece

2 - Rear tunnel cross-piece
3 - Lock nut
❑ Qty. 4
❑ 20 Nm
4 - Bolt
❑ Qty. 4
❑ 20 Nm
5.3 Removing and installing underbody

cladding
⇒ a5.3.1 nd installing underbody cladding”, page 407
⇒ a5.3.2 nd installing centre underbody cladding”, page 409
⇒ a5.3.3 nd installing short centre underbody cladding”, page
410
⇒ a5.3.4 nd installing underbody cover extension”, page 411
⇒ a5.3.5 nd installing rear underbody cladding”, page 412
5.3.1 Removing and installing underbody

cladding
5. Underbody cladding 407

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Note
Removing
– Remove centre underbody panels ⇒ page 407 .

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– Unscrew bolts -3- at front and rear.
– Remove underbody panel -1- or -4-.
Installing
Specified torque
• ⇒ o5.1 f fitting locations - underbody cladding”, page 406
5.3.2 Removing and installing centre underbody cladding
Note
Removing
Unscrew hexagon nuts -2- and remove centre underbody clad‐
ding -1-.

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Installing
Specified torques
5.3.3 Removing and installing short centre

underbody cladding
Note

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Removing
Unclip spreader river -2- and remove centre underbody panels.
Installing
Specified torques
5.3.4 Removing and installing underbody cover extension

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– Loosen lock washer -3-.
– Detach clip -2-.
– Pull out underbody cladding -1- towards rear -arrow-.
Installing
Specified torques
5.3.5 Removing and installing rear under‐

body cladding

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Note


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– Remove rear underbody panel -1-.

Installing
Specified torques
5.4 Removing and installing tunnel cross-

piece

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Removing front tunnel cross-piece

– Detach underbody cladding on left and right ⇒ page 407 .
– If fitted, remove centre underbody cladding ⇒ page 407 .
– Remove front tunnel cross-piece -1-.
Removing rear tunnel cross-piece
– If fitted, remove centre underbody cladding ⇒ page 407 .
– Remove hexagon nuts -4-.
– Remove front tunnel cross-piece -3-.
Installing
Specified torques
♦ ⇒ o5.1 f fitting locations - underbody cladding”, page 406

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6 Roof moulding and roof railing

⇒ o6.1 verview - roof railing”, page 416
⇒ a6.2 nd installing roof railing”, page 416
6.1 Assembly overview - roof railing
1 - Roof railing
❑ Left and right
ling ⇒ page 416
2 - Nut
❑ 9 Nm
3 - Bolt
❑ Sealing plug for roof
rack from accessories
6.2 Removing and installing roof railing

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Removing
– Unscrew hexagon nuts -2- at front and rear.
– Remove roof railing -1- straight upwards.
Installing
– Check seal for damage and ensure proper seating.
– Position roof railing -1- straight from above.
– Tighten hexagon nuts -2- at front and rear.
Specified torques
♦ ⇒ o6.1 verview - roof railing”, page 416
6. Roof moulding and roof railing 417

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7 Trim film and protective film
7.1 Renewing decorative film

Bonded decorative film cannot be removed without it being
damaged.
– Heat up decorative film with hot air blower -V.A.G 1416-, and
pull it off.
If the decorative film is installed for the first time on a new
vehicle or on newly painted surfaces, follow the procedure in
⇒ Repair manual "Paint"; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒
Mouldings and film.
If decorative film is removed and reattached, only use adhesive
remover to remove adhesive residue.
Remove any glue residue from adhesive tape using adhesive
strip remover -VAS 6349-.
Ensure that the adhesive surfaces are free of dust and grease.
Apply decorative film immediately after cleaning.
Only remove backing film immediately before installation.
Working temperature is approx. 21°C.
Removing
– Heat decorative film with hot air blower -V.A.G 1416-.
– Pull decorative film off body at sharp angle.

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Installing
Note
♦ This foil can be applied dry. Fluid as an assembly aid is

permissible.
♦ A non-foaming soap solution in a ratio of 100 parts water to
1 part soap is suitable as an assembly aid.
– Align decorative film -1- on C-pillar -2- evenly spaced from

edges -arrows a-.
– Remove protective film -4- on back of tabs -2-.
– Press tabs -2- on roof trim strip -3- -arrow b-.
7. Trim film and protective film 419

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– Lift decorative film -1- off side panel -arrow a-.

– Pull off protective film of bonding side -2- at a sharp angle
from decorative film -1- -arrow b-.
– Gradually fold down decorative film -1-. When doing this,
use a squeegee to firmly apply centre of film, starting at top
-arrow c-.

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– Use squeegee to firmly apply decorative film in steps and

evenly from top to bottom -arrows a- to outer edges.
– Pull off protective film -2- at sharp angle -arrow b- from dec‐
orative film -1- -arrow f-.
7. Trim film and protective film 421

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8 Exterior mirror
⇒ o8.1 verview - exterior mirror”, page 422
⇒ a8.2 nd installing exterior mirror”, page 423
⇒ a8.3 nd installing mirror glass”, page 426
⇒ a8.4 nd installing mirror adjustment unit”, page 428
⇒ a8.5 nd installing mirror cover”, page 430
⇒ a8.6 nd installing mirror trim”, page 432
⇒ a8.7 nd installing turn signal”, page 433
⇒ a8.8 nd installing entry light in exterior mirror”, page 435
8.1 Assembly overview - exterior mirror
Note
The illustrations show the left-hand side. The right side is similar.

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1 - Mirror mounting
ling ⇒ page 423
2 - Connector
3 - Mirror trim
ling ⇒ page 432
4 - Bolts
❑ Qty. 2
❑ 1.0 Nm
5 - Mirror glass
ling ⇒ page 426
6 - Bottom mirror cover
ling ⇒ page 430
7 - Bolt
❑ Qty. 3
❑ 1.0 Nm
8 - Adjuster unit
ling ⇒ page 428
9 - Entry light
ling ⇒ page 435
10 - Bolt
❑ Qty. 1
❑ 1.0 Nm
11 - Turn signal
12 - Top mirror cover
13 - Bolt
❑ Qty. 1
❑ 12 Nm
8.2 Removing and installing exterior mirror

8. Exterior mirror 423

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Removing
Note
♦ The removal and installation sequence is for the left exterior mirror only. The right side is similar.
♦ The cables and connectors in a new exterior mirror are always ready for the highest equipment level.
♦ Any superfluous connectors are secured to prevent noise.

door trim.
– Remove mirror cover trim ⇒ General body repairs, interior;
Rep. gr. 70; Front door trims; Removing and installing mirror
cover.
– Separate electrical connector -4- for exterior mirror -1- on
door control unit.
– Unscrew bolt -2- from exterior mirror -1-.
– Swivel exterior mirror upwards slightly -arrow a-.
– Pull out exterior mirror -1- from beneath window channel
-arrow b-.
– Thread electric wire -3- through hole in door, and remove
exterior mirror -1-.
Installing

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– Make sure that insulation -5- is fitted correctly.

– Push exterior mirror -1- under window channel -arrow a-.
– Fold exterior mirror -1- against door -arrow b-.
Further installation is carried out in reverse order of removal.
Observe the following:
– Renew damaged adhesive label ⇒ Item 5 (page 132) . Apply
adhesive label without creases.
– Then check function.
Specified torques
♦ ⇒ o8.1 verview - exterior mirror”, page 422
8.3 Removing and installing mirror glass


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♦ Assembly lever -80-200-
Note
Removal and installation are described only for the left mirror
glass. The right side is similar.

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Removing
CAUTION
Risk of injury to hands and eyes caused by glass splinters.
Risk of cuts.
– Protect housing edges to prevent damage to paintwork with,

for example, textile-reinforced adhesive tape.
– Press bottom of mirror glass -1- into mirror housing.
– Press mirror glass -1- off adjuster unit -2- -arrow a- using
assembly lever -80-200-.
– Swivel mirror glass -1- to side and detach connectors -3- for
electric mirror heating on back of mirror glass -1-.
Installing
– Fit connector contacts -3- on mirror glass -1-.
– Push mirror glass -1- centrally onto adjustment unit -2- in
housing.
Mirror glass engages audibly.
Note
When fitting the mirror glass, only press on the centre of the
mirror.
8.4 Removing and installing mirror adjust‐

ment unit
Note
The removal and installation sequence is only for the left adjustment unit with motor. The right side is similar.

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Removing
– Remove mirror glass ⇒ page 426 .
– Unscrew bolts -3- (qty. 3) and remove adjustment unit -1-
from mirror mounting.
– Swivel adjustment unit together with motor -1- to the side
and pull off connector -2-.
Installing
– Fit connector -2- on adjustment unit -1-.
– Place adjustment unit -1- on mirror mounting and fix in place
by tightening bolts -3- (qty. 3).
– Install mirror glass ⇒ a8.3 nd installing mirror glass”, page
426 .
Specified torques

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8.5 Removing and installing mirror cover

⇒ a8.5.1 nd installing top mirror cover”, page 430
⇒ a8.5.2 nd installing bottom mirror cover”, page 431
8.5.1 Removing and installing top mirror cover
Note
Removal and installation are described only for the left mirror cover. The right side is similar.
Removing
– Release retaining hooks -arrows a and c-
– Pull off mirror cover -1- in direction of -arrow b- from mirror
mounting.
Installing

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– Position mirror cover -1- and press on until locking hooks

engage audibly.
426 .
8.5.2 Removing and installing bottom mirror cover
Note
Removal and installation are described only for the left mirror cover. The right side is similar.
Removing
– Remove top mirror cover ⇒ page 430 .
– Release locking hooks -arrows a-
– Pull off mirror cover -1- in direction of -arrow b- from mirror
mounting.

T-Roc 2018 ➤
Installing
– Position mirror cover -1- and press on until locking hooks
engage audibly.
– Install top mirror cover ⇒ page 430 .
426 .
8.6 Removing and installing mirror trim

Note
Removal and installation are described only for the left mirror trim. The right side is similar.

T-Roc 2018 ➤
Removing
– Pull off mirror trim -1- -arrows b-.
Installing
Specified torques
8.7 Removing and installing turn signal
Note
If the event of a defective LED, the complete turn signal repeat‐

er in the exterior mirror must be renewed.

T-Roc 2018 ➤
Removing
– Remove mirror frame ⇒ page 432 .
– Separate connector.
– Release retaining hooks -3- -arrow a-.
Swivel turn signal -1- off bottom cap -2- -arrow b-.
Installing

T-Roc 2018 ➤
8.8 Removing and installing entry light in

exterior mirror
Note
If the event of a defective LED, the complete entry light in

exterior mirror needs to be renewed.
Removing
– Remove mirror frame ⇒ page 432 .
– Separate connector.
Remove entry light -1- from bottom mirror cover -arrow-.
Installing

T-Roc 2018 ➤

Specified torques
♦ Bolts ⇒ page 422

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9 Wheel housing liner

⇒ o9.1 verview - front wheel housing liner”, page 437
⇒ o9.2 verview – front wheel housing liner, R model”, page 438
⇒ o9.3 verview - rear wheel housing liner”, page 438
⇒ a9.4 nd installing front wheel housing liner”, page 439
⇒ a9.5 nd installing front wheel housing liner, R model”, page
441
⇒ a9.6 nd installing rear wheel housing liner”, page 443
9.1 Assembly overview - front wheel housing liner
Note
♦ Minor differences may be encountered in respect of front wheel housing liner, depending on vehicle
model.
♦ The illustrations show the left-hand side. Adapt accordingly for the right-hand side.
1 - Front wheel housing liner

ling ⇒ page 439
2 - Bolts
❑ 2.0 Nm
3 - Expanding nuts
9. Wheel housing liner 437

T-Roc 2018 ➤
9.2 Assembly overview – front wheel housing liner, R model
1 - Wheel housing liner

ling ⇒ page 442
2 - Bolts
❑ Qty. 20
❑ 2 Nm
3 - Wheel housing liner
❑ Lower part
ling ⇒ page 441
4 - Expanding nut
❑ Qty. 6
9.3 Assembly overview - rear wheel housing liner
Note
♦ Minor differences may be encountered in respect of front wheel housing liner, depending on vehicle
model.

T-Roc 2018 ➤
1 - Rear wheel housing liner

ling ⇒ page 443
2 - Expanding nuts
3 - Expanding nut
❑ Gas-tight.
❑ The expanding nut
seals the interior
against exhaust gases
and must always be re‐
newed in the event of
damage.
4 - Bolt
❑ 2.0 Nm
9.4 Removing and installing front wheel

housing liner

T-Roc 2018 ➤
Note
♦ Removal and installation is described for the front left wheel housing liner only. The procedure for the
right-hand side is basically the same.
♦ The removal and installation procedures may have to be modified slightly depending on model variants.
♦ For reasons of clarity of bolt illustration, the wheel is not shown.
Removing
– Pull wheel housing liner -1- out of wing.
Installing
Note
Check expanding nuts for damage and renew if necessary.
– Insert front wheel housing liner -1- into wing.

T-Roc 2018 ➤
– Align front wheel housing liner -1- with front bumper cover.
Specified torques
♦ Bolts ⇒ o9.1 verview - front wheel housing liner”, page 437 .
9.5 Removing and installing front wheel

housing liner, R model
⇒ a9.5.1 nd installing front wheel housing liner bottom section,
R model”, page 441
⇒ a9.5.2 nd installing front wheel housing liner, R model”, page
442

housing liner bottom section, R model
Note
To improve clarity, the front wheel is not shown in the following

illustrations.
Removing

– Remove bottom section of wheel housing liner -1-.

T-Roc 2018 ➤
Installing
Specified torques
♦ ⇒ o9.2 verview – front wheel housing liner, R model”, page
438 .

housing liner, R model
Note
To improve clarity, the front wheel is not shown in the following

illustrations.
Removing

– Remove front wheel housing liner -1-.
Installing

T-Roc 2018 ➤
Specified torques
♦ ⇒ o9.2 verview – front wheel housing liner, R model”, page
438 .
9.6 Removing and installing rear wheel

housing liner
Note
♦ Removal and installation are described for the rear left wheel housing liner only. The procedure for the
right-hand side is basically the same.
♦ The removal and installation procedures may have to be modified slightly depending on model variants.

T-Roc 2018 ➤
Removing
– Remove wheel ⇒ Running gear, axles, steering; Rep. gr. 44;
Wheels, tyres; Specified torque for wheel bolts.
– Pull rear wheel housing liner -1- out of wheel housing.
Installing
Note
Check spreader nuts for damage, and renew them if necessary ⇒ Item 3 (page 439) .
– Insert rear wheel housing liner -1- in wheel housing without

kinking the liner.
– Mount wheel ⇒ Running gear, axles, steering; Rep. gr. 44;
Wheels, tyres; Specified torque for wheel bolts.
Specified torques
♦ Bolts ⇒ o9.3 verview - rear wheel housing liner”, page 438 .

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10 Lettering and emblems

⇒ n10.1 otes – bonded lettering”, page 445
⇒ -10.2 lettering and emblems on rear”, page 446
⇒ -10.3 lettering and emblems on sides”, page 448
⇒ a10.4 nd installing badges at front”, page 449
⇒ l10.5 ettering and badges at rear”, page 452
10.1 Assembly notes – bonded lettering

Note
♦ The vertical and horizontal dimensions of lettering for the

different engines are identical.
♦ When fitting the lettering, observe the assembly instructions
as follows.
♦ Heat lettering or emblem with hot air blower -V.A.G 1416-
before removing.
♦ If the lettering or badge is removed and reinstalled, only use
adhesive remover -D 002 000 10- to remove the adhesive
remains.
grease.
10. Lettering and emblems 445

T-Roc 2018 ➤
♦ The lettering or emblem must be bonded in place immedi‐

ately after cleaning.
♦ Remove backing only immediately before installation.
♦ Lettering or emblem cannot be removed without being dam‐
aged.
10.2 Dimensions - lettering and emblems on

rear
⇒ -10.2.1 lettering and badges on rear lid”, page 446
⇒ -10.2.2 lettering and badges on rear lid, R model”, page 447
10.2.1 Dimensions - lettering and badges on rear lid
Note
When fitting the lettering, observe the fitting notes ⇒ page 445 .
1 - Lettering
❑ Model designation
❑ Height dimension -a- =
70 ± 1 mm from lower
edge of lettering to low‐
er edge of rear lid.
❑ Side dimension -b- =
125 ± 1 mm from cen‐
tral line -c- of rear lid to
start of lettering
2 - Lettering
❑ Engine designation
❑ Side dimension -f- =
52 ± 1 mm from outer
edge of rear lid to let‐
tering
❑ Height dimension -e- =
3 - Lettering
❑ Technical designation
❑ Height dimension -c- =
❑ Side dimension -d- =
tering

T-Roc 2018 ➤
10.2.2 Dimensions - lettering and badges on

rear lid, R model
Note
1 - Lettering
❑ Model designation
❑ Height dimension -a- =
❑ Side dimension -b- =
125 ± 1 mm from cen‐
tral line -c- of rear lid to
start of lettering
2 - Lettering
❑ Engine designation
❑ Side dimension -d- =
tering
❑ Height dimension -e- =

T-Roc 2018 ➤
10.3 Dimensions - lettering and emblems on

sides
⇒ l10.3.1 ettering and badges on front door, R model”, page
448
⇒ l10.3.2 ettering and emblems on wing, R model”, page 448
10.3.1 Dimensions – lettering and badges on

front door, R model
Note
Dimensions badge -1- on front door, R-Line, R model
a - Height: 3.2 mm
b - Side: 1 mm
10.3.2 Dimensions – lettering and emblems

on wing, R model
Note

T-Roc 2018 ➤
Dimensions emblem -1- on front wing, R-Line, R model
a - Height: 3.2 mm
b - Side: 1 mm
10.4 Removing and installing badges at

front
⇒ a10.4.1 nd installing badges at front, brand badge”, page 449
⇒ a10.4.2 nd installing badges at front, R-Line, R model”, page
451
10.4.1 Removing and installing badges at

front, brand badge
Removing

T-Roc 2018 ➤
– Remove radiator grille -2- ⇒ page 358 .

– Release locking lugs on rear -3- -arrows a-.
– Push badge -1- out of radiator grille -2- slightly -arrow b-.
– Pull badge -1- upwards out of radiator grille -2- -arrow c-.
Installing

T-Roc 2018 ➤
• Adaptive cruise control unit -J428- is installed.

Observe instructions and specifications for work on adaptive
cruise control unit -J428- -3- under ⇒ Electrical system; Rep.
gr. 27; Adaptive cruise control; Overview of fitting locations -
adaptive cruise control.
– Guide badge -1- upwards into radiator grille -3- -arrow a-.
– Push badge -1- into radiator grille -3- until retaining hooks
-2- can be heard to engage.
10.4.2 Removing and installing badges at

front, R-Line, R model

T-Roc 2018 ➤
♦ Torque screwdriver -V.A.G 1624-
Removing

– Remove emblem -2-.
Installing
Specified torques
♦ ⇒ o1.1 verview – radiator grille”, page 358
10.5 Renewing lettering and badges at rear
Note
The badge cannot be removed without damage.

T-Roc 2018 ➤

Removing
– Use a screwdriver -3- to carefully lever manufacturer em‐
blem -1- off swivel badge -2- in -direction of arrow A-.
Installing
– Press manufacturer emblem -1- onto swivel badge -2- until it
engages audibly.

T-Roc 2018 ➤
11 Towing bracket
⇒ o11.1 verview - towing bracket”, page 454
⇒ a11.2 nd installing towing bracket”, page 454
11.1 Assembly overview - towing bracket
Note
♦ Minor differences will be encountered on removal and installation, depending on version.

♦ The specified torques refer only to factory-installed towing brackets.
♦ Request torque specifications for other towing brackets from the manufacturers.
1 - Towing bracket
❑ Towing bracket with
electrically actuated
ball head.
ling ⇒ page 454
2 - Bolt
❑ Always renew bolts af‐
ter loosening
❑ 50 Nm + 180°
3 - Bolt
❑ Gas-tight threaded con‐
nections
❑ Qty. 3
❑ 20 Nm
4 - Removable ball head
5 - Wire
11.2 Removing and installing towing bracket

Removing

T-Roc 2018 ➤
– Remove left luggage compartment side trim ⇒ General body

repairs, interior; Rep. gr. 70; Luggage compartment trims;
Removing and installing luggage compartment side trim.
– Detach electrical connector from wiring harness -5- in interi‐
or.
– If present, remove reducing agent tank ⇒ Rep. gr. 26; SCR
system (selective catalytic reduction), Assembly overview -
reducing agent tank.
– Pull towing bracket -1- in a parallel movement out of longitu‐
dinal members.
Installing
11. Towing bracket 455

T-Roc 2018 ➤
– Install in reverse order of removal.
Note
The bolts -3- seal the interior against exhaust gases and must always be renewed in the event of damage.
– Perform functional check after installation of towing bracket.

Specified torques
♦ Bolts ⇒ o11.1 verview - towing bracket”, page 454

T-Roc 2018 ➤
12 Heat shields
12.1 Overview of fitting locations - heat shields
1 - Insulation
2 - Underbody heat shield
ling ⇒ page 458
3 - Heat shield for centre ex‐
haust system
ling ⇒ page 459
4 - Heat shield for rear silenc‐
er
ling ⇒ page 460
5 - Heat shield for spare
wheel well
ling ⇒ page 461
6 - Clamping washer
❑ Qty. 7 for floor heat
shield
❑ Qty. 2 for centre heat
shield
❑ Qty. 3 for heat shield of
rear silencer
❑ Qty. 5 for spare wheel
well heat shield
12. Heat shields 457

T-Roc 2018 ➤
12.2 Removing and installing underbody

heat shield
⇒ a12.2.1 nd installing underbody heat shield”, page 458
⇒ a12.2.2 nd installing heat shield for centre exhaust system”,
page 459
⇒ a12.2.3 nd installing heat shield for rear silencer”, page 460
⇒ a12.2.4 nd installing spare wheel well heat shield”, page 461
12.2.1 Removing and installing underbody heat shield
Note
Removing
– Removing centre underbody panel ⇒ page 406 .
– Remove tunnel cross-piece at front and rear -2 and 3- ⇒
page 414 .

T-Roc 2018 ➤
– Remove rear exhaust system ⇒ Rep. gr. 26; Exhaust sys‐

tem/silencer; Assembly overview - silencers.
Only for vehicles with all-wheel drive
– On vehicles with all-wheel drive, remove propshaft ⇒ Rep.
gr. 39; Propshaft; Assembly overview - propshaft.
All vehicles
– Detach lock washers -4- (qty. 6) and remove tunnel heat
shield -1- to the back.
Installing
12.2.2 Removing and installing heat shield for centre exhaust system
Note

T-Roc 2018 ➤
Removing
– Remove rear exhaust system ⇒ Rep. gr. 26; Exhaust sys‐
tem/silencer; Assembly overview - silencers.
– Loosen clamping washers -2-.
– Remove heat shield -1-.
Installing
12.2.3 Removing and installing heat shield for

rear silencer
♦ Engine and gearbox jack -V.A.G 1383 A-
Note

T-Roc 2018 ➤
Removing
– Loosen bracket for rear silencer and slightly lower using the
engine and gearbox jack -V.A.G 1383 A- ⇒ Rep. gr. 26;
Exhaust pipes/silencers; Assembly overview - silencer.
Installing
12.2.4 Removing and installing spare wheel

well heat shield

T-Roc 2018 ➤
♦ Engine and gearbox jack -V.A.G 1383 A-
Note

T-Roc 2018 ➤
Removing
– Loosen bracket for rear silencer and slightly lower using the
engine and gearbox jack -V.A.G 1383 A- ⇒ Rep. gr. 26;
Exhaust pipes/silencers; Assembly overview - silencer.
Installing

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Service

Service Department. Technical Information

55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.1 Assembly overview - tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 114

58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

2.10 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

3.1 Assembly overview - rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

1.1 Safety measures when working on vehicles with start/stop system

1.3 Safety precautions when working on cooling system

2.1 Routing and attachment of lines

2.2 Contact corrosion

2.3 Bonding surfaces for self-adhesive

2.4 Secured threaded connections

2 Rep. gr.00 - Technical data

1.1 Assembly overview – lock carrier

1 - Lock carrier with add-on

1.2 Removing and installing lock carrier

♦ Torque wrench -V.A.G 1331-

♦ Torque wrench -V.A.G 1332-

♦ Engine and gearbox jack -VAS 6931-

4 Rep. gr.50 - Body - front

– Detach radiator module from lock carrier -arrow a-, but do

♦ Do not hang condenser and hydraulic oil cooler from lines.

♦ Always fit lock carrier on the bolting points at the foremost

1.3 Moving to and back from service posi‐

6 Rep. gr.50 - Body - front

♦ Torque wrench -V.A.G 1331-

♦ Torque wrench -V.A.G 1332-

Moving to service position

– Remove front bumper cover ⇒ page 279 .

8 Rep. gr.50 - Body - front

Moving from service position

– Remove special tool adapter -T10467- on left and right from

Further installation is carried out in reverse order of removal.

Do not permit hoses and lines to be pinched.

– Adjust headlights ⇒ Electrical system; Rep. gr. 94; Head‐

10 Rep. gr.50 - Body - front

2.1 Assembly overview - wing

2.2 Removing and installing wing

♦ Torque wrench -V.A.G 1783-

– Remove front wheel housing liner ⇒ page 439 .

12 Rep. gr.50 - Body - front

– Remove front bumper cover ⇒ page 279 .

Install wing -1- without subjecting it to tensile stress.

Install in the reverse order of removal, observing the following:

14 Rep. gr.50 - Body - front

16 Rep. gr.50 - Body - front

3 Plenum chamber bulkhead

3.1 Assembly overview - plenum chamber bulkhead

1 - Plenum chamber bulkhead

3.2 Assembly overview - plenum chamber cover

3. Plenum chamber bulkhead 17

1 - Plenum chamber cover

3.3 Removing and installing bulkhead

18 Rep. gr.50 - Body - front

3. Plenum chamber bulkhead 19